CN113860896A - High-temperature precision casting low-creep corundum mullite and manufacturing method thereof - Google Patents
High-temperature precision casting low-creep corundum mullite and manufacturing method thereof Download PDFInfo
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Abstract
The invention discloses high-temperature precision casting low-creep corundum mullite and a manufacturing method thereof, and relates to the technical field of smelting. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof comprise the following specific steps: s1, basic requirements of raw materials: industrial alumina: al (Al)2O3>98％，Na2O<0.5%, high purity silica: SiO 22>99％，Fe2O3<0.03 percent; re rare earth oxide: not less than 99.95%, S2, formula of high-purity corundum mullite: the proportion of the industrial alumina is 93-97 percent; the proportion of the silicon dioxide is 3 percent to 7 percent, then 1 percent to 5 percent of Re rare earth oxide and S3 are added according to the total weight of the powderThe process is carried out by stirring and mixing evenly. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof well control the transformation of the mullite network structure rock phase by adjusting the addition proportion of rare earth, adjust and optimize the microstructure of white corundum, and are suitable for small-allowance or no-allowance precision casting and manufacturing of high-grade refractory materials of ceramic shells and cores at high temperature through crushing and screening.
Description
Technical Field
The invention relates to the technical field of smelting, in particular to high-temperature precision casting low-creep corundum mullite and a manufacturing method thereof.
Background
Corundum-mullite is a complex phase ceramic material prepared by sintering fused or calcined corundum and mullite as main raw materials at a high temperature according to a certain proportion, has better comprehensive performance than pure corundum or pure mullite, is widely applied, and is widely applied in the casting industry of the aerospace field.
The application of the electro-fused corundum still has many problems for many years, along with the reduction of the thermal shock performance of the improvement of the purity and the strength, the deformation of the prepared shell is increased when the shell is used in a high-temperature state, and the like, so that the casting of small-allowance and non-allowance precision castings can not be carried out, the major loss of enterprises is caused, the precious metals and mineral resources in China are wasted, and the manufacturing level of the industry is to be improved urgently.
The method is shown in the relevant standard YB/T4381 corundum mullite brick: 1. the content of alumina is required to be more than or equal to 88 percent at most; 2. the highest requirement of the impurity content of the ferric oxide is less than or equal to 0.8 percent; 3. Other requirements are provided for indexes such as refractoriness under load, heating permanent line change, thermal shock stability and the like; 4. The method has no control requirements on impurity elements such as sodium oxide and the like which have great influence on investment precision casting; the corundum-mullite is a polycrystalline material formed by inorganic nonmetallic compounds prepared by taking corundum and mullite as raw materials through raw material preparation, forming and high-temperature sintering, the deformation is increased along with the increase of the use temperature, the reaction with high-temperature liquid metal is intensified, the polycrystalline material cannot be applied to the manufacturing of high-temperature alloy investment precision casting shells and cores, and a refractory material which can be used for carrying out small-allowance or even no-allowance precision casting on high-temperature alloys at 1500 ℃ or even higher is urgently needed to be found.
Disclosure of Invention
The invention aims to solve at least one technical problem in the prior art, provides the high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof, and can solve the problem of a refractory material which can be used for performing small-allowance or even no-allowance precision casting on a high-temperature alloy at 1500 ℃ or even higher.
In order to achieve the purpose, the invention provides the following technical scheme: the high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof comprise the following specific steps:
s1, basic requirements of raw materials: industrial alumina: al (Al)2O3>98％，Na2O<0.5%, high purity silica: SiO 22>99％，Fe2O3<0.03%, Re rare earth oxide: not less than 99.95 percent.
S2, formula of high-purity corundum mullite: the proportion of industrial alumina is 93-97%, the proportion of silicon dioxide is 3-7%, and then 1-5% of Re rare earth oxide is added according to the total weight of the powder.
S3, stirring and mixing the powder uniformly according to the process, and then processing the powder in a continuous electric arc furnace according to a special smelting process procedure, so that the needle and columnar structure of the traditional mullite rock phase is changed, the columnar structure of the corundum phase is improved, and the uniform crystal corundum mullite with a network rock phase structure is generated.
S4, crushing, screening and grinding to obtain granular high-purity corundum-mullite sand and corundum-mullite powder with various uniform granularity and size.
Preferably, the raw materials of the material in S3 need to be purchased according to the technical requirements of the raw materials in S1, and the alumina, the silica and the rare earth oxide are respectively weighed according to the ratio in S2 according to the production amount of each smelting furnace batch per day, and the beneficial effects are that: the high-purity corundum mullite is ensured to be produced by adjusting the proportion of the alumina and the silicon oxide.
Preferably, the silicon oxide and the Re rare earth oxide (yttrium oxide) used in S3 are stirred in a mixer for 2 hours for standby, the mixture of the aluminum oxide, the silicon oxide and the rare earth oxide (yttrium oxide) is poured into the mixer for stirring for 0.5 to 1 hour according to the addition amount in each smelting in S3, the mixed raw materials are put into an electric arc furnace for smelting according to the process specification, and the arc smelting is performed in a pouring furnace in S3, which has the following beneficial effects: the long columnar acicular mullite is changed into a reticular structure and granular mullite crystal lithofacies, so that the corundum mullite is easily processed into corundum mullite sand and powder which are close to spherical.
Preferably, the S3 is divided into three stages: the method comprises the following steps of a blow-in stage, a smelting stage and a refining stage, wherein the blow-in stage comprises the following steps: placing a mixture with the thickness of about 500-800 mm in a smelting furnace before smelting, adjusting a carbon rod electrode downwards, then transmitting power for arcing, adding a small amount of powder in an arc light area to press arc light when the current rises to 20-50% of the load, and in the smelting stage: when the current rises to 80%, smelting by adopting intermittent feeding to melt the furnace burden into liquid state and where the furnace burden sinks and is added until the powder is added, and refining: the melting temperature is improved to the maximum extent by using lower voltage and maximum power, the melting area of corundum and mullite in the furnace is gradually enlarged outwards, the corundum and mullite are smelted for 40 minutes after being completely melted, then the electrode is lifted to obliquely pour the melt into the material receiving bag for cooling, and the beneficial effects are that: the crystal phase corundum-mullite with thermal shock resistance (1100 ℃ water cooling) more than 30 times is crushed and screened, and is suitable for the high-grade refractory material for manufacturing ceramic shell and core by small allowance or no allowance precision casting at high temperature.
The basic beneficial effects of the scheme are as follows: the high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof well control the transformation of the network structure rock phase of the mullite by adjusting the adding proportion of rare earth and adjust and optimize the microstructure of white corundum, thereby producing Na2O is less than or equal to 0.20 percent, caustic soda amount is less than or equal to 0.20 percent, refractoriness under load is more than 1700 ℃, change of heating line (1600 ℃, 2h) is less than or equal to 0.1 percent, thermal shock resistance (1100 ℃ water cooling) is more than 30 times, and the corundum-mullite crystal phase is crushed and screened to be suitable for fine casting with small allowance or no allowance at high temperature to manufacture the high-grade refractory material of the ceramic shell and the core.
Compared with the prior art, the invention has the beneficial effects that:
(1) the high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof well control the transformation of the network structure rock phase of the mullite by adjusting the adding proportion of the rare earth and adjust and optimize the microstructure of the white corundum, thereby producing Na2O is less than or equal to 0.20 percent, caustic soda amount is less than or equal to 0.20 percent, refractoriness under load is more than 1700 ℃, change of heating line (1600 ℃, 2h) is less than or equal to 0.1 percent, thermal shock resistance (1100 ℃ water cooling) is more than 30 times, and the corundum-mullite crystal phase is crushed and screened to be suitable for fine casting with small allowance or no allowance at high temperature to manufacture the high-grade refractory material of the ceramic shell and the core.
(2) According to the high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof, the quality of the ceramic shell and the ceramic core is more stable through the corundum mullite, and meanwhile, the conditions that the shell and the core are subjected to cold and thermal shock repeatedly in the blade casting process are reduced to a certain extent, after the rock phase structure is changed and the material volume is changed after thermodynamics and thermochemical treatment, the high-temperature performance of the material is changed differently, so that the ceramic shell and the ceramic core can be used for casting small-allowance and zero-allowance precision castings.
(3) The high temperature resistance and the deformation resistance of the corundum mullite enable the corundum mullite to be used for high-grade refractory materials for manufacturing ceramic shells and cores by small allowance or no allowance precision casting at high temperature, and enable the qualification rate of high-temperature alloy investment casting to be increased to a certain extent.
(4) The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof enable the casting shell to have excellent high-temperature thermodynamics and chemical properties such as high-temperature structural strength, low high-temperature creep rate, small thermal expansion coefficient, strong chemical erosion resistance, good thermal shock resistance and the like through the crystalline phase corundum mullite which has the refractoriness under load of more than 1700 ℃, the change of heating line (1600 ℃, 2h) of less than or equal to 0.1 percent and the thermal shock resistance (1100 ℃ water cooling) of more than 30 times.
(5) The corundum-mullite high-grade refractory material solves the problem that the high-temperature alloy precision casting requires isotropy of a high-temperature mould shell, greatly reduces the deformation of the mould shell under the high-temperature working condition, has the refractoriness under load of more than 1700 ℃, has the heating line shrinkage of less than white corundum, has thermal shock resistance superior to that of white corundum, and fully exerts the excellent high-temperature thermodynamics and chemical properties of the white corundum and the mullite.
Detailed Description
In the description of the present invention, greater than, less than, exceeding, etc. are understood as excluding the present numbers, and the above, below, inside, etc. are understood as including the present numbers. If the first and second are described for the purpose of distinguishing technical features, they are not to be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated or implicitly indicating the precedence of the technical features indicated.
In the description of the present invention, unless otherwise explicitly limited, terms such as arrangement, installation, connection and the like should be understood in a broad sense, and those skilled in the art can reasonably determine the specific meanings of the above terms in the present invention in combination with the specific contents of the technical solutions.
The first embodiment is as follows:
the invention provides a technical scheme that: the high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof comprise the following steps:
s1, basic requirements of raw materials: industrial alumina: al (Al)2O3>98％，Na2O<0.5%, high purity silica: SiO 22>99％，Fe2O3<0.03%, Re rare earth oxide: not less than 99.95 percent.
S2, formula of high-purity corundum mullite: the proportion of industrial alumina is 93 percent and the proportion of silicon dioxide is 7 percent, and then 1 percent of Re rare earth oxide is added according to the total weight of the powder.
S3, stirring and mixing the powder uniformly according to the process, and then processing the powder in a continuous electric arc furnace according to a special smelting process procedure, so that the needle and columnar structure of the traditional mullite rock phase is changed, the columnar structure of the corundum phase is improved, and the uniform crystal corundum mullite with a network rock phase structure is generated.
S4, crushing, screening and grinding to obtain granular high-purity corundum-mullite sand and corundum-mullite powder with various uniform granularity and size.
Therefore, the difficult problem that the high-temperature precision casting of the high-temperature alloy requires isotropy of a high-temperature mould shell is solved, the deformation of the mould shell under the high-temperature working condition is greatly reduced, the refractoriness under load is higher than 1700 ℃, the shrinkage of a heating line is smaller than that of white corundum, the thermal shock resistance is better than that of the crystalline corundum mullite high-grade refractory material of the white corundum, and the excellent high-temperature thermodynamics and chemical properties of the white corundum and the mullite are fully exerted.
Example two;
on the basis of the first embodiment:
s1, basic requirements of raw materials: industrial alumina: al (Al)2O3>98％，Na2O<0.5%, high purity silica: SiO 22>99％，Fe2O3<0.03%, Re rare earth oxide: not less than 99.95 percent.
S2, formula of high-purity corundum mullite: the proportion of industrial alumina is 95 percent, the proportion of silicon dioxide is 5 percent, and then 3 percent of Re rare earth oxide is added according to the total weight of the powder.
S3, stirring and mixing the powder uniformly according to the process, and then processing the powder in a continuous electric arc furnace according to a special smelting process procedure, so that the needle and columnar structure of the traditional mullite rock phase is changed, the columnar structure of the corundum phase is improved, and the uniform crystal corundum mullite with a network rock phase structure is generated.
Further, the material in S3 requires procurement of raw materials as per the specifications of the raw materials in S1.
Further, according to the production amount of each smelting furnace batch per day, the alumina, the silica and the rare earth oxide are respectively weighed according to the mixture ratio in the S2.
Further, the silica and the Re rare earth oxide (yttrium oxide) were stirred in a mixer for 2 hours.
Further, a mixture of alumina, silica and a rare earth oxide (yttrium oxide) was poured into the mixer in the amount added for each melting and stirred for 0.5 hour.
Further, the mixed raw materials are put into an electric arc furnace to be smelted according to the process rule.
Further, arc melting was performed using a tilting furnace.
S4, crushing, screening and grinding to obtain granular high-purity corundum-mullite sand and corundum-mullite powder with various uniform granularity and size.
Therefore, the difficult problem that the high-temperature precision casting of the high-temperature alloy requires isotropy of a high-temperature mould shell is solved, the deformation of the mould shell under the high-temperature working condition is greatly reduced, the refractoriness under load is higher than 1700 ℃, the shrinkage of a heating line is smaller than that of white corundum, the thermal shock resistance is better than that of the crystalline corundum mullite high-grade refractory material of the white corundum, and the excellent high-temperature thermodynamics and chemical properties of the white corundum and the mullite are fully exerted.
Meanwhile, the corundum-mullite has high purity, the Na2O content is less than or equal to 0.20%, the caustic soda content is less than or equal to 0.20%, and long columnar and acicular mullite is changed into a reticular structure and granular mullite crystal rock phase, so that corundum-mullite powder can be easily processed into corundum-mullite sand and powder close to spherical shape, and workers can process the corundum-mullite more smoothly.
Example three;
on the basis of the first and second embodiments:
s1, basic requirements of raw materials: industrial alumina: al (Al)2O3>98％，Na2O<0.5%, high purity silica: SiO 22>99％，Fe2O3<0.03%, Re rare earth oxide: not less than 99.95 percent.
S2, formula of high-purity corundum mullite: the proportion of industrial alumina is 97%, the proportion of silicon dioxide is 3%, and then 5% of Re rare earth oxide is added according to the total weight of the powder.
S3, stirring and mixing the powder uniformly according to the process, and then processing the powder in a continuous electric arc furnace according to a special smelting process procedure, so that the needle and columnar structure of the traditional mullite rock phase is changed, the columnar structure of the corundum phase is improved, and the uniform crystal corundum mullite with a network rock phase structure is generated.
Further, the material in S3 requires procurement of raw materials as per the specifications of the raw materials in S1.
Further, according to the production amount of each smelting furnace batch per day, the alumina, the silica and the rare earth oxide are respectively weighed according to the mixture ratio in the S2.
Further, the silica and the Re rare earth oxide (yttrium oxide) were stirred in a mixer for 2 hours.
Further, a mixture of alumina, silica and a rare earth oxide (yttrium oxide) was poured into the mixer in the amount added for each melting and stirred for 1 hour.
Further, the mixed raw materials are put into an electric arc furnace to be smelted according to the process rule.
Further, arc melting was performed using a tilting furnace.
S4, crushing, screening and grinding to obtain granular high-purity corundum-mullite sand and corundum-mullite powder with various uniform granularity and size.
Therefore, the difficult problem that the high-temperature precision casting of the high-temperature alloy requires isotropy of a high-temperature mould shell is solved, the deformation of the mould shell under the high-temperature working condition is greatly reduced, the refractoriness under load is higher than 1700 ℃, the shrinkage of a heating line is smaller than that of white corundum, the thermal shock resistance is better than that of the crystalline corundum mullite high-grade refractory material of the white corundum, and the excellent high-temperature thermodynamics and chemical properties of the white corundum and the mullite are fully exerted.
Further, S3 is divided into three stages: a furnace opening stage, a smelting stage and a refining stage.
Further, a blow-in stage: placing the mixture with the thickness of about 500-800 mm in a smelting furnace before smelting, adjusting a carbon rod electrode downwards, and then transmitting power for arc striking.
Further, when the current rises to 20% -50% of the load, a small amount of powder is added in the arc region to press the arc.
Further, the smelting stage: when the current rises to 80%, the batch charging is adopted for smelting, so that the furnace burden is melted into liquid state, and the furnace burden is added to the position where the furnace burden sinks until the powder is completely charged. The temperature of the molten corundum-mullite solution is higher than or equal to 2050 ℃, and the liquid level of the molten corundum-mullite solution slowly rises along with the smelting.
Further, the refining stage: the melting temperature is improved to the maximum extent by using lower voltage and maximum power, and the melting area of corundum and mullite in the furnace is gradually enlarged outwards.
And further, smelting for 40 minutes after the molten materials are completely melted, and then lifting the electrode to obliquely pour the molten materials into a material receiving bag for cooling.
Through the crystalline phase corundum mullite with refractoriness under load of more than 1700 ℃, heating line change (1600 ℃, 2h) of less than or equal to 0.1 percent and thermal shock resistance (1100 ℃ water cooling) of more than 30 times, the cast shell has excellent high-temperature thermodynamics and chemical properties such as high-temperature structural strength, low high-temperature creep rate, small thermal expansion coefficient, strong chemical erosion resistance, good thermal shock resistance and the like.
The corundum-mullite is used for manufacturing high-grade refractory materials of ceramic shells and cores by small allowance or no allowance precision casting at high temperature through the high-temperature resistance and deformation resistance of the corundum-mullite, and the qualification rate of high-temperature alloy investment casting is increased to a certain extent.
Meanwhile, the transformation of the mullite network structure rock phase is well controlled by adjusting the addition proportion of the rare earth, and the microstructure of the white corundum is adjusted and optimized, so that Na is produced2O is less than or equal to 0.20 percent, caustic soda amount is less than or equal to 0.20 percent, refractoriness under load is more than 1700 ℃, change of heating line (1600 ℃, 2h) is less than or equal to 0.1 percent, thermal shock resistance (1100 ℃ water cooling) is more than 30 times, and the corundum-mullite crystal phase is crushed and screened to be suitable for fine casting with small allowance or no allowance at high temperature to manufacture the high-grade refractory material of the ceramic shell and the core.
The corundum-mullite ceramic shell and the ceramic core have more stable quality, and meanwhile, the conditions that the shell and the core are subjected to cold and thermal shock repeatedly in the blade casting process are reduced to a certain extent, and after the rock phase structure is changed and the material volume is changed after thermodynamics and thermochemical treatment, the high-temperature performance of the material is changed differently, so that the ceramic shell and the ceramic core can be used for casting small-allowance and zero-allowance precision castings.
While the embodiments of the present invention have been described in detail, the present invention is not limited to the embodiments, and various changes can be made without departing from the spirit of the present invention within the knowledge of those skilled in the art.
Claims (9)
1. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof are characterized in that: the method comprises the following specific steps:
s1, basic requirements of raw materials: industrial alumina: al (Al)2O3>98％，Na2O<0.5%, high purity silica: SiO 22>99％，Fe2O3<0.03%, Re rare earth oxide: not less than 99.95 percent.
S2, formula of high-purity corundum mullite: the proportion of industrial alumina is 93-97%, the proportion of silicon dioxide is 3-7%, and then 1-5% of Re rare earth oxide is added according to the total weight of the powder.
S3, stirring and mixing the powder uniformly according to the process, and then processing the powder in a continuous electric arc furnace according to a special smelting process procedure, so that the needle and columnar structure of the traditional mullite rock phase is changed, the columnar structure of the corundum phase is improved, and the corundum mullite crystal with a uniform network rock phase structure is generated.
S4, crushing, screening and grinding to obtain granular high-purity corundum-mullite sand and corundum-mullite powder with various uniform granularity and size.
2. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof as claimed in claim 1, characterized in that: the raw materials in the S3 need to be purchased according to the technical requirements of the raw materials in the S1, and the alumina, the silica and the rare earth oxide are respectively weighed according to the proportion in the S2 according to the production of each smelting furnace batch per day.
3. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof as claimed in claim 1, characterized in that: the silica and the Re rare earth oxide (yttrium oxide) used in S3 were stirred in a mixer for 2 hours.
4. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof as claimed in claim 1, characterized in that: and in the step S3, the mixture of the aluminum oxide, the silicon oxide and the rare earth oxide (yttrium oxide) is poured into a mixing stirrer according to the adding amount of each smelting, the mixture is stirred for 0.5 to 1 hour, and the mixed raw materials are put into an electric arc furnace to be smelted according to the process specification.
5. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof as claimed in claim 1, characterized in that: in the step S3, arc melting is performed using a tilting furnace.
6. The high-temperature precision casting low-creep corundum mullite and the manufacturing method thereof as claimed in claim 1, characterized in that: the S3 is divided into three stages: a furnace opening stage, a smelting stage and a refining stage.
7. The high-temperature precision-cast low-creep corundum mullite as claimed in claim 6, wherein: the blow-in stage: placing a mixture with the thickness of about 500-800 mm in a smelting furnace before smelting, adjusting a carbon rod electrode downwards, then transmitting power for arcing, and adding a small amount of powder in an arc light area to press arc light when the current rises to 20-50% of the load.
8. The high-temperature precision-cast low-creep corundum mullite as claimed in claim 6, wherein: the smelting stage comprises the following steps: when the current rises to 80%, the batch charging is adopted for smelting, so that the furnace burden is melted into liquid state, and the furnace burden is added to the position where the furnace burden sinks until the powder is completely charged.
9. The high-temperature precision-cast low-creep corundum mullite as claimed in claim 6, wherein: the refining stage comprises the following steps: the melting temperature is improved to the maximum extent by using lower voltage and maximum power, the melting area of corundum and mullite in the furnace is gradually enlarged outwards, the corundum and mullite are smelted for 40 minutes after being completely melted, and then the electrode is lifted to obliquely pour the melt into a material receiving bag for cooling.
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Application publication date: 20211231 |