CN113511899A - 耐磨碳化硅陶瓷制备方法及其应用 - Google Patents
耐磨碳化硅陶瓷制备方法及其应用 Download PDFInfo
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- 229910010271 silicon carbide Inorganic materials 0.000 title claims abstract description 55
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 title claims abstract description 54
- 239000000919 ceramic Substances 0.000 title claims abstract description 45
- 238000002360 preparation method Methods 0.000 title claims abstract description 37
- 238000000227 grinding Methods 0.000 claims abstract description 39
- 238000005245 sintering Methods 0.000 claims abstract description 35
- 239000002002 slurry Substances 0.000 claims abstract description 35
- 239000000843 powder Substances 0.000 claims abstract description 27
- 239000000203 mixture Substances 0.000 claims abstract description 24
- 229910021431 alpha silicon carbide Inorganic materials 0.000 claims abstract description 19
- 238000000498 ball milling Methods 0.000 claims abstract description 15
- 238000005469 granulation Methods 0.000 claims abstract description 15
- 230000003179 granulation Effects 0.000 claims abstract description 15
- 238000004519 manufacturing process Methods 0.000 claims abstract description 15
- 239000000463 material Substances 0.000 claims abstract description 15
- 238000001816 cooling Methods 0.000 claims abstract description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 12
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 9
- 239000011230 binding agent Substances 0.000 claims abstract description 9
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 9
- 239000002270 dispersing agent Substances 0.000 claims abstract description 9
- 238000001694 spray drying Methods 0.000 claims abstract description 9
- 239000008367 deionised water Substances 0.000 claims abstract description 7
- 229910021641 deionized water Inorganic materials 0.000 claims abstract description 7
- 238000003825 pressing Methods 0.000 claims abstract description 3
- 238000000034 method Methods 0.000 claims description 13
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 claims description 9
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims description 9
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims description 8
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 claims description 6
- 229910052786 argon Inorganic materials 0.000 claims description 6
- 230000002572 peristaltic effect Effects 0.000 claims description 6
- WGTYBPLFGIVFAS-UHFFFAOYSA-M tetramethylammonium hydroxide Chemical compound [OH-].C[N+](C)(C)C WGTYBPLFGIVFAS-UHFFFAOYSA-M 0.000 claims description 6
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 5
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 5
- 239000002202 Polyethylene glycol Substances 0.000 claims description 4
- 239000000395 magnesium oxide Substances 0.000 claims description 4
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 4
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 claims description 4
- 229920001223 polyethylene glycol Polymers 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 3
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 3
- 229920002125 Sokalan® Polymers 0.000 claims description 3
- 235000019437 butane-1,3-diol Nutrition 0.000 claims description 3
- 229910052681 coesite Inorganic materials 0.000 claims description 3
- 229910052906 cristobalite Inorganic materials 0.000 claims description 3
- 229920003063 hydroxymethyl cellulose Polymers 0.000 claims description 3
- 229940031574 hydroxymethyl cellulose Drugs 0.000 claims description 3
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 3
- 239000012188 paraffin wax Substances 0.000 claims description 3
- 239000005011 phenolic resin Substances 0.000 claims description 3
- 229920001568 phenolic resin Polymers 0.000 claims description 3
- 239000004584 polyacrylic acid Substances 0.000 claims description 3
- 238000001272 pressureless sintering Methods 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 229910052682 stishovite Inorganic materials 0.000 claims description 3
- 229910052905 tridymite Inorganic materials 0.000 claims description 3
- 229940083957 1,2-butanediol Drugs 0.000 claims description 2
- BMRWNKZVCUKKSR-UHFFFAOYSA-N butane-1,2-diol Chemical compound CCC(O)CO BMRWNKZVCUKKSR-UHFFFAOYSA-N 0.000 claims description 2
- 239000002245 particle Substances 0.000 claims description 2
- 229920001495 poly(sodium acrylate) polymer Polymers 0.000 claims description 2
- NNMHYFLPFNGQFZ-UHFFFAOYSA-M sodium polyacrylate Chemical compound [Na+].[O-]C(=O)C=C NNMHYFLPFNGQFZ-UHFFFAOYSA-M 0.000 claims description 2
- 235000011187 glycerol Nutrition 0.000 claims 1
- 238000002156 mixing Methods 0.000 abstract description 8
- 235000015895 biscuits Nutrition 0.000 abstract description 7
- 238000007873 sieving Methods 0.000 abstract description 4
- 238000001953 recrystallisation Methods 0.000 abstract description 2
- 239000007921 spray Substances 0.000 description 24
- 239000006259 organic additive Substances 0.000 description 12
- 239000007788 liquid Substances 0.000 description 9
- 229910010293 ceramic material Inorganic materials 0.000 description 8
- 238000000462 isostatic pressing Methods 0.000 description 8
- 239000000126 substance Substances 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 239000004677 Nylon Substances 0.000 description 4
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000005065 mining Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000002912 waste gas Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000009991 scouring Methods 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
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Abstract
本发明公开了一种耐磨碳化硅陶瓷制备方法及其应用,旨在解决目前氧化铝生产中不耐磨损的装置或部件更换或维修频繁,不利于生产的安全性和稳定性的技术问题。本发明的制备方法为:取α‑SiC微粉、烧结助剂加入去离子水中,混合均匀,再加入分散剂、成型剂、粘结剂,混合均匀,得研磨混合料;将所述研磨混合料加入研磨球;球磨,过筛,得浆料;将所述浆料喷雾干燥,造粒;将所述造粒所得的粉料压制得素胚,无压烧结,冷却即成。本发明将所述的耐磨碳化硅陶瓷制备方法制得的材料在氧化铝生产中应用。本发明的碳化硅陶瓷制备方法将碳化硅的烧结温度较传统烧结温度降低50~100℃,有效控制碳化硅晶粒长大和重结晶,提高材料机械性能。
Description
技术领域
本发明涉及碳化硅陶瓷制备技术领域,具体涉及一种耐磨碳化硅陶瓷制备方法及其应用。
背景技术
氧化铝生产过程中,生产系统大量的装置和部件(比如管道阀门内衬、底流锥板、过流孔板、机械密封、弯头等)需要较高的耐磨损性能。不耐磨损的装置或部件增加了生产中的维修更换次数,同时也影响到配套设备运行系统的安全性、稳定性,增加了工人的劳动强度,也使得生产成本大大提高。
碳化硅陶瓷具有优异的机械性能(如硬度高、耐磨损、耐酸碱腐蚀、重量轻等独有特点,尤其与大部分材料不润湿,可长时间耐受强碱性质料浆的冲刷,延长使用寿命),较低的热膨胀系数和高的热传导系数,使得碳化硅陶瓷呈现出优异的耐磨擦性能。
然而,由于碳化硅化学键特性,其陶瓷烧结条件较为苛刻,必须借助添加剂或外部压力或反应才能实现致密化,碳化硅陶瓷的难烧结性使高性能碳化硅陶瓷的成本居高不下,严重阻碍了其应用。且现有的碳化硅陶瓷材料的低摩擦系数并不能满足所有转动润滑或转动密封工件的要求,对其他工件仍具有较大的磨损,需要使用额外的润滑剂,故有待改进。
因此,开发一种耐磨损的碳化硅陶瓷,以为氧化铝生产提供耐磨需求较高的部件,是当前氧化铝生产中迫切需要解决的技术问题之一。
发明内容
本发明要解决的技术问题是提供一种耐磨碳化硅陶瓷制备方法及其应用。旨在解决目前氧化铝生产中不耐磨损的装置或部件更换或维修频繁,不利于生产的安全性和稳定性的技术问题。
为解决上述技术问题,本发明采用如下技术方案:
本发明设计一种耐磨碳化硅陶瓷制备方法,包括以下步骤:
(1)以质量份数计,取α-SiC微粉95~99份、烧结助剂0.4~1份加入100~105份去离子水中,混合均匀,再加入分散剂2.5~4份、成型剂0.3~0.8份、粘结剂0.1~0.9份,混合均匀,得研磨混合料;
(3)将所述研磨混合料以料球质量比为2~2.5:1的比例加入研磨球;以150~250r/min转速球磨5~10h,将研磨球过250~300目筛筛除,得浆料;
(4)将所述浆料喷雾干燥,造粒;
(5)将所述造粒所得的粉料送入模具中,压制得素胚,在氩气的保护下进行无压烧结,烧结温度为1650~1700℃,保温2.5~3.5小时后缓慢降温到1350~1450℃,冷却即成。
优选的,所述α-SiC微粉的粒度为W0.5。
优选的,所述α-SiC微粉由0.027%的SiO2、0.018%的Fe2O3、0.026%的K2O、0.08%的Na2O、99.85%的SiC组成。
优选的,所述烧结助剂为氧化钇或氧化镁;
优选的,所述分散剂为聚丙烯酸、聚丙烯酸钠、羟甲基纤维素、四甲基氢氧化铵、聚乙烯醇、酚醛树脂中的至少一种;
优选的,所述成型剂石蜡、乙酸乙酯、聚乙二醇中的至少一种;
优选的,所述粘结剂为甘油、乙二醇、聚乙烯醇、1,2-丁二醇、1,3-丁二醇中的至少一种。
优选的,在所述步骤(4)中,所述喷雾干燥采用的技术参数为:热风进口温度为250~300℃,出口温度为90~150℃,进料蠕动泵转速为20~80r/min,喷嘴雾化器转速为20000r/min。
将所述的耐磨碳化硅陶瓷制备方法制得的材料在氧化铝生产中应用。
与现有技术相比,本发明的有益技术效果在于:
1. 本发明采用的是无压烧结的方式,成本低、操作简单,可以制备出形状、大小复杂的陶瓷部件,适合大规模生产。
2. 本发明的碳化硅陶瓷制备方法将碳化硅的烧结温度较传统烧结温度降低50~100℃,有效控制碳化硅晶粒长大和重结晶,提高材料机械性能。
3. 在氧化铝生产工艺中耐磨损环境下使用本发明的制备方法找辈出的碳化硅陶瓷零部件,以代替合金材料,可延长使用寿命5~10倍;还可保持生产连续、稳定,节省大量因人工、水电、其他材料及停车而造成的经济损失。
4. 本发明的碳化硅陶瓷制备方法不产生二次污染,无废气、废液及废气排放,对环境友好。
具体实施方式
下面结合实施例来说明本发明的具体实施方式,但以下实施例只是用来详细说明本发明,并不以任何方式限制本发明的范围。
在以下实施例中所涉及的仪器设备如无特别说明,均为常规仪器设备;所涉及的工业原料如无特别说明,均为市售常规工业原料;所涉及的试验方法,如无特别说明,均为常规方法。所涉及的“份”,均代表重量份。
实施例1:耐磨碳化硅陶瓷制备方法
(1)取α-SiC微粉、烧结助剂和有机添加剂,有机添加剂包括分散剂、成型剂和粘结剂。
其中,α-SiC微粉的粒度为W0.5;化学成分如表1所示:
表1 α-SiC化学成分
成分 | SiO<sub>2</sub> | Fe<sub>2</sub>O<sub>3</sub> | K<sub>2</sub>O | Na<sub>2</sub>O | SiC |
含量/% | 0.027 | 0.018 | 0.026 | 0.08 | 99.85 |
其中,烧结助剂为化学纯,有机添加剂均为工业纯。
(2)制备研磨混合料
取α-SiC微粉95份、氧化钇1份加入100份去离子水中,混合均匀,再加入聚丙烯酸3.6份、石蜡0.3份、甘油0.1份,混合均匀,得研磨混合料。
(3)制备浆料
将配置好的研磨混合料置于尼龙球磨罐中,以料球质量比为2:1的比例加入碳化硅陶瓷球作为研磨球,将盖拧紧。将球磨罐置于滚筒式球磨机上以150r/min转速球磨10h,将研磨球过300目筛筛除,即可得到各组分均匀分散的浆料。
(4)制备造粒粉料
将浆料转移到用蒸水量25kg/h喷雾造粒塔中进行造粒,使用LGZ-8高速离心式喷雾干燥机对浆料进行喷雾干燥,采用的技术参数为:热风进口温度为260℃,出口温度为95℃,进料蠕动泵转速为30r/min,喷嘴雾化器转速为20000r/min。
具体的喷雾造粒过程为:
1)打开送风机、引风机及加热开关将喷雾干燥机升温到所需温度;
2)将浆料搅拌均匀,打开喷头调好转速并运行,使离心喷雾开始高速旋转,将制备好的浆料通过嫣动泵传送到喷头进料口;
3)随着喷嘴高速旋转,浆料雾化成比表面积极的小液滴,其遇到热空气后干燥收缩,落入下方布袋收集器形成了造粒粉料。
(5)烧结
将造粒粉料送入等静压成型模具中,采用湿袋等静压成型机300-800/250成型得素胚,置于石墨坩埚内,再将该素胚放入无压真空烧结炉HYTVHS12-320中,在氩气的保护下进行烧结,烧结温度为1700℃,保温3小时后缓慢降温到1400℃,随炉冷却。
(6)对烧结的陶瓷毛坯进行轻磨加工,保证产品的精度和表面光洁度。
检测制备的碳化硅陶瓷材料性能如下:
体密度为3.2g/cm2;抗弯强度为420MPa;洛氏硬度(HRA)为92;制品完全制备成本为118元/kg。
实施例2:耐磨碳化硅陶瓷制备方法
(1)取α-SiC微粉、烧结助剂和有机添加剂,有机添加剂包括分散剂、成型剂和粘结剂。
其中,α-SiC的粒度为W0.5;化学成分如表1所示:烧结助剂为化学纯,有机添加剂均为工业纯。
(2)制备研磨混合料
取α-SiC微粉95份、氧化钇0.4份加入100份去离子水中,混合均匀,再加入羟甲基纤维素4份、乙酸乙酯0.3份、乙二醇0.3份,混合均匀,得研磨混合料。
(3)制备浆料
将配置好的研磨混合料置于尼龙球磨罐中,以料球质量比为2.5:1的比例加入碳化硅陶瓷球作为研磨球,将盖拧紧。将球磨罐置于滚筒式球磨机上以200r/min转速球磨8h,将研磨球过350目筛筛除,即可得到各组分均匀分散的浆料。
(4)制备造粒粉料
将浆料转移到用蒸水量25kg/h喷雾造粒塔中进行造粒,使用LGZ-8高速离心式喷雾干燥机对浆料进行喷雾干燥,采用的技术参数为:热风进口温度为280℃,出口温度为120℃,进料蠕动泵转速为50r/min,喷嘴雾化器转速为20000r/min。
具体的喷雾造粒过程为:
1)打开送风机、引风机及加热开关将喷雾干燥机升温到所需温度;
2)将浆料搅拌均匀,打开喷头调好转速并运行,使离心喷雾开始高速旋转,将制备好的浆料通过嫣动泵传送到喷头进料口;
3)随着喷嘴高速旋转,浆料雾化成比表面积极的小液滴,其遇到热空气后干燥收缩,落入下方布袋收集器形成了造粒粉料。
(5)烧结
将造粒粉料送入等静压成型模具中,采用湿袋等静压成型机300-800/250成型得素胚,置于石墨坩埚内,再将该素胚放入无压真空烧结炉HYTVHS12-320中,在氩气的保护下进行烧结,烧结温度为1750℃,保温2.5小时后缓慢降温到1450℃,随炉冷却。
(6)对烧结的陶瓷毛坯进行轻磨加工,保证产品的精度和表面光洁度。
检测制备的碳化硅陶瓷材料性能如下:
体密度为3.18g/cm2;抗弯强度为426MPa;洛氏硬度(HRA)为93;制品完全制备成本为115元/kg。
实施例3:耐磨碳化硅陶瓷制备方法
(1)取α-SiC微粉、烧结助剂和有机添加剂,有机添加剂包括分散剂、成型剂和粘结剂。
其中,α-SiC的粒度为W0.5;化学成分如表1所示:烧结助剂为化学纯,有机添加剂均为工业纯。
(2)制备研磨混合料
取α-SiC微粉98份、氧化镁0.8份加入100份去离子水中,混合均匀,再加入四甲基氢氧化铵2.5份、聚乙二醇0.8份、聚乙烯醇0.9份,混合均匀,得研磨混合料。
(3)制备浆料
将配置好的研磨混合料置于尼龙球磨罐中,以料球质量比为2.2:1的比例加入碳化硅陶瓷球作为研磨球,将盖拧紧。将球磨罐置于滚筒式球磨机上以180r/min转速球磨9h,将研磨球过300目筛筛除,即可得到各组分均匀分散的浆料。
(4)制备造粒粉料
将浆料转移到用蒸水量25kg/h喷雾造粒塔中进行造粒,使用LGZ-8高速离心式喷雾干燥机对浆料进行喷雾干燥,采用的技术参数为:热风进口温度为250℃,出口温度为90℃,进料蠕动泵转速20r/min,喷嘴雾化器转速为20000r/min。
具体的喷雾造粒过程为:
1)打开送风机、引风机及加热开关将喷雾干燥机升温到所需温度;
2)将浆料搅拌均匀,打开喷头调好转速并运行,使离心喷雾开始高速旋转,将制备好的浆料通过嫣动泵传送到喷头进料口;
3)随着喷嘴高速旋转,浆料雾化成比表面积极的小液滴,其遇到热空气后干燥收缩,落入下方布袋收集器形成了造粒粉料。
(5)烧结
将造粒粉料送入等静压成型模具中,采用湿袋等静压成型机300-800/250成型得素胚,置于石墨坩埚内,再将该素胚放入无压真空烧结炉HYTVHS12-320中,在氩气的保护下进行烧结,烧结温度为1700℃,保温3时后缓慢降温到1400℃,随炉冷却。
(6)对烧结的陶瓷毛坯进行轻磨加工,保证产品的精度和表面光洁度。
检测制备的碳化硅陶瓷材料性能如下:
体密度为3.15g/cm2;抗弯强度为421MPa;洛氏硬度(HRA)为91.5;制品完全制备成本为110元/kg。
实施例4:耐磨碳化硅陶瓷制备方法
(1)取α-SiC微粉、烧结助剂和有机添加剂,有机添加剂包括分散剂、成型剂和粘结剂。
其中,α-SiC的粒度为W0.5;化学成分如表1所示:烧结助剂为化学纯,有机添加剂均为工业纯。
(2)制备研磨混合料
取α-SiC微粉99份、氧化镁1份加入100份去离子水中,混合均匀,再加入酚醛树脂3.5份、聚乙二醇0.5份、1,3-丁二醇0.4份,混合均匀,得研磨混合料。
(3)制备浆料
将配置好的研磨混合料置于尼龙球磨罐中,以料球质量比为2:1的比例加入碳化硅陶瓷球作为研磨球,将盖拧紧。将球磨罐置于滚筒式球磨机上以250r/min转速球磨5h,将研磨球400目筛筛除,即可得到各组分均匀分散的浆料。
(4)制备造粒粉料
将浆料转移到用蒸水量25kg/h喷雾造粒塔中进行造粒,使用LGZ-8高速离心式喷雾干燥机对浆料进行喷雾干燥,采用的技术参数为:热风进口温度为300℃,出口温度为120℃,进料蠕动泵转速80r/min,喷嘴雾化器转速为20000r/min。
具体的喷雾造粒过程为:
1)打开送风机、引风机及加热开关将喷雾干燥机升温到所需温度;
2)将浆料搅拌均匀,打开喷头调好转速并运行,使离心喷雾开始高速旋转,将制备好的浆料通过嫣动泵传送到喷头进料口;
3)随着喷嘴高速旋转,浆料雾化成比表面积极的小液滴,其遇到热空气后干燥收缩,落入下方布袋收集器形成了造粒粉料。
(5)烧结
将造粒粉料送入等静压成型模具中,采用湿袋等静压成型机300-800/250成型得素胚,置于石墨坩埚内,再将该素胚放入无压真空烧结炉HYTVHS12-320中,在氩气的保护下进行烧结,烧结温度为1650℃,保温3.5时后缓慢降温到1350℃,随炉冷却。
(6)对烧结的陶瓷毛坯进行轻磨加工,保证产品的精度和表面光洁度。
检测制备的碳化硅陶瓷材料性能如下:
体密度为3.16g/cm2;抗弯强度为420MPa;洛氏硬度(HRA)为91.3;制品完全制备成本为116元/kg。
工程例1:
采用实施例2的制备方法制得的碳化硅陶瓷材料支撑,碳化物陶瓷旋流器底流口,自2018年5月在中铝矿业有限公司氧化铝配料车间试用,在前3个月试用期内,内径从90mm磨损至94mm,连续运行至2019年3月份,使用寿命可达1年,展现出了优异的耐磨性能,经观察,无压碳化硅陶瓷整体磨损均匀,过流件底座内表面光滑,没有失圆现象,也没有局部凹凸不平现象,耐磨性能良好,而该矿业公司原先使用的硬质合金质底流口使用30天则因磨损严重而报废。
工程例2:
采用实施例2的制备方法制得的碳化硅陶瓷材料支撑,碳化物陶瓷旋流器底流口,自2019年6月在东方希望三门峡铝业有限公司试用,连续运行1个半月,内径没有出现磨损,表面光滑,而该公司之前所使用的硬质合金材质的底流口不到1个月则报废。
上面结合实施例对本发明作了详细的说明,但是,所属技术领域的技术人员能够理解,在不脱离本发明宗旨的前提下,还可以对上述实施例中的各个具体参数进行变更,形成多个具体的实施例,均为本发明的常见变化范围,在此不再一一详述。
Claims (9)
1.一种耐磨碳化硅陶瓷制备方法,其特征在于:包括以下步骤:
(1)以质量份数计,取α-SiC微粉95~99份、烧结助剂0.4~1份加入100~105份去离子水中,混合均匀,再加入分散剂2.5~4份、成型剂0.3~0.8份、粘结剂0.1~0.9份,混合均匀,得研磨混合料;
(3)将所述研磨混合料以料球质量比为2~2.5:1的比例加入研磨球;以150~250r/min转速球磨5~10h,将研磨球过250~300目筛筛除,得浆料;
(4)将所述浆料喷雾干燥,造粒;
(5)将所述造粒所得的粉料送入模具中,压制得素胚,在氩气的保护下进行无压烧结,烧结温度为1650~1700℃,保温2.5~3.5小时后缓慢降温到1350~1450℃,冷却即成。
2.依据权利要求1所述的耐磨碳化硅陶瓷制备方法,其特征在于,所述α-SiC微粉的粒度为W0.5。
3.依据权利要求2所述的耐磨碳化硅陶瓷制备方法,其特征在于,所述α-SiC微粉由0.027%的SiO2、0.018%的Fe2O3、0.026%的K2O、0.08%的Na2O、99.85%的SiC组成。
4.依据权利要求1所述的耐磨碳化硅陶瓷制备方法,其特征在于,所述烧结助剂为氧化钇或氧化镁。
5.依据权利要求1所述的耐磨碳化硅陶瓷制备方法,其特征在于,所述分散剂为聚丙烯酸、聚丙烯酸钠、羟甲基纤维素、四甲基氢氧化铵、聚乙烯醇、酚醛树脂中的至少一种。
6.依据权利要求1所述的耐磨碳化硅陶瓷制备方法,其特征在于,所述成型剂石蜡、乙酸乙酯、聚乙二醇中的至少一种。
7.依据权利要求1所述的耐磨碳化硅陶瓷制备方法,其特征在于,所述粘结剂为甘油、乙二醇、聚乙烯醇、1,2-丁二醇、1,3-丁二醇中的至少一种。
8.依据权利要求1所述的耐磨碳化硅陶瓷制备方法,其特征在于,在所述步骤(4)中,所述喷雾干燥采用的技术参数为:热风进口温度为250~300℃,出口温度为90~150℃,进料蠕动泵转速为20~80r/min,喷嘴雾化器转速为20000r/min。
9.权利要求1所述的耐磨碳化硅陶瓷制备方法制得的材料在氧化铝生产中的应用。
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JPH05194034A (ja) * | 1991-08-19 | 1993-08-03 | Solvay Deutsche Gmbh | 炭化珪素粉末を基礎とする顆粒、該顆粒の製造法、および常圧焼結された炭化珪素セラミック |
US5756409A (en) * | 1993-02-04 | 1998-05-26 | Korund Laufenburg, Gmbh | Silicon-carbide sintered abrasive grain and process for its production |
CN102030534A (zh) * | 2010-11-09 | 2011-04-27 | 浙江大学 | 碳化硅陶瓷的制备方法 |
CN106431414A (zh) * | 2016-09-29 | 2017-02-22 | 连云港东渡碳化硅有限公司 | 一种无压烧结碳化硅陶瓷的制备方法 |
CN108203300A (zh) * | 2018-02-07 | 2018-06-26 | 陕西科谷新材料科技有限公司 | 一种高韧性、高电阻率碳化硅陶瓷的制备方法 |
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