CN113651625A - 一种不开裂抗侵蚀高铝浇注料及其应用 - Google Patents
一种不开裂抗侵蚀高铝浇注料及其应用 Download PDFInfo
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- 241001408630 Chloroclystis Species 0.000 abstract 1
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Abstract
本发明属于耐火材料技术领域,具体涉及一种不开裂抗侵蚀高铝浇注料及其应用,包括如下步骤:1)浇注主料和外加剂配比加入混料机,制成浇注泥料;2)制作成型模具置于设备铁壳内部放到振动平台上;3)设备铁壳内设防爆纤维层和保温层;4)注入浇注泥料,振实成型,制得耐火内衬坯体;5)取下成型模具,坯体内侧养护,刮除多余浇注泥料;6)坯体低温热处理;7)坯体烧结,制得成品;8)随机取样成品检测。浇注主料由焦宝石骨料、ρ‑氧化铝、分散型氧化铝、纤维粉、白刚玉和复合添加剂组成;复合添加剂由冰晶石、防爆纤维和纯铝酸钙水泥组成。采用该浇注料制作的耐火材料内部组织致密,具有良好的抗热震、不粘铝和抗侵蚀热,不易开裂。
Description
技术领域
本发明属于耐火材料技术领域,具体涉及一种不开裂抗侵蚀高铝浇注料及其应用。
背景技术
在铝合金热成型生产工艺中,铝液要经过融化、输送、净化、结晶成型等工序加工,生产过程中需要用到相关生产设备,例如,熔化炉、溜槽、除气箱和过滤箱等。各设备需内衬耐火材料以免污染铝液,并且要保证铝液不能泄露,另一方面必须保温隔热效果好,因此,要求耐火内衬必须具有耐高温、抗侵蚀、不沾铝、不开裂等性能。传统的制作耐火内衬的浇注料虽然抗侵蚀性能良好,但是对于较大型设备(如:除气箱、过滤箱)的耐火内衬制作,目前一般都是先将制作耐火内衬的浇注料浇注进特定成型模具里制作成内衬预制件,然后再内衬预制件装配到相应的生产设备铁壳内侧,由于铝合金热成型原料铝液温度很高,热膨胀系数较大,生产过程中容易出现设备内衬预制件开裂导致铝液泄漏的情况,造成铝合金产品存在质量隐患,并且生产过程存在安全隐患。
发明内容
针对上述情况,本发明提供了一种不开裂抗侵蚀高铝浇注料,以及使用该浇注料制作耐火内衬的应用方法,能够有效解决铝合金热成型生产设备耐火内衬预制件生产过程中易开裂的问题。
为了实现以上目的,本发明采用如下技术方案:
一种不开裂抗侵蚀高铝浇注料,包括浇注主料和外加剂,所述浇注主料由焦宝石骨料、ρ-氧化铝、分散型氧化铝、纤维粉、白刚玉和复合添加剂组成;所述复合添加剂由冰晶石、防爆纤维和纯铝酸钙水泥组成。
进一步地,按质量百分比计,所述浇注主料由以下成分组成:
焦宝石骨料1-8mm,40-50%;
ρ-氧化铝0.1-3mm,3-5%;
分散型氧化铝0.5-2.5μm,1-5%;
碳纳米纤维粉,4-6%;
白刚玉300目,10-15%;
石英粉1500目,15-20%
复合添加剂,8-12%。
进一步地,按质量百分比计,所述复合添加剂在浇注主料中配比为:冰晶石325目,25%;防爆纤维4-5mm,10%;纯铝酸钙水泥,65%。
进一步地,所述外加剂由占所述浇注主料总质量0.1%-0.3%的六偏磷酸钠、0.01%-0.03%的三聚氰氨树脂和5-7%的水组成。
利用上述不开裂抗侵蚀高铝浇注料制作耐火内衬的方法,步骤如下:
1)将不开裂抗侵蚀高铝浇注料浇注主料和外加剂各组分按照配比加入混料机,温度15-35℃,搅拌40-60min,混合均匀,制成浇注泥料;
2)按照图纸制作耐火内衬成型模具;将所述耐火内衬成型模具置于设备铁壳内部一起放置到振动平台上;
3)在所述设备铁壳内侧配合设置防爆纤维层,并在所述防爆纤维层内侧设置多层保温层,且最内层保温层内侧紧密设置一层保温砖;
4)在保温砖层与所述耐火内衬成型模具之间注入步骤1)制得的浇注泥料,启动振动平台对浇注泥料进行振实成型,制得耐火内衬坯体;
5)取下所述耐火内衬坯体内部的成型模具,同时对所述耐火内衬坯体内侧进行养护,刮除其内多余浇注泥料;
6)对所述耐火内衬坯体整体进行缓慢低温热处理,干燥脱去其中游离水,消除其内部应力;
7)将所述耐火内衬坯体按照450-600℃烧制曲线进行烧结,除去其中自由水和结晶水,制得耐火内衬成品;
8)随机取样检测所述耐火内衬成品的强度和不沾铝性能,检测性能达标,即可入库或出厂。
本发明还包括能够使其正常使用的其它组件,均为本领域的常规手段,另外,本发明中未加限定的装置或组件,均采用本领域的现有技术。
本发明的有益效果如下:
采用本发明提供的不开裂抗侵蚀高铝浇注料制得的耐火内衬,通过合理控制浇注料各组分配比和制备工艺等,使得耐火内衬密度较高,铝合金生产结束后铝皮易清理、衬体不掉块,生产的铝合金成品的各项物理性能指标合格,适用于高端铝合金材料生产,能够减轻工人劳动强度,降低生产成本,提高耐火内衬的浇注性能,润湿角大,热膨胀系数低,抗冲刷性强,具有良好的抗热振性能和抗侵蚀性能,不易开裂,有利于延长其使用寿命,消除铝合金产品质量隐患和生产过程安全隐患。
附图说明
图1为实施例中不开裂抗侵蚀高铝浇注料的生产工艺流程图。
具体实施方式
下面将结合具体的实施例,对本发明的技术方案进行清晰完整地描述,显然,所描述实施例仅仅是本发明的部分实施例,而非全部实施例。
实施例
如图1所示,一种不开裂抗侵蚀高铝浇注料,包括浇注主料和外加剂,所述浇注主料由焦宝石骨料、ρ-氧化铝、分散型氧化铝、纤维粉、白刚玉和复合添加剂组成;所述复合添加剂由冰晶石、防爆纤维和纯铝酸钙水泥组成。
按质量百分比计,所述浇注主料由以下成分组成:
焦宝石骨料1-8mm,40-50%;
ρ-氧化铝0.1-3mm,3-5%;
分散型氧化铝0.5-2.5μm,1-5%;
碳纳米纤维粉,4-6%;
白刚玉300目,10-15%;
石英粉1500目,15-20%
复合添加剂,8-12%。
按质量百分比计,所述复合添加剂在浇注主料中配比为:冰晶石325目,25%;防爆纤维4-5mm,10%;纯铝酸钙水泥,65%。
所述外加剂由占所述浇注主料总质量0.1%-0.3%的六偏磷酸钠、0.01%-0.03%的三聚氰氨树脂和5-7%的水组成。
利用上述不开裂抗侵蚀高铝浇注料制作耐火内衬的方法,步骤如下:
1)将不开裂抗侵蚀高铝浇注料浇注主料和外加剂各组分按照配比加入混料机,温度15-35℃,搅拌40-60min,混合均匀,制成浇注泥料;
2)按照图纸制作耐火内衬成型模具;将所述耐火内衬成型模具置于设备铁壳内部一起放置到振动平台上;
3)在所述设备铁壳内侧配合设置防爆纤维层,起到降低应力集中的作用,并在所述防爆纤维层内侧设置多层保温层,起到铝液保温作用,降低热损失,且最内层保温层内侧设置一层高强度的保温砖,确保各保温砖之间结合紧密;
4)在保温砖层与所述耐火内衬成型模具之间注入步骤1)制得的浇注泥料,启动振动平台对浇注泥料进行振实成型,制得耐火内衬坯体;
5)取下所述耐火内衬坯体内部的成型模具,同时对所述耐火内衬坯体内侧进行养护,用铲刀刮除其内多余浇注泥料;
6)对所述耐火内衬坯体进行缓慢低温热处理,干燥脱去其中游离水,消除其内部应力;
7)将所述耐火内衬坯体按照450-600℃烧制曲线进行烧结,除去其中自由水和结晶水,制得耐火内衬成品;
8)耐火内衬成品随机取三块试样,检测其强度和不沾铝性能,(外观:表面光洁、无飞边、无毛刺;不沾铝性能:铝液过后,铝皮易清理、耐火内衬无开裂、无掉块;体积密度:≤2.5-2.8g/cm3;抗折强度:750℃条件下,≥18.7MPa;加热线变化率:-0.3%;)检测性能达标,成品才可入库或出厂。
为解决浇注料的抗热震性能,需严格控制石英粉的加入量;添加ρ-氧化铝微粉和焦宝石骨料增加材料的强度、致密性和体积的稳定性,特别是焦宝石骨料释放出结晶水和结构水及少量的有机物,体积收缩致密,最后形成莫来石相、方石英相和少量的玻璃相;添加抗铝液浸润剂改善抗铝液的浸润性,添加冰晶石提高其耐磨性能,添加纤维粉等材料以提高材料的保温性能、添加铝酸钙水泥增加其强度等,从而达到良好效果。
本发明的技术方案并不限于上述具体实施例的限制,在不偏离所说明实施例的范围和精神的情况下,对于本技术领域的普通技术人员来说许多修改和变更都是显而易见的,凡在本发明的精神和原则之内,所作的任何技术变形,均落入本发明的保护范围之内。
Claims (5)
1.一种不开裂抗侵蚀高铝浇注料,其特征在于:包括浇注主料和外加剂,所述浇注主料由焦宝石骨料、ρ-氧化铝、分散型氧化铝、纤维粉、白刚玉和复合添加剂组成;所述复合添加剂由冰晶石、防爆纤维和纯铝酸钙水泥组成。
2.根据权利要求1所述的一种不开裂抗侵蚀高铝浇注料,其特征在于:按质量百分比计,所述浇注主料由以下成分组成:
焦宝石骨料1-8mm,40-50%;
ρ-氧化铝0.1-3mm,3-5%;
分散型氧化铝0.5-2.5μm,1-5%;
碳纳米纤维粉,4-6%;
白刚玉300目,10-15%;
石英粉1500目,15-20%
复合添加剂,8-12%。
3.根据权利要求1所述的一种不开裂抗侵蚀高铝浇注料,其特征在于:按质量百分比计,所述复合添加剂在浇注主料中配比为:冰晶石325目,25%;防爆纤维4-5mm,10%;纯铝酸钙水泥,65%。
4.根据权利要求1所述的一种不开裂抗侵蚀高铝浇注料,其特征在于:所述外加剂由占所述浇注主料总质量0.1%-0.3%的六偏磷酸钠、0.01%-0.03%的三聚氰氨树脂和5-7%的水组成。
5.一种耐火内衬的制作方法,其特征在于,包括如下步骤:
1)将权利要求1-4中任意一项所述的不开裂抗侵蚀高铝浇注料各组分按照配比加入混料机,搅拌混合均匀,制成浇注泥料;
2)制作耐火内衬成型模具;将所述耐火内衬成型模具置于设备铁壳内部一起放置到振动平台上;
3)在所述设备铁壳内侧配合设置防爆纤维层,并在所述防爆纤维层内侧设置多层保温层,且最内层保温层内侧紧密设置一层保温砖;
4)在保温砖层与所述耐火内衬成型模具之间注入步骤1)制得的浇注泥料,启动振动平台对浇注泥料进行振实成型,制得耐火内衬坯体;
5)取下成型模具,同时对所述耐火内衬坯体内侧进行养护,刮除其内多余浇注泥料;
6)对所述耐火内衬坯体整体进行低温热处理,脱去其中游离水,消除其内部应力;
7)将所述耐火内衬坯体按照450-600℃烧制曲线进行烧结,除去其中自由水和结晶水,制得耐火内衬成品;
8)随机取样检测所述耐火内衬成品的强度和不沾铝性能,检测性能达标,即可入库或出厂。
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