CN113200753B - 一种中间包包盖浇注料及用其制备中间包包盖的方法 - Google Patents
一种中间包包盖浇注料及用其制备中间包包盖的方法 Download PDFInfo
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Abstract
一种中间包包盖浇注料及用其制备中间包包盖的方法,目的是防止包盖开裂、剥落及掉块等;中间包包盖浇注料的配方是:55‑65wt%的矾土颗粒、10‑20wt%的矾土细粉、2‑4wt%的硅微粉、3‑5wt%的预制粉料、5‑10wt%的预制颗粒、3‑6wt%的氧化铝微粉、0.1wt%的金属铝粉、3‑6wt%的铝酸盐水泥、1‑3wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.02‑0.1wt%的藻酸丙二醇酯,4‑6wt%的水;用该浇注料制备中间包包盖的方法是:将混合好的浇注料放于模具中振动成型,经室温静置24小时,再经110℃热处理24小时。
Description
技术领域
本发明属于耐火材料技术领域。具体涉及一种中间包包盖浇注料,以及利用该浇注料制备中间包包盖的方法。
背景技术
中间包是冶金行业连铸生产中钢包与结晶器之间的中间容器,盖在中间包上的中包盖是为了便于操作人员完成测温、取样等操作的需要,并具有隔热、防止钢水二次氧化等作用。中间包包盖的工作环境恶劣,主要包括高温、热气流烘烤、急热急冷、中间包渣侵蚀以及包壳变形传递的机械应力等。因此,使用过程中,中间包包盖大多表现为盖板变形、翘曲,局部剥落、掉块等,进而导致整体变形、包盖金属结构框架烧坏,不但影响中间包包盖的实际使用寿命与使用效果,而且备件消耗量大,影响浇钢的正常操作。现有技术大多通过调整包盖用材的化学及矿物组成、调节衬层搭配以及加强包壳与耐火材料间的结合等方法,来改善中间包包盖的使用性能,但收效甚微。
发明内容
本发明旨在克服现有技术的不足,目的是提供一种中间包包盖浇注料以及利用该浇注料制备中间包包盖的方法。本发明方法优化了中间包包盖在高温使用过程中的显微结构、改善了材料的热震稳定性、强化了包盖的隔热效果。所制备的中间包包盖整体热震稳定性高,使用期间包盖无开裂、剥落及掉块等现象,有利于连铸生产的安全、稳定、顺行的进行。
本发明一种中间包包盖浇注料的原料及其质量百分比配方是:50-60wt%的矾土颗粒、10-20wt%的矾土细粉、2-4wt%的硅微粉、3-5wt%的预制粉料、5-10wt%的预制颗粒、3-6wt%的氧化铝微粉、0.1wt%的金属铝粉、3-6wt%的铝酸盐水泥、1-3wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.02-0.1wt%的藻酸丙二醇酯,4-6wt%的水。
所述预制细粉和预制颗粒是:将30-40wt%的玻璃粉、10-20wt%的碳化硅粉、25-35wt%的碳化硅颗粒、2-5wt%的硅微粉、3-5wt%的葡萄糖、3-6wt%的水,按比例混合均匀后,于120MPa条件下压制成型,置于650-750℃热处理3小时,随炉冷却至室温,再经破碎、筛分后得到;粒度小于0.088mm的是预制粉料;粒度为0.088-2mm的是预制颗粒。
所述玻璃粉中SiO2的含量为50-70wt%,Na2O的含量为2-10wt%,K2O的含量为3-8wt%,CaO的含量为5-15wt%,MgO的含量为2-10wt%,玻璃粉的颗粒粒度小于0.045mm所述碳化硅中SiC的含量大于97wt%,碳化硅粉的粒度小于0.088mm,碳化硅颗粒的粒度为0.5-1mm。
所述矾土中Al2O3的含量为85-88wt%,Fe2O3的含量小于2wt%,矾土颗粒的粒度为1-10mm,矾土细粉的粒度小于0.088mm。所述硅微粉中SiO2的含量大于92wt%;所述铝酸盐水泥中Al2O3的含量大于65wt%;所述氧化铝微粉中Al2O3的含量大于98wt%,粒度小于0.088mm。所述金属铝粉的粒度小于0.088mm。
所述不锈钢纤维为含镍元素的耐热钢纤维(310#),横截面为弯月形,所述不锈钢纤维的尺寸为(0.1-0.2mm)×(0.8-1.2mm)×(38-42mm)。
采用如权利要求1所述中间包包盖浇注料制备中间包包盖的方法,其特征是:
(1)按比例制备预制细粉和预制颗粒;
(2)按比例混合成中间包包盖浇注料;
(3)将中间包包盖浇注料放于模具中振动成型,经室温静置24小时,再经110℃热处理24小时,即得。
本发明由于采用上述技术方案,与现有技术相比具有如下积极效果:
⑴本发明利用不同原料的热、力学特性,调节颗粒、配比、温度等工艺参数,改善浇注料高温使用过程中的显微结构,优化材料的热传递特性;尤其是制备了预制粉料和预制颗粒,使适量玻璃粉分布在碳化硅粉和颗粒之间,并通过热处理对其形成了适度包裹,在添加入中间包包盖浇注料中后,能够降低碳化硅的氧化,利用碳化硅本身的优良属性(如硬度大、热膨胀系数低等),使本发明制备方法制得的中间包包盖在高温使用过程中,表现出较高的热震稳定性。
⑵本发明通过调节制备工艺参数,利用预制粉料和预制颗粒的结构特点,即玻璃粉对碳化硅的适度分散包裹,以及矾土颗粒、矾土细粉、硅微粉、氧化铝微粉等原料的合理搭配,使本发明制备方法制得的中间包包盖在高温使用过程中,材料内部孔隙形成了均匀分布的莫来石晶须交叉结构,因而表现出较强的隔热性能。
⑶本发明利用不同原料之间的高温反应性,通过制备预制粉料和预制颗粒,以及调节制备工艺参数,高温下在本发明制备方法制得的中间包包盖内部孔隙形成均匀分布的莫来石晶须交叉结构的同时,不同种类和粒度的原料之间也形成了适度的烧结,因而与现有技术相比,采用本发明方法制备的中间包包盖在高温使用过程中具有更强的力学性能。
采用本发明制备方法制得的中间包包盖,具有热震稳定性高(1100℃水冷大于24次)、隔热性能优良(1000℃导热系数小于2.0W/m·K)、力学强度大(1500℃热处理3小时后常温抗折强度大于14MPa,高温抗折强度(1450℃,0.5小时)大于2.3MPa)等特点,因而在使用期间包盖无开裂、剥落及掉块等现象,有利于连铸生产安全、稳定的顺行。
具体实施方式
下面结合具体实施方式对本发明作进一步的描述,并非对其保护范围的限制。
实施例1
将32wt%的玻璃粉、20wt%的碳化硅粉、35wt%的碳化硅颗粒、5wt%的硅微粉、4wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于750℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、18wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、6wt%的预制颗粒、4.75wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯,加5wt%的水搅拌均匀后,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例2
将35wt%的玻璃粉、18wt%的碳化硅粉、34wt%的碳化硅颗粒、4wt%的硅微粉、5wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于650-℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、18wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、6wt%的预制颗粒、4.73wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.07wt%的藻酸丙二醇酯、5wt%的水搅拌均匀后,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例3
将40wt%的玻璃粉、20wt%的碳化硅粉、29wt%的碳化硅颗粒、2wt%的硅微粉、5wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于650℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、18wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、6wt%的预制颗粒、4.75wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯、5wt%的水搅拌均匀后,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例4
将32wt%的玻璃粉、20wt%的碳化硅粉、34wt%的碳化硅颗粒、5wt%的硅微粉、4wt%的葡萄糖、5wt%的水,混合均匀后于120MPa条件下压制成型,置于700℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、18wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、6wt%的预制颗粒、4.74wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.06wt%的藻酸丙二醇酯、5wt%的水搅拌均匀后,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例5
将32wt%的玻璃粉、20wt%的碳化硅粉、35wt%的碳化硅颗粒、5wt%的硅微粉、5wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于750℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将58wt%的矾土颗粒、15wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、6wt%的预制颗粒、4.75wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯、5wt%的水搅拌均匀,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例6
将32wt%的玻璃粉、20wt%的碳化硅粉、35wt%的碳化硅颗粒、5wt%的硅微粉、5wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于750℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将60wt%的矾土颗粒、10wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、10wt%的预制颗粒、4.75wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯、4wt%的水搅拌均匀,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例7
将40wt%的玻璃粉、20wt%的碳化硅粉、30wt%的碳化硅颗粒、3wt%的硅微粉、3wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于650℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、16wt%的矾土细粉、2wt%的硅微粉、5wt%的预制粉料、6wt%的预制颗粒、4.75wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯、5wt%的水搅拌均匀,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例8
将40wt%的玻璃粉、20wt%的碳化硅粉、30wt%的碳化硅颗粒、3wt%的硅微粉、3wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于650℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、15.85wt%的矾土细粉、4wt%的硅微粉、5wt%的预制粉料、6wt%的预制颗粒、2.9wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯、5wt%的水搅拌均匀,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例9
将32wt%的玻璃粉、20wt%的碳化硅粉、35wt%的碳化硅颗粒、5wt%的硅微粉、4wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于750℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将60wt%的矾土颗粒、10wt%的矾土细粉、3wt%的硅微粉、3wt%的预制粉料、10wt%的预制颗粒、4.75wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、1wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯、4wt%的水搅拌均匀,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例10
将32wt%的玻璃粉、20wt%的碳化硅粉、34wt%的碳化硅颗粒、3wt%的硅微粉、5wt%的葡萄糖、6wt%的水,混合均匀后于120MPa条件下压制成型,置于700℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、15wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、6wt%的预制颗粒、4.74wt%的氧化铝微粉、0.1wt%的金属铝粉、6wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.06wt%的藻酸丙二醇酯、加入6wt%的水搅拌均匀,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
实施例11
将40wt%的玻璃粉、15wt%的碳化硅粉、35wt%的碳化硅颗粒、3wt%的硅微粉、3wt%的葡萄糖、4wt%的水,混合均匀后于120MPa条件下压制成型,置于650℃热处理3小时,随炉冷却至室温后,经破碎、筛分得到粒度小于0.088mm的预制粉料和粒度为0.088-2mm的预制颗粒。
将55wt%的矾土颗粒、18wt%的矾土细粉、2wt%的硅微粉、3wt%的预制粉料、6wt%的预制颗粒、4.75wt%的氧化铝微粉、0.1wt%的金属铝粉、4wt%的铝酸盐水泥、2wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.05wt%的藻酸丙二醇酯、5wt%的水搅拌均匀,放于模具中振动成型,再先后经室温静置24小时、110℃热处理24小时,即得所述中间包包盖。
本发明产品中间包包盖主要性能指标的测试方法如下:
常温抗折强度:将本发明制备方法制得的中间包包盖取样,按照耐火材料常温抗折强度试验方法(中华人民共和国黑色冶金行业标准)进行测试,加荷速率为0.15MPa/s±0.015MPa/s。本发明涉及实施例提供的该性能指标,是将试样经1500℃热处理3小时,冷却至室温,再按照上述行业标准测试常温抗折强度。
高温抗折强度:将本发明制备方法制得的中间包包盖取样,按照耐火材料高温抗折强度试验方法(中华人民共和国黑色冶金行业标准)进行测试,加荷速率为(0.15±0.015)MPa/s。本发明涉及实施例提供的该性能指标,是将试样经1450℃保温0.5小时后,再按照上述行业标准测试高温抗折强度。
热震稳定性:将本发明制备方法制得的中间包包盖取样,按照耐火浇注料抗热震性试验方法(水急冷法)(中华人民共和国黑色冶金行业标准)进行测试。本发明涉及实施例提供的该性能指标,试样预加热温度为1100℃。
导热系数:将本发明制备方法制得的中间包包盖取样,按照耐火材料导热系数试验方法(水流量平板法)(中华人民共和国黑色冶金行业标准)进行测试。本发明涉及实施例提供的该性能指标,试验温度为1000℃(热面温度)。
上述各实施例制备的中间包包盖,经取样测试,得到的性能列于表1。
表1本发明各实施例对应中间包包盖的性能对比
说明:实施例1-11主要是利用原料配比的变化制备预制粉料和预制颗粒,实验结果看出,采用本发明制备方法制得的中间包包盖,具有热震稳定性高(1100℃水冷大于24次)、隔热性能优良(1000℃导热系数小于2.0W/m·K)、力学强度大(1500℃热处理3小时后常温抗折强度大于14MPa,高温抗折强度(1450℃,0.5小时)大于2.3MPa)等特点,因而在使用期间包盖无开裂、剥落及掉块等现象,有利于连铸生产安全、稳定的顺行。
Claims (9)
1.一种中间包包盖浇注料,其特征是其原料及其质量百分比配方是:50-60wt%的矾土颗粒、10-20wt%的矾土细粉、2-4wt%的硅微粉、3-5wt%的预制粉料、5-10wt%的预制颗粒、3-6wt%的氧化铝微粉、0.1wt%的金属铝粉、3-6wt%的铝酸盐水泥、1-3wt%的不锈钢纤维、0.1wt%的三聚磷酸钠、0.02-0.1wt%的藻酸丙二醇酯,4-6wt%的水;所述预制粉料和预制颗粒是:将30-40wt%的玻璃粉、10-20wt%的碳化硅粉、25-35wt%的碳化硅颗粒、2-5wt%的硅微粉、3-5wt%的葡萄糖、3-6wt%的水,按比例混合均匀后,于120MPa条件下压制成型,置于650-750℃热处理3小时,随炉冷却至室温,再经破碎、筛分得到;粒度小于0.088mm的是预制粉料;粒度为0.088-2mm的是预制颗粒。
2.如权利要求1所述的中间包包盖浇注料,其特征是所述玻璃粉中SiO2的含量为50-70wt%,Na2O的含量为2-10wt%,K2O的含量为3-8wt%,CaO的含量为5-15wt%,MgO的含量为2-10wt%,玻璃粉的颗粒粒度小于0.045mm。
3.如权利要求1或2所述的中间包包盖浇注料,其特征是所述碳化硅中SiC的含量大于97wt%,碳化硅粉的粒度小于0.088mm,碳化硅颗粒的粒度为0.5-1mm。
4.如权利要求1或2所述的中间包包盖浇注料,其特征是所述矾土中Al2O3的含量为85-88wt%,Fe2O3的含量小于2wt%,矾土颗粒的粒度为1-10mm,矾土细粉的粒度小于0.088mm。
5.如权利要求1或2所述的中间包包盖浇注料,其特征是所述不锈钢纤维为含镍元素的耐热钢纤维,横截面为弯月形,所述不锈钢纤维的尺寸为(0.1-0.2mm)×(0.8-1.2mm)×(38-42mm)。
6.如权利要求5所述的中间包包盖浇注料,其特征是所述不锈钢纤维为310#。
7.如权利要求1或2所述的中间包包盖浇注料,其特征是所述金属铝粉的粒度小于0.088mm。
8.如权利要求1或2所述中间包包盖浇注料,其特征是所述硅微粉中SiO2的含量大于92wt%;所述铝酸盐水泥中Al2O3的含量大于65wt%;所述氧化铝微粉中Al2O3的含量大于98wt%,粒度小于0.088mm。
9.采用如权利要求1所述中间包包盖浇注料制备中间包包盖的方法,其特征是:
(1)按比例制备预制粉料和预制颗粒;
(2)按比例混合成中间包包盖浇注料;
(3)将中间包包盖浇注料放于模具中振动成型,经室温静置24小时,再经110℃热处理24小时,即得。
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