CN113213962B - 一种具有贯穿孔的多孔陶瓷及其制备方法和应用 - Google Patents
一种具有贯穿孔的多孔陶瓷及其制备方法和应用 Download PDFInfo
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Abstract
一种具有贯穿孔的多孔陶瓷,由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、30‑50份烧结助剂、5‑12份粘结剂、12‑18份二氧化锆纤维、2‑10份球形造孔剂和3‑6支三叉形有机造孔剂组成,所述三叉形有机造孔剂由底部相连的三个圆柱体组成,分离角度是15‑30°,其中圆柱体的直径为10‑100μm,三叉形有机造孔剂在烧结前加入反应原料中;所述烧结条件是:从室温以8‑10℃/min的速率升温至450‑550℃后保温2‑5h,以3‑5℃/min的速率升温至950‑1050℃保温2‑3h,再以1‑2℃/min的速率升温至1450‑1550℃后保温5‑8h。本发明还公开了具有贯穿孔的多孔陶瓷的制备方法和其在气浮轴承中的应用。
Description
技术领域
本发明属于多孔陶瓷技术领域,具体涉及一种具有贯穿孔的多孔陶瓷及其制备方法和应用。
背景技术
轴承是当今时代各类机械装备中必不可少的基础件,其性能的优劣直接的影响和决定着机械装备的性能好坏。人们认为轴承的摩擦力基本上是轴承材料的函数。直到1883年,工程师彼得罗夫首次对流体润滑。轴承摩擦效应作了理论分析,指出产生这种摩擦效应的主要因素不是轴承材料,而是润滑膜。气浮轴承也叫气体轴承,用空气作为润滑剂的滑动轴承。正常工作时,轴和轴承表面完全由气膜所隔开,凭借气膜中压力的变化来支承轴和外力负荷。由于空气比油粘滞性小,耐高温,无污染,因而气浮轴承可用于高速机器、仪器及放射性装置中。目前应用于气浮轴承的多孔材料主要有:多孔质青铜和多孔质不锈钢。多孔材料的渗透率是决定气浮轴承性能的主要因素,但是因为青铜和不锈钢材料硬度小,用机械加工的方法会产生磨削碎屑,堵塞多孔材料表面的孔隙,降低多孔材料的渗透率,从而影响气浮轴承的性能。
现有的气浮轴承气体流动的槽道多是延内圆的半径向外,这样不能发挥动压的最佳效应,并且气体流动小时承载力不足,气体流动大时,流向及流量分散不稳定。
发明内容
为解决现有技术中以合金作为材质制作的气浮轴承在加工时容易产生碎屑堵孔以及气浮轴承内槽道方向影响气体流量的问题,本发明提供一种具有贯穿孔的多孔陶瓷及其制备方法和应用。
本发明采用的方案如下:
一种具有贯穿孔的多孔陶瓷,由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、30-50份烧结助剂、5-12份粘结剂、12-18份二氧化锆纤维、2-10份球形造孔剂和3-6支三叉形有机造孔剂组成,所述三叉形有机造孔剂由底部相连的三个圆柱体组成,分离角度是15-30°,其中圆柱体的直径为10-100μm,三叉形有机造孔剂在烧结前加入反应原料中;
所述烧结条件是:从室温以8-10℃/min的速率升温至450-550℃后保温2-5h,以3-5℃/min的速率升温至950-1050℃保温2-3h,再以1-2℃/min的速率升温至1450-1550℃后保温5-8h。
作为本发明的一种优选技术方案,所述烧结助剂是氧化镁、氧化钇或氧化铝。
作为本发明的一种优选技术方案,所述粘结剂是浓度为5-10wt%的PVA溶液。
作为本发明的一种优选技术方案,所述二氧化锆纤维的平均长度为20-100μm。
作为本发明的一种优选技术方案,所述球形造孔剂是粒径为20-50μm的石墨粉。
作为本发明的一种优选技术方案,所述三叉形有机造孔剂成分是环氧树脂、聚乙烯、聚丙烯或聚苯乙烯。
一种具有贯穿孔的多孔陶瓷的制备方法,包括以下步骤:
A、按质量份数配比称取碳化硅颗粒、烧结助剂、二氧化锆纤维和球形造孔剂混合,加入等同于上述原料总质量2-3倍的乙醇,球磨6-10h;
B、在60-80℃温度条件下烘干,研磨10-30分钟,加入所述质量份数的粘结剂,造粒、研磨,并过80-120目筛网;
C、将步骤B得到的粉料加入到环形模具中,将3-6支三叉形有机造孔剂埋在模具二分之一高度的位置,三叉形向外,其中三叉形有机造孔剂彼此间分离角度是120-60°、长度至少贯穿粉料;
D、经压制成型后烧结,烧结条件是:从室温以8-10℃/min的速率升温至450-550℃后保温2-5h,以3-5℃/min的速率升温至950-1050℃保温2-3h,再以1-2℃/min的速率升温至1450-1550℃后保温5-8h,冷却至室温得到具有贯穿孔的多孔陶瓷。
作为本发明的一种优选技术方案,步骤C所述三叉形有机造孔剂的方向是使得位于中间的圆柱体与内圆相切。
作为本发明的一种优选技术方案,步骤D冷却时设置降温程序:以1-2℃/min的速率降温至950-1050℃,再以3-5℃/min的速率降温至450-550℃,之后自然冷却至室温。
一种具有贯穿孔的多孔陶瓷在气浮轴承中的应用。
与现有技术相比,本发明具有的有益效果是:
(1)提供一种制备具有贯穿孔的多孔陶瓷的制备方法;
(2)制备得到的具有贯穿孔的多孔陶瓷具有稳定性好、耐磨效果优、使用寿命长、刚性大,、耐高温的优点;
(3)造孔剂的加入使得陶瓷的显气孔率大幅上升,显气孔率有明显的增加,并且都在60%以上,提升了气体在槽道内的运输效率,优化了气体流动方向,应用于气浮轴承时能够提高工作状态下的稳定性;
(4)多孔陶瓷的硬度与未加入造孔剂的陶瓷比相近,并且抗磨损性能相较于未加造孔剂的陶瓷有大幅提升,从0.12g/cm2提升至0.09 g/cm2左右。
附图说明
图1是三叉形有机造孔剂的模型示意图;
图2是烧结前3支三叉形有机造孔剂的方向示意图。
具体实施方式
以下结合实施例对本发明作进一步的描述,实施例仅用于对本发明进行说明,并不构成对权利要求范围的限制,本领域技术人员可以想到的其他替代手段,均在本发明权利要求范围内。
实施例1
一种具有贯穿孔的多孔陶瓷,由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、30份烧结助剂、5份粘结剂、12份二氧化锆纤维、2份球形造孔剂和3支三叉形有机造孔剂组成,所述三叉形有机造孔剂由底部相连的三个圆柱体组成,分离角度是15°,其中圆柱体的直径为10μm,三叉形有机造孔剂在烧结前加入反应原料中;
所述烧结条件是:从室温以8℃/min的速率升温至450℃后保温2-3h,以3℃/min的速率升温至950℃保温2h,再以1℃/min的速率升温至1450℃后保温5h。
具体地,所述烧结助剂是氧化镁。
具体地,所述粘结剂是浓度为5wt%的PVA溶液。
具体地,所述二氧化锆纤维的平均长度为20-100μm。
具体地,所述球形造孔剂是粒径为20-50μm的石墨粉。
具体地,所述三叉形有机造孔剂成分是环氧树脂。
上述具有贯穿孔的多孔陶瓷的制备方法,包括以下步骤:
A、按质量份数配比称取碳化硅颗粒、烧结助剂、二氧化锆纤维和球形造孔剂混合,加入等同于上述原料总质量2倍的乙醇,球磨6h;
B、在60℃温度条件下烘干,研磨10分钟,加入所述质量份数的粘结剂,造粒、研磨,并过80目筛网;
C、将步骤B得到的粉料加入到环形模具中,将3支三叉形有机造孔剂埋在模具二分之一高度的位置,三叉形向外,其中三叉形有机造孔剂彼此间分离角度是120°、长度至少贯穿粉料;
D、经压制成型后烧结,烧结条件是:从室温以8℃/min的速率升温至450℃后保温2h,以3℃/min的速率升温至950℃保温2h,再以1℃/min的速率升温至1450℃后保温5h,冷却至室温得到具有贯穿孔的多孔陶瓷。
具体地,步骤C所述三叉形有机造孔剂的方向是使得位于中间的圆柱体与内圆相切。
具体地,步骤D冷却时设置降温程序:以1℃/min的速率降温至950℃,再以3℃/min的速率降温至450℃,之后自然冷却至室温。
上述制备方法制备得到的具有贯穿孔的多孔陶瓷在气浮轴承中的应用。
实施例2
一种具有贯穿孔的多孔陶瓷,由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、50份烧结助剂、12份粘结剂、18份二氧化锆纤维、10份球形造孔剂和6支三叉形有机造孔剂组成,所述三叉形有机造孔剂由底部相连的三个圆柱体组成,分离角度是30°,其中圆柱体的直径为100μm,三叉形有机造孔剂在烧结前加入反应原料中;
所述烧结条件是:从室温以10℃/min的速率升温至550℃后保温5h,以5℃/min的速率升温至1050℃保温3h,再以2℃/min的速率升温至1550℃后保温8h。
具体地,所述烧结助剂是氧化钇。
具体地,所述粘结剂是浓度为10wt%的PVA溶液。
具体地,所述二氧化锆纤维的平均长度为20-100μm。
具体地,所述球形造孔剂是粒径为20-50μm的石墨粉。
具体地,所述三叉形有机造孔剂成分是聚乙烯。
上述具有贯穿孔的多孔陶瓷的制备方法,包括以下步骤:
A、按质量份数配比称取碳化硅颗粒、烧结助剂、二氧化锆纤维和球形造孔剂混合,加入等同于上述原料总质量3倍的乙醇,球磨10h;
B、在80℃温度条件下烘干,研磨30分钟,加入所述质量份数的粘结剂,造粒、研磨,并过120目筛网;
C、将步骤B得到的粉料加入到环形模具中,将6支三叉形有机造孔剂埋在模具二分之一高度的位置,三叉形向外,其中三叉形有机造孔剂彼此间分离角度是60°、长度至少贯穿粉料;
D、经压制成型后烧结,烧结条件是:从室温以10℃/min的速率升温至550℃后保温5h,以5℃/min的速率升温至1050℃保温3h,再以2℃/min的速率升温至1550℃后保温8h,冷却至室温得到具有贯穿孔的多孔陶瓷。
具体地,步骤C所述三叉形有机造孔剂的方向是使得位于中间的圆柱体与内圆相切。
具体地,步骤D冷却时设置降温程序:以2℃/min的速率降温至1050℃,再以5℃/min的速率降温至550℃,之后自然冷却至室温。
上述制备方法制备得到的具有贯穿孔的多孔陶瓷在气浮轴承中的应用。
实施例3
一种具有贯穿孔的多孔陶瓷,由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、40份烧结助剂、8份粘结剂、15份二氧化锆纤维、5份球形造孔剂和4支三叉形有机造孔剂组成,所述三叉形有机造孔剂由底部相连的三个圆柱体组成,分离角度是20°,其中圆柱体的直径为50μm,三叉形有机造孔剂在烧结前加入反应原料中;
所述烧结条件是:从室温以9℃/min的速率升温至500℃后保温3h,以4℃/min的速率升温至1000℃保温2.5h,再以1.5℃/min的速率升温至1500℃后保温7h。
具体地,所述烧结助剂是氧化铝。
具体地,所述粘结剂是浓度为8wt%的PVA溶液。
具体地,所述二氧化锆纤维的平均长度为20-100μm。
具体地,所述球形造孔剂是粒径为20-50μm的石墨粉。
具体地,所述三叉形有机造孔剂成分是聚丙烯。
上述具有贯穿孔的多孔陶瓷的制备方法,包括以下步骤:
A、按质量份数配比称取碳化硅颗粒、烧结助剂、二氧化锆纤维和球形造孔剂混合,加入等同于上述原料总质量2.5倍的乙醇,球磨8h;
B、在70℃温度条件下烘干,研磨20分钟,加入所述质量份数的粘结剂,造粒、研磨,并过100目筛网;
C、将步骤B得到的粉料加入到环形模具中,将4支三叉形有机造孔剂埋在模具二分之一高度的位置,三叉形向外,其中三叉形有机造孔剂彼此间分离角度是90°、长度至少贯穿粉料;
D、经压制成型后烧结,烧结条件是:从室温以9℃/min的速率升温至500℃后保温3h,以4℃/min的速率升温至1000℃保温2.5h,再以1.5℃/min的速率升温至1500℃后保温7h,冷却至室温得到具有贯穿孔的多孔陶瓷。
具体地,步骤C所述三叉形有机造孔剂的方向是使得位于中间的圆柱体与内圆相切。
具体地,步骤D冷却时设置降温程序:以1℃/min的速率降温至1000℃,再以4℃/min的速率降温至500℃,之后自然冷却至室温。
上述制备方法制备得到的具有贯穿孔的多孔陶瓷在气浮轴承中的应用。
实施例4
一种具有贯穿孔的多孔陶瓷,由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、50份烧结助剂、5份粘结剂、18份二氧化锆纤维、2份球形造孔剂和4支三叉形有机造孔剂组成,所述三叉形有机造孔剂由底部相连的三个圆柱体组成,分离角度是30°,其中圆柱体的直径为60μm,三叉形有机造孔剂在烧结前加入反应原料中;
所述烧结条件是:从室温以10℃/min的速率升温至500℃后保温4h,以3℃/min的速率升温至1000℃保温2h,再以1℃/min的速率升温至1500℃后保温6h。
具体地,所述烧结助剂是氧化铝。
具体地,所述粘结剂是浓度为5wt%的PVA溶液。
具体地,所述二氧化锆纤维的平均长度为20-100μm。
具体地,所述球形造孔剂是粒径为20-50μm的石墨粉。
具体地,所述三叉形有机造孔剂成分是聚苯乙烯。
上述具有贯穿孔的多孔陶瓷的制备方法,包括以下步骤:
A、按质量份数配比称取碳化硅颗粒、烧结助剂、二氧化锆纤维和球形造孔剂混合,加入等同于上述原料总质量2倍的乙醇,球磨8h;
B、在60℃温度条件下烘干,研磨30分钟,加入所述质量份数的粘结剂,造粒、研磨,并过80目筛网;
C、将步骤B得到的粉料加入到环形模具中,将4支三叉形有机造孔剂埋在模具二分之一高度的位置,三叉形向外,其中三叉形有机造孔剂彼此间分离角度是90°、长度至少贯穿粉料;
D、经压制成型后烧结,烧结条件是:从室温以10℃/min的速率升温至500℃后保温4h,以3℃/min的速率升温至1000℃保温2h,再以1℃/min的速率升温至1500℃后保温6h,冷却至室温得到具有贯穿孔的多孔陶瓷。
具体地,步骤C所述三叉形有机造孔剂的方向是使得位于中间的圆柱体与内圆相切。
具体地,步骤D冷却时设置降温程序:以1℃/min的速率降温至1000℃,再以5℃/min的速率降温至500℃,之后自然冷却至室温。
上述制备方法制备得到的具有贯穿孔的多孔陶瓷在气浮轴承中的应用。
对比例
一种具有贯穿孔的多孔陶瓷,由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、50份烧结助剂、5份粘结剂、18份二氧化锆纤维;
所述烧结条件是:从室温以10℃/min的速率升温至500℃后保温4h,以3℃/min的速率升温至1000℃保温2h,再以1℃/min的速率升温至1500℃后保温6h。
具体地,所述烧结助剂是氧化铝。
具体地,所述粘结剂是浓度为5wt%的PVA溶液。
具体地,所述二氧化锆纤维的平均长度为20-100μm。
上述具有贯穿孔的多孔陶瓷的制备方法,包括以下步骤:
A、按质量份数配比称取碳化硅颗粒、烧结助剂和二氧化锆纤维混合,加入等同于上述原料总质量2倍的乙醇,球磨8h;
B、在60℃温度条件下烘干,研磨30分钟,加入所述质量份数的粘结剂,造粒、研磨,并过80目筛网;
C、将步骤B得到的粉料加入到环形模具中;
D、经压制成型后烧结,烧结条件是:从室温以10℃/min的速率升温至500℃后保温4h,以3℃/min的速率升温至1000℃保温2h,再以1℃/min的速率升温至1500℃后保温6h,冷却至室温得到具有贯穿孔的多孔陶瓷。
具体地,步骤D冷却时设置降温程序:以1℃/min的速率降温至1000℃,再以5℃/min的速率降温至500℃,之后自然冷却至室温。
上述制备方法制备得到的陶瓷在气浮轴承中的应用。
对比例和实施例4的工艺步骤基本相同,只是不加入球形造孔剂和三叉形有机造孔剂。
根据GBT1966-1996“多孔陶瓷显气孔率、容重试验方法”测试实施例1-4及对比例的显气孔率,根据GTB16534-1996“工程陶瓷维氏硬度试验方法”测试实施例1-4及对比例的硬度,根据JC/T2345-2015“精细陶瓷常温耐磨性试验方法”测试实施例1-4及对比例的耐磨性能,测试结果如下表1所示。
表1 实施例1-4及对比例的显气孔率、硬度和磨损率的测试结果
显气孔率(%) | 硬度(HV) | 磨损率(g/cm<sup>2</sup>) | |
实施例1 | 65 | 360 | 0.09 |
实施例2 | 62 | 370 | 0.091 |
实施例3 | 66 | 380 | 0.088 |
实施例4 | 63 | 370 | 0.095 |
对比例 | 23 | 385 | 0.124 |
表1的测试结果表明,造孔剂的加入使得陶瓷的显气孔率大幅上升,加入造孔剂的实施例1-4与对比例相比,显气孔率有明显的增加,并且都在60%以上,同时硬度下降不大,磨损率也有了较高的提升,表明本发明方案提升了显气孔率并且提升了抗磨损性能。
上述实施例仅仅是为清楚地说明所作的举例,而并非对实施方式的限定。对于所属领域的普通技术人员来说,在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引伸出的显而易见的变化或变动仍处于本发明创造的保护范围之中。
Claims (8)
1.一种具有贯穿孔的多孔陶瓷的制备方法,其特征在于:所述具有贯穿孔的多孔陶瓷用于气浮轴承;
所述具有贯穿孔的多孔陶瓷由反应原料烧结而成,所述反应原料按质量份数配比由100份碳化硅颗粒、30-50份烧结助剂、5-12份粘结剂、12-18份二氧化锆纤维、2-10份球形造孔剂和3-6支三叉形有机造孔剂组成,所述三叉形有机造孔剂由底部相连的三个圆柱体组成,分离角度是15-30°,其中圆柱体的直径为10-100μm,三叉形有机造孔剂在烧结前加入反应原料中;
所述具有贯穿孔的多孔陶瓷的制备方法包括以下步骤:
A、按质量份数配比称取碳化硅颗粒、烧结助剂、二氧化锆纤维和球形造孔剂混合,加入等同于上述原料总质量2-3倍的乙醇,球磨6-10h;
B、在60-80℃温度条件下烘干,研磨10-30分钟,加入所述质量份数的粘结剂,造粒、研磨,并过80-120目筛网;
C、将步骤B得到的粉料加入到环形模具中,将3-6支三叉形有机造孔剂埋在模具二分之一高度的位置,三叉形向外,其中三叉形有机造孔剂彼此间分离角度是120-60°、长度至少贯穿粉料;
D、经压制成型后烧结,烧结条件是:从室温以8-10℃/min的速率升温至450-550℃后保温2-5h,以3-5℃/min的速率升温至950-1050℃保温2-3h,再以1-2℃/min的速率升温至1450-1550℃后保温5-8h,冷却至室温得到具有贯穿孔的多孔陶瓷。
2.根据权利要求1所述的具有贯穿孔的多孔陶瓷的制备方法,其特征在于:所述烧结助剂是氧化镁、氧化钇或氧化铝。
3.根据权利要求1所述的具有贯穿孔的多孔陶瓷的制备方法,其特征在于:所述粘结剂是浓度为5-10wt%的PVA溶液。
4.根据权利要求1所述的具有贯穿孔的多孔陶瓷的制备方法,其特征在于:所述二氧化锆纤维的平均长度为20-100μm。
5.根据权利要求1所述的具有贯穿孔的多孔陶瓷的制备方法,其特征在于:所述球形造孔剂是粒径为20-50μm的石墨粉。
6.根据权利要求1所述的具有贯穿孔的多孔陶瓷的制备方法,其特征在于:所述三叉形有机造孔剂成分是环氧树脂、聚乙烯、聚丙烯或聚苯乙烯。
7.根据权利要求1所述的具有贯穿孔的多孔陶瓷的制备方法,其特征在于:步骤C所述三叉形有机造孔剂的方向是使得位于中间的圆柱体与内圆相切。
8.根据权利要求1所述的具有贯穿孔的多孔陶瓷的制备方法,其特征在于:步骤D冷却时设置降温程序:以1-2℃/min的速率降温至950-1050℃,再以3-5℃/min的速率降温至450-550℃,之后自然冷却至室温。
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