CN113998989A - 一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其制备方法 - Google Patents

一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其制备方法 Download PDF

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CN113998989A
CN113998989A CN202111283838.2A CN202111283838A CN113998989A CN 113998989 A CN113998989 A CN 113998989A CN 202111283838 A CN202111283838 A CN 202111283838A CN 113998989 A CN113998989 A CN 113998989A
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石凯
马世行
夏熠
韩晓源
刘洋
商剑钊
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Henan University of Technology
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Abstract

本发明公开了一种高耐磨烧成Al2O3‑ZrO2‑C滑板砖及其制备方法，生产该产品所用原料的各组分按重量百分比分别为：Si粉改性板状刚玉颗粒（40‑60%），含锆原料（2‑30%），板状刚玉细粉（15‑25%），α‑Al2O3微粉（3‑10%），Si粉（1‑6%），炭黑（1‑5%），B4C粉（0.5‑2%），酚醛树脂结合剂（3‑5%）。制备方法如下：先制得Si粉改性板状刚玉颗粒，再准确称量按重量百分比计的各组分，混练20‑30分钟后出料，困料12‑24h后，用压机成型，成型的砖坯经干燥、埋炭或氮气气氛下高温烧成，制得烧成Al2O3‑ZrO2‑C滑板砖。本发明中所生产的烧成Al2O3‑ZrO2‑C滑板砖，具有较高的高温抗折强度，良好的耐磨性，可提高烧成Al2O3‑ZrO2‑C滑板的使用寿命。

Description

一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其制备方法
技术领域
本发明涉及一种炼钢连铸用滑板砖，特别涉及一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其制备方法，属于功能耐火材料领域。
背景技术
滑板砖是炼钢连铸用功能耐火材料，使用中配合滑动机构起调节、控制钢水流量及出钢挡渣作用。由于使用条件的苛刻性，对滑板的抗冲刷性、抗热震性、抗氧化性、抗侵蚀性等综合高温性能都提出了较高的要求。高温烧成的Al2O3-ZrO2-C滑板具有较好的抗热震性、抗侵蚀性，是目前高档滑板的主流材质。大量统计表明：滑动面拉毛、扩孔是滑板报废的主要原因。引起滑动面拉毛、扩孔的原因除了氧化、侵蚀，主要是冲刷磨损造成的。
从Al2O3-ZrO2-C滑板的组成和结构看，颗粒是电熔或高温烧结的刚玉或锆质致密原料，一般具有较高的强度；细粉由炭素、α-Al2O3微粉、Si粉等组成，它们在高温烧成过程中形成陶瓷结合和碳结合，使基质也具有较高的强度；但颗粒和基质间的结合较弱。另一方面，由于热失配在颗粒与基质间存在一定量的裂隙，也影响颗粒与基质的结合。使用时在机械摩擦力和钢水冲刷作用下，颗粒容易从基质中剥离，加速滑动面拉毛、扩孔。因此，要提高Al2O3-ZrO2-C滑板的使用寿命需要强化颗粒与基质的结合。目前强化颗粒与基质结合的工作还没引起耐火材料技术人员的重视。
生产Al2O3-ZrO2-C滑板时一般加有刚玉颗粒，由于刚玉的热膨胀系数较大（273-1273K为7-9×10-6），高温时刚玉颗粒与基质界面处易产生应力集中，引起裂纹的萌生、扩展，降低滑板的抗热震性，同时劣化材料的强度和耐磨性，影响滑板使用寿命。因此，吸收刚玉颗粒的热膨胀对提高滑板使用寿命很有必要。
发明内容
为强化颗粒与基质的结合，吸收刚玉颗粒的热膨胀，提高滑板的耐磨性，降低滑动面拉毛、扩孔程度，提高滑板使用寿命，本专利提出一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其制备方法。通过加入Si粉包覆改性板状刚玉颗粒，高温下Si粉在板状刚玉颗粒表面原位生成SiC，将颗粒与基质桥接起来，强化颗粒与基质的结合。由于SiC的热膨胀系数（273-1273K为4.7×10-6）低于刚玉（273-1273K为7-9×10-6），可吸收刚玉颗粒产生的热膨胀，舒缓热应力；另一方面，生成的SiC呈纤维状，起侨联、拔出、偏转增韧作用，抑制裂纹的产生或扩展，提高材料的高温强度及抗热震性；同时SiC有较好的导热性，可降低刚玉颗粒表面及材料内部的温差，耗散热应力，改善材料的耐磨性，提高烧成Al2O3-ZrO2-C滑板的使用寿命。
本发明为解决技术问题所采取的技术方案是：
A、制备Si粉包覆改性板状刚玉颗粒：
a、先将板状刚玉颗粒加入搅拌机中，加入2-3%的结合剂搅拌均匀，再缓慢加入1-6%的硅粉，待硅粉均匀粘附到颗粒表面后，将颗粒倒出，进行200℃×6-8h的干燥，制得Si粉包覆改性板状刚玉颗粒。
b、上述结合剂可采用酚醛树脂或脲醛树脂与乙醇的均匀混合液，其比例为2∶1～1∶2；所用包覆硅粉的粒度小于0.045mm。
B、依重量百分比准确称量下述各组分并加入湿碾机中：Si粉改性板状刚玉颗粒（40-60%），含锆原料（2-30%），板状刚玉细粉（15-25%），α-Al2O3微粉（3-10%），Si粉（1-6%），炭黑（1-5%），B4C粉（0.5-2%），酚醛树脂结合剂（3-5%）。混练20-30分钟后困料12-24h，之后用压机成型。
C、成型的砖坯经干燥、埋炭或氮气气氛下高温烧成，制得烧成Al2O3-ZrO2-C滑板砖。
一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其生产方法，其特征在于，Si粉改性板状刚玉颗粒的粒径为3-0.5mm，所用含锆原料中锆刚玉、锆莫来石的粒径小于2mm，氧化锆的粒径小于0.045mm，α-Al2O3微粉的粒径小于3μm。含锆原料可以是上述中的一种或多种。
本发明的积极有益效果如下：
1、本发明中，采用酚醛树脂或脲醛树脂与乙醇的均匀混合液作为结合剂，制得Si粉包覆改性板状刚玉颗粒。不仅有原料易得、多样的优点，还具有工艺简单、易于控制等优势。
2、本发明通过加入Si粉包覆改性板状刚玉颗粒，高温下Si粉在板状刚玉颗粒表面原位生成SiC纤维，将颗粒与基质桥接起来，强化颗粒与基质的结合。利用SiC的低膨胀性、高导热性，降低材料热应力，提高高温强度，改善耐磨性。
3、本发明中所生产的烧成Al2O3-ZrO2-C滑板砖，具有较好的高温强度，耐磨性，及良好的抗热震性，应用于大型钢包及中间包，结果表明：多次使用后颗粒热剥落减少，滑程拉毛程度降低，冲刷扩孔速度下降，裂纹细小，滑板的使用寿命得到提高，并降低了耐材的耗量，环境及经济效益明显。
4、本发明为包括但不限于刚玉、镁砂、尖晶石等耐火原料，提供了骨料改性的新思路，对诸如功能耐火材料、含碳耐火材料等产品的性能改善，指出了一个新方向，有望改善此类产品的高温强度以及耐磨性等高温性能。
具体实施方式
下面对本发明做进一步的解释、说明：
实施例一：
一种高耐磨烧成Al2O3-ZrO2-C滑板砖，生产该产品所用原料各组分含量按重量百分比分别为：3-0.5mm板状刚玉颗粒50%，0.5-0mm板状刚玉颗粒17%，0.045mm氧化锆细粉5%，0.045mm板状刚玉细粉16%，d50为2µm的α-Al2O3微粉5%，0.045mmSi粉3%，N220炭黑3%，0.045mm的B4C粉1%，外加酚醛树脂结合剂3%。
实施例二：
一种高耐磨烧成Al2O3-ZrO2-C滑板砖，生产该产品所用原料各组分含量按重量百分比分别为：3-0.5mm的2%Si粉包覆改性板状刚玉颗粒51%，0.5-0mm板状刚玉颗粒17%，0.045mm氧化锆细粉5%，0.045mm板状刚玉细粉16%，d50为2µm的α-Al2O3微粉5%，0.045mmSi粉2%，N220炭黑3%，0.045mm的B4C粉1%，外加酚醛树脂结合剂3%。
实施例三
一种高耐磨烧成Al2O3-ZrO2-C滑板砖，生产该产品所用原料各组分含量按重量百分比分别为：3-0.5mm的2%Si粉包覆改性板状刚玉颗粒51%，0.5-0mm锆刚玉颗粒17%，0.045mm板状刚玉细粉21%，d50为2µm的α-Al2O3微粉5%，0.045mmSi粉2%，N220炭黑3%，0.045mm的B4C粉1%，外加酚醛树脂结合剂3%。
实施例四：
一种高耐磨烧成Al2O3-ZrO2-C滑板砖，生产该产品所用原料各组分含量按重量百分比分别为：3-0.5mm的3%Si粉包覆改性板状刚玉颗粒41%，2-0.5mm的锆莫来石10%，0.5-0mm板状刚玉颗粒17%，0.045mm氧化锆细粉5%，0.045mm板状刚玉细粉16%，d50为2µm的α-Al2O3微粉5%，0.045mm的Si粉2%，N220炭黑3%，0.045mm的B4C粉1%，外加酚醛树脂结合剂3%。
如上所述实施例一至四的滑板砖，其具体的制备方法如下：
1、实施例二至四中的Si粉包覆改性板状刚玉颗粒的制备。
首先将3-0.5mm板状刚玉颗粒加入搅拌机中，加入2%的结合剂搅拌均匀，分别缓慢加入2%、3%的硅粉，待硅粉均匀粘附到颗粒表面后，将颗粒倒出，进行200℃×8h的干燥，制得Si粉包覆改性板状刚玉颗粒。上述结合剂采用酚醛树脂与乙醇的均匀混合液，其比例为55∶45。
2、按实施例一至四中的重量百分比，准确称量各组分并加入至湿碾机中，混练25分钟后出料，混练好的泥料以干湿适当为佳。困料12h后成型滑板砖坯。
3、成型的砖坯经自然干燥24h、200℃烘干12h、埋炭1350℃保温8h高温烧成，制得烧成Al2O3-ZrO2-C滑板砖。
对实施例一至四中的滑板进行检测，结果如下：按照GB/T 3002-2017检测，实施例一至四滑板的高温抗折强度分别是21 MPa、27MPa、28 MPa和27 MPa，Si粉包覆改性板状刚玉颗粒后，材料的高温强度明显提高，可提高滑板的耐磨性及使用寿命。
本领域技术人员应知悉，实施例中就添加不同Si粉改性板状刚玉及锆质原料进行实施、说明，任何调整含锆原料中的一种或多种，或调整权利要求中的烧成工艺等，均受到本专利的保护。

Claims (3)

1.一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其制备方法，其特征在于，该滑板砖的各组分按重量百分比分别为：Si粉改性板状刚玉颗粒（40-60%），含锆原料（2-30%），板状刚玉细粉（15-25%），α-Al2O3微粉（3-10%），Si粉（1-6%），炭黑（1-5%），B4C粉（0.5-2%），酚醛树脂结合剂（3-5%）。
2.权利要求1中的一种高耐磨烧成Al2O3-ZrO2-C滑板砖的制备方法，具体步骤如下：
A、制备Si粉包覆改性板状刚玉颗粒；
a、先将板状刚玉颗粒加入搅拌机中，加入2-3%的结合剂搅拌均匀，再缓慢加入1-6%的硅粉，待硅粉均匀粘附到颗粒表面后，将颗粒倒出，进行200℃×6-8h的干燥，制得Si粉包覆改性板状刚玉颗粒；
b、上述结合剂可采用酚醛树脂或脲醛树脂与乙醇的均匀混合液，其比例为2∶1～1∶2；所用包覆硅粉的粒度小于0.045mm；
B、依重量百分比准确称量下述各组分并加入湿碾机中：Si粉改性板状刚玉颗粒（40-60%），含锆原料（2-30%），板状刚玉细粉（15-25%），α-Al2O3微粉（3-10%），Si粉（1-6%），炭黑（1-5%），B4C粉（0.5-2%），酚醛树脂结合剂（3-5%）；混练20-30分钟后困料12-24h，之后用压机成型；
C、成型的砖坯经干燥、埋炭或氮气气氛下高温烧成，制得烧成Al2O3-ZrO2-C滑板砖。
3.根据权利要求1所述，一种高耐磨烧成Al2O3-ZrO2-C滑板砖及其生产方法，其特征在于，Si粉改性板状刚玉颗粒的粒径为3-0.5mm，所用含锆原料中锆刚玉、锆莫来石的粒径小于2mm，氧化锆的粒径小于0.045mm，所用α-Al2O3微粉的粒径小于3μm；含锆原料可以是上述中的一种或多种。
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