CN113105254B - Novel ceramic sand and preparation method thereof - Google Patents

Novel ceramic sand and preparation method thereof Download PDF

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CN113105254B
CN113105254B CN202110334779.0A CN202110334779A CN113105254B CN 113105254 B CN113105254 B CN 113105254B CN 202110334779 A CN202110334779 A CN 202110334779A CN 113105254 B CN113105254 B CN 113105254B
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sand
meshes
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temperature
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CN113105254A (en
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邓宇辉
张博
张宇晖
李家波
邓旭东
李长彬
史书源
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ZHANGWU COUNTY LIAN XIN FOUNDRY SILICON SAND CO LTD
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ZHANGWU COUNTY LIAN XIN FOUNDRY SILICON SAND CO LTD
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Abstract

The invention discloses novel ceramic sand and a preparation method thereof. The novel ceramic sand comprises the following chemical components: al (Al) 2 O 3 40～80％、SiO 2 5～20％、Fe 2 O 3 0～5％、(Zr·Hf)O 2 1～20％、Cr 2 O 3 0～5％、MnO 0～5％、NiO 0～5％、MoO 3 0～10％、V 2 O 5 0～6％、TiO 2 0～5％、FeS 1～3％、P 2 O 5 1-3% and rare earth oxide 1-10%. The novel ceramic sand provided by the invention is prepared by taking high-alumina ore and zirconite ore as main materials, adding a certain proportion of functional additives after preparation, high-temperature melting, crushing, washing, drying and grinding, meeting the production and use requirements of customers according to different specific prepared products of customer materials and production conditions, is a neutral refractory material, and has the characteristics of high refractoriness, small thermal expansion coefficient, compact structure, low content of low-melting-point substances, high cost performance and the like.

Description

Novel ceramic sand and preparation method thereof
Technical Field
The invention relates to the technical field of refractory materials, in particular to novel ceramic sand and a preparation method thereof.
Background
The refractory materials used as the shell surface layer in the investment precision casting process comprise quartz, fused corundum, zircon, high-alumina and the like, and the proper refractory materials are selected according to the binder for shell making in the actual processing process. The traditional investment precision casting process in China uses water glass and ethyl silicate as binders and quartz, fused alumina and high-alumina bauxite as surface refractory materials, and is widely applied.
In the 80 s of the 20 th century, investment precision casting and joint venture enterprises entered China, and most of the enterprises made up investment precision casting and joint venture enterprises adopted the advanced silica sol shell-making technology abroad, and most of the refractory materials of the shell surface layer were imported zircon sand (powder). The casting industry in China has been developed rapidly in recent decades, so that China becomes the largest consumer of zircon, and due to supply and demand, zircon sand (powder) is very pretty and high in price, and research on other alternative refractory materials is becoming a great trend. Zircon (ZrO) 2 -SiO 2 ) Is the only compound in the binary system. Pure ZrSiO 4 The refractoriness is above 2000 ℃, and the decomposition temperature of the zircon is 1540 ℃. When K and Na oxides are contained, the decomposition temperature is reduced to about 900 ℃, and when Ca and Mg oxides are contained, the decomposition temperature is about 1300 ℃. Therefore, the investment casting generally adopts first-grade zircon sand (powder) with low impurity content, but the market demand is large, the price is high, the casting production cost is increased, and if the zircon sand (powder) ZrO provided by a supplier is used 2 The low content, in particular the high content of impurities, may be cheap, but the surface quality of the casting may be reduced.
At present, zircon sand is replaced by special fused corundum precision casting sand in China, but fused corundum is prepared by high-temperature smelting, so that the cost is high, the energy consumption is high, and the problems of difficulty in cleaning shells after casting and the like occur in the using process. High residual strength of electric melting corundum precision casting sand mould shell, high activity Al in porous aluminum-silicon refractory material particles 2 O 3 Homogeneous colloidal SiO 2 Secondary mullite is produced with a concomitant volume expansion. Liquid phase sintering, solid phase sintering and secondary mullite generation exist in the shell roasting and casting processes, and shell sand grains are tightly combined. When the casting shell is removed, the corundum fine casting sand surface layer and the back layer of bauxite sand are connected into a whole, and the combination is firmer. The combination of the above factors can cause that the shells of the inner cavities, the holes and the grooves of the castings are difficult to clean.
Main chemical component Al of bauxite sand 2 O 3 The primary crystal phase is corundum, the secondary crystal phase is mullite and a small amount of TiO 2 Solid solution crystals and a glassy phase. However, bauxite contains high content of impurities, (CaO + MgO + K) 2 O+Na 2 O) high total alkali metal oxide content, reducing the high temperature performance of the bauxite. The bauxite refractory material has low strength and hardness and is easy to crack, so that powder particles are too fine and distributed dispersedly, sand material dust is too much, and the granularity grading can not reach the standard similar to zircon powder (sand). The bauxite is suitable for the production of common castings and is not suitable for the production of some castings made of high-end materials because the quality of the bauxite on the market is uneven and cannot be ensured.
Therefore, the refractory material with low production cost and high refractoriness is provided to replace the existing refractory materials such as zircon sand and the like, and has important significance.
Disclosure of Invention
In view of the above, a need exists for a novel ceramic sand and a preparation method thereof, which are used to solve the technical problems of low refractoriness and high production cost of refractory materials in the prior art.
The first aspect of the invention provides a novel ceramic sand, which comprises the following chemical components: al (Al) 2 O 3 40～80％、SiO 2 5～20％、Fe 2 O 3 0～5％、(Zr·Hf)O 2 1～20％、Cr 2 O 3 0～5％、MnO 0～5％、NiO 0～5％、MoO 3 0～10％、V 2 O 5 0～6％、TiO 2 0～5％、FeS 1～3％、P 2 O 5 1-3% and rare earth oxide 1-10%.
The invention provides a preparation method of novel ceramic sand, which comprises the following steps:
s1, mixing high-alumina ore, zircon sand, quartz ore, chromium-nickel alloy, iron-manganese ore, vanadium-molybdenum alloy, titanium dioxide and rare earth oxide for the first time, and then melting at high temperature, blowing, screening and mixing for the second time to obtain mixed sand;
s2, uniformly mixing the mixed sand, chromite, black iron sand, calcium stearate, high-temperature resin and water glass, then calcining at 1300-1600 ℃ for 4-12 h in a reducing atmosphere, and cooling and crushing to obtain the novel ceramic sand.
Compared with the prior art, the invention has the beneficial effects that:
the novel ceramic sand provided by the invention is prepared by taking high-alumina ore and zirconite ore as main materials and adding a certain proportion of functional additives after preparation, high-temperature melting, crushing, washing, drying and grinding, meets the production and use requirements of customers according to different specific preparation products of customer materials and production conditions, is a neutral refractory material, and has the characteristics of high refractoriness, small thermal expansion coefficient, compact structure, low content of low-melting-point substances, high cost performance and the like. The novel ceramic sand provided by the invention is mainly applied to investment precision casting shell making and casting coatings.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
The first aspect of the invention provides novel ceramic sand, which comprises the following chemical components: al (Al) 2 O 3 40～80％、SiO 2 5～20％、Fe 2 O 3 0～5％、(Zr·Hf)O 2 1～20％、Cr 2 O 3 0～5％、MnO 0～5％、NiO 0～5％、MoO 3 0～10％、V 2 O 5 0～6％、TiO 2 0～5％、FeS 1～3％、P 2 O 5 1-3% and rare earth oxide 1-10%.
Specifically, the rare earth element corresponding to the rare earth oxide is a lanthanide element, including lanthanum, cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), and lutetium (Lu).
Further, the novel ceramic sand comprises the following chemical components: al (Al) 2 O 3 40～70％、SiO 2 5～15％、Fe 2 O 3 0.5～5％、(Zr·Hf)O 2 6～15％、Cr 2 O 3 0.3～3.1％、MnO 0.3～3.3％、NiO 0.2～3.5％、MoO 3 0.8～3.7％、V 2 O 5 0.5～2.3％、TiO 2 0.4～2.1％、FeS 1.3～2.1％、P 2 O 5 1.1～2.7％、La 2 O 3 1.1～2.5％、Ce 2 O 3 1.3～3.2％。
In the above chemical composition, al 2 O 3 、SiO 2 、(Zr·Hf)O 2 The refractory degree is improved, a sintering layer is formed, and the ceramic sand is a novel ceramic sand main material; moO 3 、V 2 O 5 、TiO 2 The novel ceramic sand is combined according to a specific formula, so that the characteristics of high-temperature heat strength, suspension property, leveling property and the like of the novel ceramic sand can be obviously improved; feS, P 2 O 5 The shedding performance of the product is improved, so that the product can better shed; fe 2 O 3 The NiO improves the heat dissipation coefficient of the product, so that the heat dissipation coefficient of the product is increased; rare earth refines the product structure, improves coating property and improves high-temperature performance; mnO and Cr 2 O 3 The toughness and the leveling property of the product are improved.
Further, moO 3 ：V 2 O 5 +TiO 2 1, and MoO = 0.8-1.2 3 、V 2 O 5 、TiO 2 The total content of (A) is 1.7-8.1%. Within this ratio range, the effect is optimal.
The invention provides a preparation method of novel ceramic sand, which comprises the following steps:
s1, mixing high-alumina ore, zircon sand, quartz ore, chrome-nickel alloy, iron-manganese ore, vanadium-molybdenum alloy, titanium dioxide and rare earth oxide for the first time, and then performing high-temperature melting, blowing, screening and secondary mixing to obtain mixed sand;
s2, uniformly mixing the mixed sand, chromite, black iron sand, calcium stearate, high-temperature resin and water glass, then calcining at 1300-1600 ℃ for 4-12 h in a reducing atmosphere, and cooling and crushing to obtain the novel ceramic sand.
In the step S1, the high-alumina ore, the zircon sand, the quartz ore, the chrome-nickel alloy, the iron-manganese ore, the vanadium-molybdenum alloy, the titanium dioxide and the rare earth oxide are adopted to prepare the mixed sand, and the chemical composition and the performance of the mixed sand can be chemically regulated and controlled in the high-temperature melting process of the raw materials.
Further, the raw materials of the mixed sand comprise, by weight: 20 to 30 parts of high-alumina ore, 5 to 15 parts of zircon sand, 5 to 10 parts of quartz ore, 0 to 5 parts of chrome-nickel alloy, 0 to 5 parts of iron-manganese ore, 0 to 5 parts of vanadium-molybdenum alloy, 0 to 3 parts of titanium dioxide and 1 to 10 parts of rare earth oxide. Furthermore, the raw materials of the mixed sand comprise, by weight: 20 to 30 parts of high-alumina ore, 5 to 15 parts of zircon sand, 5 to 10 parts of quartz ore, 0.3 to 5 parts of chromium-nickel alloy, 0.5 to 4 parts of iron-manganese ore, 0.4 to 2 parts of vanadium-molybdenum alloy, 0.3 to 2 parts of titanium dioxide, 0.6 to 1.3 parts of lanthanum oxide and 0.7 to 1.8 parts of cerium oxide.
In step S1 of the present invention, the high-temperature melting step specifically includes: melting the ore raw materials into liquid at high temperature, removing low-melting-point impurities, and simultaneously fully mixing the main materials; further, the high-temperature melting temperature is more than 2300 ℃, and is further 2350-2500 ℃; the blowing step specifically comprises: blowing the molten liquid by using high-pressure air to solidify the molten liquid under the action of the high-pressure air and surface tension to obtain particles with different particle sizes; the secondary mixing comprises the following steps: mixing the screened particles according to the particle size grading, then mixing for 1-2 h at 100-200 ℃, washing with water after cooling, removing micro powder and drying; further, the grain size grading selected for secondary mixing is as follows: 0 to 5 percent of 200 meshes, 0 to 5 percent of 270 meshes, 50 to 80 percent of 325 meshes and 10 to 20 percent of 400 meshes. In the invention, the grading is adopted, so that the material is more favorably and uniformly distributed.
In the step S2 of the invention, the performances such as the heat dissipation speed of the material can be improved by adding the chromite and the black iron sand, the appearance of the novel ceramic sand can be fully wrapped by adding the high-temperature resin, the angle coefficient is improved, and the strength of the material in the production and use processes is improved.
Further, the novel ceramic sand comprises the following raw materials in parts by weight: 85-94 parts of mixed sand, 0-3 parts of chromite, 0-5 parts of black iron sand, 2-5 parts of calcium stearate, 1-2 parts of high-temperature resin and 1-2 parts of water glass.
Further, the high-temperature resin is a silicone high-temperature resistant resin.
Furthermore, the particle size range of the ferrochrome sand is 300-400 meshes, and the particle size range of the black iron sand is 300-400 meshes.
Further, the water glass is polyacrylamide modified water glass. Further, the modified water glass is prepared by mixing polyacrylamide and water glass with the modulus of 2.8-3.5 according to the weight ratio of 1: 5-10, and mixing uniformly.
In the following embodiments of the present invention, some of the raw materials are summarized as follows:
modified water glass is prepared by mixing polyacrylamide and water glass with modulus of 3.2 according to the weight ratio of 1:8, and uniformly mixing the components in a mass ratio;
the grain size of the ferrochromium sand is 325 meshes, and the grain size of the black iron sand is 325 meshes.
The grain size grading selected for the secondary mixing is as follows: 200 meshes 3%, 270 meshes 3%, 325 meshes 78%, 400 meshes 16%.
Example 1
The embodiment provides a preparation method of novel ceramic sand, which comprises the following steps:
(1) Mixing 25 parts of high-alumina ore, 5 parts of zircon sand, 7 parts of quartz ore, 0.3 part of chromium-nickel alloy, 2 parts of iron-manganese ore, 2 parts of vanadium-molybdenum alloy, 2 parts of titanium dioxide, 1.3 parts of lanthanum oxide and 1.8 parts of cerium oxide for the first time, and then performing high-temperature melting, blowing, screening and secondary mixing to obtain mixed sand; the high-temperature melting method specifically comprises the following steps: melting the ore raw materials into liquid at high temperature, removing low-melting-point impurities, and simultaneously fully mixing the main materials; further, the temperature of high-temperature melting is 2350 ℃; the blowing step specifically comprises: blowing the molten liquid by using high-pressure air to solidify the molten liquid under the action of the high-pressure air and surface tension to obtain particles with different particle sizes; the secondary mixing comprises the following steps: and mixing the screened particles according to the particle size grading, then mixing for 1.5h at 150 ℃, cooling, washing with water, removing micro powder, and drying.
(2) 91 parts of mixed sand, 3 parts of chromite, 3 parts of calcium stearate, 1.5 parts of organic silicon high-temperature-resistant resin and 1.5 parts of modified water glass are uniformly mixed, then the mixture is calcined at 1400 ℃ for 8 hours in a reducing atmosphere, and the mixture is cooled and crushed to obtain novel ceramic sand, wherein the chemical composition of the novel ceramic sand is shown in table 1.
Example 2
The embodiment provides a preparation method of novel ceramic sand, which comprises the following steps:
(1) Mixing 30 parts of high-alumina ore, 10 parts of zircon sand, 5 parts of quartz ore, 2 parts of chromium-nickel alloy, 0.5 part of iron-manganese ore, 1 part of vanadium-molybdenum alloy, 0.5 part of titanium dioxide, 0.6 part of lanthanum oxide and 0.7 part of cerium oxide for the first time, and then carrying out high-temperature melting, blowing, screening and secondary mixing to obtain mixed sand; the high-temperature melting method specifically comprises the following steps: melting the ore raw materials into liquid at high temperature, removing low-melting-point impurities, and fully mixing the main materials; further, the temperature of high-temperature melting is 2400 ℃; the blowing step specifically comprises: blowing the molten liquid by using high-pressure air to solidify the molten liquid under the action of the high-pressure air and surface tension to obtain particles with different particle sizes; the secondary mixing comprises the following steps: and mixing the screened particles according to the particle size grading, then mixing for 1h at 200 ℃, cooling, washing with water, removing micro powder, and drying.
(2) The preparation method comprises the following steps of uniformly mixing 94 parts of mixed sand, 1 part of chromite, 2 parts of calcium stearate, 2 parts of organic silicon high-temperature-resistant resin and 1 part of water glass, then calcining at 1600 ℃ for 4 hours in a reducing atmosphere, cooling and crushing to obtain novel ceramic sand, wherein the chemical composition of the novel ceramic sand is shown in Table 1.
Example 3
The embodiment provides a preparation method of novel ceramic sand, which comprises the following steps:
(1) Mixing 20 parts of high-alumina ore, 15 parts of zircon sand, 10 parts of quartz ore, 5 parts of chromium-nickel alloy, 4 parts of iron-manganese ore, 0.4 part of vanadium-molybdenum alloy, 0.3 part of titanium dioxide, 0.9 part of lanthanum oxide and 1.1 part of cerium oxide for the first time, and then performing high-temperature melting, blowing, screening and secondary mixing to obtain mixed sand; the high-temperature melting method specifically comprises the following steps: melting the ore raw materials into liquid at high temperature, removing low-melting-point impurities, and simultaneously fully mixing the main materials; further, the temperature of high-temperature melting is 2500 ℃; the blowing step specifically comprises: blowing the molten liquid by using high-pressure air to solidify the molten liquid under the action of the high-pressure air and surface tension to obtain particles with different particle sizes; the secondary mixing comprises the following steps: mixing the sieved particles according to the particle size grading, then mixing for 2 hours at 100 ℃, washing with water after cooling, removing micro powder and drying.
(2) The preparation method comprises the following steps of uniformly mixing 85 parts of mixed sand, 2 parts of chromite, 5 parts of black iron sand, 5 parts of calcium stearate, 1 part of organic silicon high-temperature-resistant resin and 2 parts of water glass, then calcining at 1300 ℃ for 12 hours in a reducing atmosphere, and cooling and crushing to obtain novel ceramic sand, wherein the chemical composition of the novel ceramic sand is shown in Table 1.
Comparative example 1
Compared with example 1, the only difference is that: no silicone high temperature resistant resin was added.
Comparative example 2
Compared with example 1, the only difference is that: and (2) calcining at high temperature under the air condition.
Comparative example 3
The only difference compared to example 1 is that chromite in step (2) is added in one compounding pass of step (1).
TABLE 1 chemical composition of the novel ceramic sands obtained in examples 1 to 3
Figure BDA0002997623120000081
Test group
The novel ceramic sands obtained in the above examples 1 to 3 and comparative examples 1 to 3 were subjected to a performance test, and the results are shown in table 2.
TABLE 2
Figure BDA0002997623120000091
As can be seen from Table 2, the novel ceramic sands obtained in the embodiments 1 to 3 of the present invention have the characteristics of high refractoriness, small thermal expansion rate, high thermal conductivity, high heat-resistant strength, and low production cost, and are more conducive to industrial production.
While the invention has been described with reference to specific preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.

Claims (8)

1. A ceramic sand for investment precision casting shell making is characterized by comprising the following chemical compositions: al (Al) 2 O 3 40~70%、SiO 2 5~15%、Fe 2 O 3 0.5~5%、（Zr·Hf）O 2 6~15%、Cr 2 O 3 0.3~3.1%、MnO 0.3~3.3%、NiO 0.2~3.5%、MoO 3 0.8~3.7%、V 2 O 5 0.5~2.3%、TiO 2 0.4~2.1%、FeS 1.3~2.1%、P 2 O 5 1.1~2.7%、La 2 O 3 1.1~2.5%、Ce 2 O 3 1.3~3.2%。
2. The method of preparing ceramic sand for investment casting shell making according to claim 1, comprising the steps of:
mixing high-alumina ore, zircon sand, quartz ore, chromium-nickel alloy, iron-manganese ore, vanadium-molybdenum alloy, titanium dioxide, lanthanum oxide and cerium oxide for the first time, and then performing high-temperature melting, blowing, screening and secondary mixing to obtain mixed sand;
and uniformly mixing the mixed sand, chromite, black iron sand, calcium stearate, high-temperature resin and water glass, then calcining at 1300-1600 ℃ for 4-12h in a reducing atmosphere, and cooling and crushing to obtain the ceramic sand.
3. The preparation method of claim 2, wherein the raw materials of the mixed sand comprise, by weight: 20 to 30 parts of high-alumina ore, 5 to 15 parts of zircon sand, 5 to 10 parts of quartz ore, 0.3 to 5 parts of chromium-nickel alloy, 0.5 to 4 parts of iron-manganese ore, 0.4 to 2 parts of vanadium-molybdenum alloy, 0.3 to 2 parts of titanium dioxide, 0.6 to 1.3 parts of lanthanum oxide and 0.7 to 1.8 parts of cerium oxide.
4. The method of claim 2, wherein the high temperature melting temperature is greater than 2300 ℃; the secondary mixing step specifically comprises the following steps: and mixing the screened particles according to the particle size grading, then mixing for 1 to 2h at the temperature of 100 to 200 ℃, cooling, washing with water, removing micro powder, and drying.
5. The method according to claim 4, wherein the secondary compounding is carried out using a particle size distribution of: 0 to 5 percent of 200 meshes, 0 to 5 percent of 270 meshes, 50 to 80 percent of 325 meshes and 10 to 20 percent of 400 meshes, wherein the sum of the proportion of 200 meshes, 270 meshes, 325 meshes and 400 meshes in the particle size distribution is 100 percent.
6. The preparation method of claim 2, wherein the ceramic sand comprises the following raw materials in parts by weight: 85-94 parts of mixed sand, 0-3 parts of chromite, 0-5 parts of black iron sand, 2-5 parts of calcium stearate, 1-2 parts of high-temperature resin and 1-2 parts of water glass.
7. The preparation method according to claim 6, wherein the high-temperature resin is a silicone high-temperature resin, and the water glass is polyacrylamide modified water glass.
8. The preparation method according to claim 6, wherein the particle size of the chromite is 300-400 meshes, and the particle size of the black iron sand is 300-400 meshes.
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