CN113754414B - 一种高密度高强度中铝/中高铝氧化铝球磨介质及其制备方法 - Google Patents

一种高密度高强度中铝/中高铝氧化铝球磨介质及其制备方法 Download PDF

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CN113754414B
CN113754414B CN202111266711.XA CN202111266711A CN113754414B CN 113754414 B CN113754414 B CN 113754414B CN 202111266711 A CN202111266711 A CN 202111266711A CN 113754414 B CN113754414 B CN 113754414B
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张忠祥
郑萍
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Jingdezhen Betterwear New Materials Co ltd
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Abstract

本发明公开了一种高密度高强度中铝/中高铝氧化铝球磨介质,其原料组成为:煅烧α‑Al2O360~80wt%、铁精粉15~25wt%、软锰矿5~15wt%。此外,还公开了上述高密度高强度中铝/中高铝氧化铝球磨介质的制备方法。本发明以铁精粉和软锰矿作为复合助烧结剂,实现液相和晶格活化作用,从而获得了高密度高强度氧化铝球磨介质;并且显著降低了氧化铝的烧结温度和保温时间,从而有效降低了产品能耗。

Description

一种高密度高强度中铝/中高铝氧化铝球磨介质及其制备 方法
技术领域
本发明涉及陶瓷工业技术领域,尤其涉及一种氧化铝球磨介质及其制备方法。
背景技术
在超细粉碎生产作业中,广泛使用介质磨机如球磨机、搅拌磨机、振动磨机、离心行星磨机等,这些设备需要研磨介质来完成粉碎作业。在生产应用中主要有如下产品:碳钢球、铬钢球、不锈钢球、高铬铸铁球、刚玉球(氧化铝球)、玻璃球、玛瑙球、氧化锆球和天然砂等。氧化铝研磨球具有硬度高、密度大、磨耗低、表面光滑、耐腐蚀等特点,是研磨釉料、坯料及各种粉末材料最理想的耐研磨介质。根据不同的氧化铝含量,氧化铝研磨球可以分为中铝球(氧化铝含量60~65%)、中高铝球(氧化铝含量75~80%)和高铝球(氧化铝含量90%以上)。
从粉碎效率方面考虑,在研磨过程中,介质的密度决定了冲击力作用的强弱。一般来说,介质密度越大,研磨能力越强,粉碎效率越高。99高铝球的密度可以达到3.9g/cm3,但是,其煅烧温度达1600℃以上,保温时间10小时以上,这导致能耗较高。为降低烧成温度,可以添加如SiO2和MgO、CaO、SrO、BaO等碱土金属氧化物,在晶界形成低熔点的玻璃相,促进烧结。但这导致铝球的密度较低(3.2~3.5g/cm3),莫氏硬度不高(约等于8)。也可以添加如Cr2O3、Fe2O3、TiO2、MnO2等,它们与氧化铝基体形成有限置换固溶体,使晶格发生一定程度的畸变,而且由于这些化合物为变价化合物,可以活化晶格,降低烧结温度。它们主要是通过质点扩散或界面移动来实现致密化,但是,这种烧结是在缺少液相的条件下进行的,需要较长的保温时间(≥10小时),因此,单纯地添加这些添加剂并不能有效降低能耗。
发明内容
本发明的目的在于克服现有技术的不足,提供一种高密度高强度中铝/中高铝氧化铝球磨介质,以铁精粉和软锰矿作为复合助烧结剂,实现液相和晶格活化作用,从而获得高密度高强度氧化铝球磨介质。本发明的另一目的在于提供上述高密度高强度中铝/中高铝氧化铝球磨介质的制备方法。
本发明的目的通过以下技术方案予以实现:
本发明提供的一种高密度高强度中铝/中高铝氧化铝球磨介质,其原料组成为:煅烧α-Al2O360~80wt%、铁精粉15~25wt%、软锰矿5~15wt%。
进一步地,本发明所述的高密度高强度中铝/中高铝氧化铝球磨介质,以氧化物计量,其化学组成为Al2O360~80%、SiO22~4%、Fe2O39.4~16.3%、MnO23.2~9.5%、TiO22.5~3.5%、其他氧化物2.9~6.7%。
本发明的另一目的通过以下技术方案予以实现:
本发明提供的上述高密度高强度中铝/中高铝氧化铝球磨介质的制备方法,包括以下步骤:
(1)将所述原料各组成进行混料处理获得浆料颗粒度为过200目筛筛余<0.1%的物料,经喷雾造粒后,得到混合粉体;
(2)向旋转滚球机中先加入预制的球坯晶种,然后边旋转喷水雾边添加所述混合粉体,混合粉体不断粘附于球坯晶种表面逐渐长大,得到直径为10~70mm的球坯;
(3)所述球坯干燥后,在1200~1350℃温度下煅烧,保温3~5小时,经过修坯后即得到直径为8~60mm的中铝/中高铝氧化铝球磨介质。
本发明具有以下有益效果:
(1)铁精粉和软锰矿中除含有Fe2O3和MnO2主要物质外,还含有Al2O3、SiO2、TiO2、MgO、CaO等杂质。其中,Al2O3-SiO2-MgO-CaO体系可以形成液相,能够加速物质的传递,而Al2O3-Fe2O3-MnO2-TiO2体系则有助于活化煅烧α-Al2O3的晶格,有助于Al2O3的物质迁移。两种体系相互融合后,Al2O3-SiO2-MgO-CaO体系形成的液相则进一步加强了活化后煅烧α-Al2O3的物质迁移速率,从而可以在较低的煅烧温度下获得较高的迁移速率,而得到高致密度的氧化铝球。
(2)铁精粉的密度约为4.8g/cm3,软锰矿的密度约为4.7~5.0g/cm3,均大于Al2O3的密度(3.98g/cm3),因此,以此为烧结助剂,可以使得中铝/中高铝氧化铝球的密度在3.8~4.1g/cm3,远高于常规的中铝/中高铝氧化铝球的密度(3.2~3.5g/cm3),这有助于提高氧化铝球的破碎效率。
(3)由于铁精粉和软锰矿所组成的复合助烧结剂,既有液相,也有晶格活化作用,因此,所得的中铝/中高铝氧化铝球能有效避免单一助烧结剂的缺点,在获得高密度的同时,也能够控制烧结微结构,减少微孔的存在,获得较高的硬度(莫氏硬度大于8)和较高的强度(抗弯强度大于250MPa)。
(4)以铁精粉和软锰矿作为烧结助剂来源,降低了氧化铝的烧结温度,可以降低至1200~1350℃,保温3~5小时,有效降低了产品能耗。
(5)可以采用常规的氧化铝球制备方法来制备本发明的氧化铝球,无需更改现有设备即可生产,具有较好的推广性。
下面将结合实施例对本发明作进一步的详细描述。
具体实施方式
实施例一:
1、一种高密度高强度中铝氧化铝球磨介质,其原料组成为:煅烧α-Al2O370wt%、铁精粉20wt%、软锰矿10wt%。
2、本实施例高密度高强度中铝氧化铝球磨介质的制备方法,其步骤如下:
(1)将所述原料各组成进行混料处理获得浆料颗粒度为过200目筛筛余<0.1%的物料,经喷雾造粒后,得到混合粉体;
(2)向旋转滚球机中先加入预制的球坯晶种,然后边旋转喷水雾边添加上述混合粉体,混合粉体不断粘附于球坯晶种表面逐渐长大,得到直径为17mm的球坯;
(3)上述球坯在85℃烘房内干燥后,在窑炉中于1300℃温度下煅烧,保温4小时,经过修坯后即得到直径为15mm的中铝氧化铝球磨介质。
本实施例制得的中铝氧化铝球磨介质,其抗弯强度为300MPa、密度为3.99g/cm3、莫氏硬度为8.5。
实施例二:
1、一种高密度高强度中高铝氧化铝球磨介质,其原料组成为:煅烧α-Al2O380wt%、铁精粉15wt%、软锰矿5wt%。
2、本实施例高密度高强度中高铝氧化铝球磨介质的制备方法,其步骤如下:
(1)将所述原料各组成进行混料处理获得浆料颗粒度为过200目筛筛余<0.1%的物料,经喷雾造粒后,得到混合粉体;
(2)向旋转滚球机中先加入预制的球坯晶种,然后边旋转喷水雾边添加上述混合粉体,混合粉体不断粘附于球坯晶种表面逐渐长大,得到直径为17mm的球坯;
(3)上述球坯在85℃烘房内干燥后,在窑炉中于1330℃温度下煅烧,保温4小时,经过修坯后即得到直径为15mm的中高铝氧化铝球磨介质。
本实施例制得的中高铝氧化铝球磨介质,其抗弯强度为350MPa、密度为3.95g/cm3、莫氏硬度为8.5。
实施例三:
1、一种高密度高强度中铝氧化铝球磨介质,其原料组成为:煅烧α-Al2O360wt%、铁精粉25wt%、软锰矿15wt%。
2、本实施例高密度高强度中铝氧化铝球磨介质的制备方法,其步骤如下:
(1)将所述原料各组成进行混料处理获得浆料颗粒度为过200目筛筛余<0.1%的物料,经喷雾造粒后,得到混合粉体;
(2)向旋转滚球机中先加入预制的球坯晶种,然后边旋转喷水雾边添加上述混合粉体,混合粉体不断粘附于球坯晶种表面逐渐长大,得到直径为17mm的球坯;
(3)上述球坯在85℃烘房内干燥后,在窑炉中于1250℃温度下煅烧,保温4小时,经过修坯后即得到直径为15mm的中铝氧化铝球磨介质。
本实施例制得的中铝氧化铝球磨介质,其抗弯强度为280MPa、密度为4.05g/cm3、莫氏硬度为9。

Claims (2)

1.一种高密度高强度中铝/中高铝氧化铝球磨介质,其特征在于原料组成为:煅烧α-Al2O3 60~80 wt%、铁精粉15~25 wt%、软锰矿5~15 wt%;以氧化物计量,化学组成为Al2O360~80%、SiO2 2~4%、Fe2O3 9.4~16.3%、MnO2 3.2~9.5%、TiO2 2.5~3.5%、其他氧化物2.9~6.7%。
2.权利要求1所述高密度高强度中铝/中高铝氧化铝球磨介质的制备方法,其特征在于包括以下步骤:
(1) 将所述原料各组成进行混料处理获得浆料颗粒度为过200目筛筛余<0.1%的物料,经喷雾造粒后,得到混合粉体;
(2) 向旋转滚球机中先加入预制的球坯晶种,然后边旋转喷水雾边添加所述混合粉体,混合粉体不断粘附于球坯晶种表面逐渐长大,得到直径为10~70mm的球坯;
(3) 所述球坯干燥后,在1200~1350℃温度下煅烧,保温3~5小时,经过修坯后即得到直径为8~60mm的中铝/中高铝氧化铝球磨介质。
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