CN113910116B - 一种陶瓷砂轮成型用可溶性无机液体粘结剂制备方法 - Google Patents
一种陶瓷砂轮成型用可溶性无机液体粘结剂制备方法 Download PDFInfo
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- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B24D3/346—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties utilised during polishing, or grinding operation
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Abstract
本发明涉及一种陶瓷砂轮成型用可溶性无机液体粘结剂制备方法，以Na2O、K2O、B2O3、P2O5及SiO2等为主要成分，经高温熔制后成K2O‑Na2O‑B2O3‑P2O5‑SiO2体系玻璃液，将均化后的高温玻璃液倒入石墨模具中自然冷却至室温，再将冷却后的玻璃破碎，配以3～5倍质量的水于80～100℃高温熬煮1～3h，并持续搅拌，使得玻璃颗粒完全溶解于热水中形成胶状物，冷却后即为砂轮成型用无机液体粘结剂。本发明制备的粘结剂可克服传统水玻璃粘结剂及有机粘结剂导致陶瓷砂轮烧成后强度降低的技术难题，从而显著提高陶瓷砂轮的结合强度，提高陶瓷砂轮的磨削线速度，改善陶瓷砂轮的性能，因此具有广阔的市场前景。
Description
技术领域
本发明涉及无机新材料领域，尤其涉及陶瓷砂轮行业成型用可溶性液体粘结剂的制备方法，所制备的液体粘结剂可广泛应用于磨具制造业、陶瓷工业及相关用领域。
背景技术
陶瓷砂轮又称陶瓷结合剂砂轮，是指以陶瓷或玻璃为结合剂将磨料颗粒固结而制备的磨具，根据所用磨料不同可以分为刚玉砂轮、碳化硅砂轮、cBN砂轮及金刚石砂轮等。砂轮制备时首先要根据加工对象的不同设计特定形状和尺寸规格的模具以便于成型，然后将混合均匀的结合剂和磨料放入模具中压制成型，经修整后于高温条件下烧结使其获得足够的强度。由于结合剂与磨料均为瘠性料，成型过程中很难获得足够强度的生坯，同时为了确保结合剂能够实现对磨料颗粒的均匀包裹，砂轮成型过程中一般需要先对磨料颗粒进行预处理，通过液体粘结剂润湿磨料颗粒表面，在不断搅动的条件下加入陶瓷结合剂微粉，使得结合剂微粉均匀的附着在磨料颗粒表面，从而实现对磨料颗粒的包裹。由于不同工况条件下对液体粘结剂的浓度不一样，所以要求液体粘结剂可以与任意比例水混溶。当前陶瓷砂轮常用的可溶性液体粘结剂分为有机粘结剂和无机粘结剂，其中有机粘结剂一般为改性淀粉类物质如糊精等，无机粘结剂则普遍使用水玻璃。尽管有机粘结剂成本低廉但是高温条件下烧失后会形成气孔，且烧失时形成的气体会导致粘结剂与磨料颗粒之间新界面的形成，因而会显著降低陶瓷砂轮的结合强度。水玻璃作为常用的无机粘结剂，本身不会导致新气孔和新界面的形成，但是水玻璃的主要成分是Na2O和SiO2，水玻璃中高含量Na2O的存在必然会导致结合剂和磨料之间过渡层热膨胀系数的显著升高，这种膨胀系数的不匹配则会导致砂轮在高温烧结的降温过程中形成热应力，导致微裂纹的生成，从而降低陶瓷砂轮的结合强度。
因此，不管用有机粘结剂还是水玻璃粘结剂都会在一定程度上导致结合剂与磨料颗粒之间界面结合强度差的问题。开发一种新型的无机液体粘结剂，使其在室温条件下能够润湿磨料颗粒，同时在高温条件下不显著降低结合剂与磨料颗粒之间的结合强度，是目前陶瓷砂轮行业共同的技术诉求。然而，在水泥、玻璃和陶瓷三类主要无机材料中，除了水玻璃（硅酸钠/钾）以外，其他的成分很难溶于水，更难形成具有粘结能力的胶状物。
发明内容
本发明的目的在于克服现有陶瓷砂轮成型用可溶性液体粘结剂的不足，提供一种陶瓷砂轮成型用可溶性无机液体粘结剂制备方法，该粘结剂可实现在室温条件下与水的无限混溶，使其不仅可以在室温条件下完成结合剂微粉对磨料颗粒的均匀包裹，同时也不会导致高温烧结后结合剂和磨料颗粒之间界面与裂纹的形成，从而改善陶瓷砂轮的性能，提高其强度和磨削速度。
本发明的技术方案是：一种陶瓷砂轮成型用可溶性无机液体粘结剂制备方法，其特征在于包括如下步骤：
步骤一：制备K2O-Na2O-B2O3-P2O5-SiO2体系基础玻璃；
步骤二：将步骤一获得的基础玻璃配以3～5倍质量的自来水，装入容器中于80～100℃高温熬煮1～3h，并持续搅拌，使得玻璃颗粒完全溶解于热水中形成胶状物；
步骤三：将步骤二获得的胶状物冷却后装入容器封存3～5天进行陈腐，使其进一步均化，即可获得可溶性无机液体粘结剂。
所述步骤一中基础玻璃的制备步骤为：按重量百分比：Na2O 10～35%、K2O 2～25%、B2O32～5%、P2O545～58%、SiO25～12%，将原料混合均匀并过80～150目标准筛后，经900～1100℃高温熔融并保温0.5～2.0小时获得澄清和均匀的玻璃熔体，将玻璃熔体引入到石墨模具中进行自然冷却，将冷却至室温后的玻璃破碎，过5～30目标准筛备用。
所述Na2O与K2O以其碳酸盐引入、P2O5以(NH4)2HPO4引入、B2O3以H3BO3引入。
所述步骤三中可溶性无机液体粘结剂的应用步骤为：
步骤A：将可溶性无机液体粘结剂进一步稀释，配以8～10倍的自来水，充分搅拌均匀后备用；
步骤B：将结合剂微粉与磨料颗粒按需求配比并混合均匀，在搅拌过程中将步骤一稀释后的可溶性无机液体粘结剂以喷雾形式喷洒在混合磨料的表面，使混合磨料表面形成一层粘结剂润湿层，再将润湿后的混合磨料装入模具中压制成型即可获得陶瓷砂轮生坯备用。
所述步骤B获得陶瓷砂轮生坯烧成后的结合强度为90～110 MPa。
本发明具有以下有益效果：
本发明组成上完全不同于传统的水玻璃无机胶粘结剂，不仅可以显著降低玻璃的烧成温度同时可以提高玻璃的性能。一方面，该成分中增加了B2O3和P2O5等玻璃网络形成体组成，这些氧化物熔点很低，可以降低玻璃的熔制温度，从而实现原料在1000℃以下融化形成玻璃；另一方面，K2O与Na2O的同时加入，可以利用混合碱效应降低过量碱金属离子对玻璃网络结构的破坏，同时B2O3的加入还可以修补玻璃的网络结构，利用硼反常效应实现对玻璃性能的提升；此外，本体系SiO2含量很低而P2O5的含量较高，这有利于粘结剂与结合剂微粉之间形成较低热膨胀系数的磷酸盐，从而避免陶瓷砂轮在烧成冷却过程中结合剂与磨料颗粒之间热膨胀不匹配而形成微裂纹。以本粘结剂制备的陶瓷砂轮，相比以传统水玻璃为粘结剂制备的陶瓷砂轮，可以提高砂轮的结合强度20～60%。
实施方式
为更进一步阐述本发明、为达成预定发明目的所采取的技术手段及功效，以下结合较佳实施例，对本发明进行详细说明：
实施例1
所合成玻璃K2O-Na2O-B2O3-P2O5-SiO2体系中各氧化物的质量组成为：Na2O 为33%、K2O为5%、B2O3为5%、P2O5为51%、SiO2为6%，其中述Na2O与K2O以Na2CO3与K2CO3引入、P2O5以(NH4)2HPO4引入、B2O3以H3BO3引入。按照所述配比，将所述各组成混合均匀并过80目标准筛后，经950℃的高温熔融，并在高温下保温1.5小时以促进玻璃熔体的澄清与均匀。将充分澄清与均匀后的玻璃液引入到石墨模具中进行自然冷却。将冷却至室温后的玻璃破碎，过20目标准筛备用。将以上过程制得的玻璃颗粒，配以5倍质量的自来水，装入容器中于95℃高温熬煮1h，使得玻璃颗粒完全溶解于热水中形成胶状物，冷却后装入容器封存3天进行陈腐，获得液体粘结剂，再配以10倍的自来水进一步稀释备用。
.将结合剂微粉与磨料颗粒按需求配比并混合均匀，在搅拌过程中将稀释后的可溶性无机液体粘结剂以喷雾形式喷洒在混合磨料的表面，使混合磨料表面形成一层粘结剂润湿层，再将润湿后的混合磨料装入模具中压制成型即可获得陶瓷砂轮生坯并搅拌均匀后即可用于陶瓷砂轮成型。
上述结合剂为采用专利配方ZL201710456315.0制备的微晶玻璃，相比以传统水玻璃为粘结剂制备的刚玉砂轮，在同等情况下采用本粘结剂所制备刚玉砂轮的结合强度可以从62 MPa提高至90 MPa以上。
实施例2
所合成玻璃K2O-Na2O-B2O3-P2O5-SiO2体系中各氧化物的质量组成为：Na2O 为15%、K2O为25%、B2O3为3%、P2O5为46%、SiO2为11%，其中Na2O与K2O以Na2CO3与K2CO3引入、P2O5以(NH4)2HPO4引入、B2O3以H3BO3引入。按照所述配比，将所述各组成混合均匀并过120目标准筛后，经900℃的熔融并保温2小时，将澄清与均化后的玻璃液引入到石墨模具中进行自然冷却。将冷却至室温后的玻璃破碎，过10目标准筛备用。将以上过程制得的玻璃颗粒，配以4倍质量的自来水，装入容器中于90℃高温熬煮1.5h，使得玻璃颗粒完全溶解于热水中形成胶状物，冷却后装入容器封存5天进行陈腐，获得液体粘结剂，再配以8倍的自来水进一步稀释备用。
将结合剂微粉与磨料颗粒按需求配比并混合均匀，在搅拌过程中将稀释后的可溶性无机液体粘结剂以喷雾形式喷洒在混合磨料的表面，使混合磨料表面形成一层粘结剂润湿层，再将润湿后的混合磨料装入模具中压制成型即可获得陶瓷砂轮生坯并搅拌均匀后即可用于陶瓷砂轮成型。
上述结合剂为采用专利配方US10815146B2制备的微晶玻璃，相比以传统水玻璃为粘结剂制备的碳化硅砂轮，在同等情况下采用本粘结剂所制备的碳化硅砂轮的结合强度可以从80 MPa提高至110 MPa以上。
.实施例3
所合成玻璃K2O-Na2O-B2O3-P2O5-SiO2体系中各氧化物的质量组成为：Na2O为21%、K2O为14%、B2O3为2%、P2O5为56%、SiO2为7%，其中Na2O与K2O以Na2CO3与K2CO3引入、P2O5以(NH4)2HPO4引入、B2O3以H3BO3引入。按照所述配比，将所述各组成混合均匀并过150目标准筛后，经1050℃的高温熔融，并在高温下保温0.5小时以促进玻璃熔体的澄清与均匀。将充分澄清与均匀后的玻璃液引入到石墨模具中进行自然冷却。将冷却至室温后的玻璃破碎，过30目标准筛备用。将以上过程制得的玻璃颗粒，配以3倍质量的自来水，装入容器中于85℃高温熬煮3h，使得玻璃颗粒完全溶解于热水中形成胶状物，冷却后装入容器封存4天进行陈腐，获得液体粘结剂，再配以9倍的自来水进一步稀释备用。
将结合剂微粉与磨料颗粒按需求配比并混合均匀，在搅拌过程中将稀释后的可溶性无机液体粘结剂以喷雾形式喷洒在混合磨料的表面，使混合磨料表面形成一层粘结剂润湿层，再将润湿后的混合磨料装入模具中压制成型即可获得陶瓷砂轮生坯并搅拌均匀后即可用于陶瓷砂轮成型。
上述结合剂为专利配方ZL20178002903.5制备的微晶玻璃，相比以传统水玻璃为粘结剂制备的立方氮化硼砂轮，在同等情况下采用本粘结剂所制备立方氮化硼砂轮的结合强度可以从77MPa提高至106 MPa以上。
Claims (4)
1.一种陶瓷砂轮成型用可溶性无机液体粘结剂制备方法，其特征在于包括如下步骤：
步骤一：制备K2O-Na2O-B2O3-P2O5-SiO2体系基础玻璃；
步骤二：将步骤一获得的基础玻璃配以3～5倍质量的自来水，装入容器中于80～100℃高温熬煮1～3h，并持续搅拌，使得玻璃颗粒完全溶解于热水中形成胶状物；
步骤三：将步骤二获得的胶状物冷却后装入容器封存3～5天进行陈腐，使其进一步均化，即可获得可溶性无机液体粘结剂；
所述步骤一中基础玻璃的制备步骤为：按重量百分比：Na2O 10～35%、K2O 2～25%、B2O3 2～5%、P2O5 45～58%、SiO2 5～12%，将原料混合均匀并过80～150目标准筛后，经900～1100℃高温熔融并保温0.5～2.0小时获得澄清和均匀的玻璃熔体，将玻璃熔体引入到石墨模具中进行自然冷却，将冷却至室温后的玻璃破碎，过5～30目标准筛备用。
2.根据权利要求1所述的制备方法，其特征在于：所述Na2O与K2O以其碳酸盐引入、P2O5以(NH4)2HPO4引入，B2O3以H3BO3引入。
3.一种可溶性无机液体粘结剂的应用，所述可溶性无机液体粘结剂采用如权利要求1所述的陶瓷砂轮成型用可溶性无机液体粘结剂制备方法制得，其特征在于应用步骤为：
步骤A：将可溶性无机液体粘结剂进一步稀释，配以8～10倍的自来水，充分搅拌均匀后备用；
步骤B：将结合剂微粉与磨料颗粒按需求配比并混合均匀，在搅拌过程中将步骤一稀释后的可溶性无机液体粘结剂以喷雾形式喷洒在混合磨料的表面，使混合磨料表面形成一层粘结剂润湿层，再将润湿后的混合磨料装入模具中压制成型即可获得陶瓷砂轮生坯备用。
4.根据权利要求3所述的可溶性无机液体粘结剂的应用，其特征在于：所述步骤B获得的陶瓷砂轮生坯，其烧成后结合强度为90～110 MPa。
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