CN114951609A - Foamed aluminum plate with uniform closed pores and preparation method thereof - Google Patents
Foamed aluminum plate with uniform closed pores and preparation method thereof Download PDFInfo
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- CN114951609A CN114951609A CN202210385615.5A CN202210385615A CN114951609A CN 114951609 A CN114951609 A CN 114951609A CN 202210385615 A CN202210385615 A CN 202210385615A CN 114951609 A CN114951609 A CN 114951609A
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 107
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 84
- 239000011148 porous material Substances 0.000 title claims abstract description 22
- 238000002360 preparation method Methods 0.000 title abstract description 24
- 239000000843 powder Substances 0.000 claims abstract description 62
- 239000002245 particle Substances 0.000 claims abstract description 56
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical group [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract description 50
- 239000000203 mixture Substances 0.000 claims abstract description 41
- 239000000463 material Substances 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 31
- 239000004088 foaming agent Substances 0.000 claims abstract description 27
- 229910000019 calcium carbonate Inorganic materials 0.000 claims abstract description 25
- 239000002994 raw material Substances 0.000 claims abstract description 24
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 21
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 15
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 14
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical group [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052700 potassium Inorganic materials 0.000 claims abstract description 13
- 239000011591 potassium Substances 0.000 claims abstract description 13
- 239000000919 ceramic Substances 0.000 claims abstract description 11
- 229910001610 cryolite Inorganic materials 0.000 claims abstract description 10
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 4
- 238000010304 firing Methods 0.000 claims description 31
- 238000001816 cooling Methods 0.000 claims description 28
- 238000010438 heat treatment Methods 0.000 claims description 24
- 230000008569 process Effects 0.000 claims description 21
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 17
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 17
- 238000005245 sintering Methods 0.000 claims description 15
- 238000002156 mixing Methods 0.000 claims description 12
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 239000011261 inert gas Substances 0.000 claims description 5
- 239000004604 Blowing Agent Substances 0.000 claims description 3
- 239000012298 atmosphere Substances 0.000 claims description 3
- 230000009467 reduction Effects 0.000 claims description 3
- 230000004907 flux Effects 0.000 claims description 2
- 239000002318 adhesion promoter Substances 0.000 claims 2
- 239000004411 aluminium Substances 0.000 claims 1
- 230000000052 comparative effect Effects 0.000 description 13
- 238000005187 foaming Methods 0.000 description 12
- 238000009826 distribution Methods 0.000 description 8
- 230000006872 improvement Effects 0.000 description 8
- 238000009472 formulation Methods 0.000 description 7
- 239000007789 gas Substances 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 239000012300 argon atmosphere Substances 0.000 description 3
- 238000013329 compounding Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000012299 nitrogen atmosphere Substances 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- 238000010791 quenching Methods 0.000 description 3
- 230000000171 quenching effect Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000005997 Calcium carbide Substances 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- CLZWAWBPWVRRGI-UHFFFAOYSA-N tert-butyl 2-[2-[2-[2-[bis[2-[(2-methylpropan-2-yl)oxy]-2-oxoethyl]amino]-5-bromophenoxy]ethoxy]-4-methyl-n-[2-[(2-methylpropan-2-yl)oxy]-2-oxoethyl]anilino]acetate Chemical group CC1=CC=C(N(CC(=O)OC(C)(C)C)CC(=O)OC(C)(C)C)C(OCCOC=2C(=CC=C(Br)C=2)N(CC(=O)OC(C)(C)C)CC(=O)OC(C)(C)C)=C1 CLZWAWBPWVRRGI-UHFFFAOYSA-N 0.000 description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000007688 edging Methods 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/005—Casting metal foams
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/08—Alloys with open or closed pores
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/08—Alloys with open or closed pores
- C22C1/083—Foaming process in molten metal other than by powder metallurgy
- C22C1/086—Gas foaming process
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Abstract
The invention discloses a foamed aluminum plate with uniform closed pores, which is mainly prepared from the following raw materials in parts by weight: 90-98 parts of base material, 0.5-5 parts of fluxing agent, 0.5-5 parts of high-temperature tackifier and 0.1-1 part of foaming agent. Wherein the base material is selected from aluminum powder, aluminum scraps and/or aluminum alloy powder; the foaming agent is calcium carbonate powder, and the particle size of the foaming agent is 400-800 meshes; the fluxing agent is potassium fluoroaluminate and/or cryolite; the high-temperature tackifier is one or a mixture of more of alumina powder, mullite powder and ceramic powder. Correspondingly, the invention also discloses a preparation method for preparing the foamed aluminum plate with uniform closed cells. By implementing the method, the large-size closed-cell foamed aluminum plate with uniform pore diameter, high purity and high strength can be obtained.
Description
Technical Field
The invention relates to the field of foamed metal materials, in particular to a foamed aluminum plate with uniform closed pores and a preparation method thereof.
Background
The foamed aluminum is a composite material which is formed by a metal aluminum/aluminum alloy and gas, wherein a large number of bubbles exist in the metal aluminum/aluminum alloy. The foamed aluminum has the advantages of high porosity, small density, high temperature resistance, corrosion resistance, low heat conductivity, strong electromagnetic shielding performance, good sound absorption and vibration reduction performance and the like. Foamed aluminum is widely applied to the fields of music halls, conference centers, road barriers, ventilation equipment and the like as a functional material and a structural material.
The existing closed-cell foamed aluminum preparation processes mainly comprise two processes, one process is a powder metallurgy foaming method,which is mainly a blowing agent (usually TiH) 2 Powder) and metal aluminum powder are mixed, and the mixture is subjected to mould pressing, high-temperature foaming and cooling to obtain foamed aluminum; by adopting the method, the high-temperature foaming temperature is generally controlled between 690 and 800 ℃. The method has narrow process parameter interval, the prepared foamed aluminum has small size, and different shapes of foamed aluminum require different molds due to the mold pressing process, so the mold preparation cost is high, the mold needs to be frequently changed in the production process, and the process cost is high. The other method is a foaming agent foaming method, which is mainly characterized in that a foaming agent is added into a melt obtained after aluminum is melted, and then gas generated by the foaming agent is foamed and cooled to obtain foamed aluminum. The blowing agent used in this process is usually TiH 2 、ZrH 2 And the like. The process needs to add a foaming agent into the aluminum melt, the foaming agent is difficult to be uniformly mixed, and the uniformity of pores obtained by foaming is poor. And because the temperature of the aluminum melt is high, the addition of the foaming agent is difficult.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a foamed aluminum plate with uniform closed pores, wherein the foamed pores have high aperture uniformity and high strength, and the foamed aluminum plate has large specification and can be processed as required.
The technical problem to be solved by the present invention is to provide a method for manufacturing a foamed aluminum sheet with uniform closed pores, which has a simple process and can manufacture a large-sized foamed aluminum sheet (maximum size 2400mm × 3000mm × 200 mm).
In order to solve the technical problem, the invention provides a foamed aluminum plate with uniform closed pores, which is mainly prepared from the following raw materials in parts by weight:
90-98 parts of base material, 0.5-5 parts of fluxing agent, 0.5-5 parts of high-temperature tackifier and 0.1-1 part of foaming agent;
the foaming agent is calcium carbonate powder, and the particle size of the foaming agent is 400-800 meshes; the fluxing agent is potassium fluoroaluminate (K3AlF6) and/or cryolite; the high-temperature tackifier is one or a mixture of more of alumina powder, mullite powder and ceramic powder, and the particle size of the high-temperature tackifier is 100-325 meshes.
As an improvement of the technical scheme, the amount of the foaming agent is 0.1-0.5 part, and the particle size of the foaming agent is 500-600 meshes.
As an improvement of the technical scheme, the particle size of the base material is 10-100 meshes, the particle size of the fluxing agent is 250-1500 meshes, and the particle size of the high-temperature tackifier is 100-325 meshes.
As an improvement of the technical scheme, the high-temperature tackifier is alumina powder with the particle size of 200-300 meshes.
As an improvement of the technical scheme, the base material is aluminum powder with the particle size of 40-80 meshes.
As an improvement of the technical scheme, the foamed aluminum plate is prepared from the following raw materials in parts by weight:
93-96 parts of aluminum powder, 0.1-0.5 part of calcium carbonate powder, 1.5-3 parts of alumina powder and 1.5-3 parts of potassium fluoroaluminate (K3AlF 6).
Correspondingly, the invention also discloses a preparation method of the foamed aluminum plate with uniform closed cells, which comprises the following steps:
(1) providing raw materials, and uniformly mixing the raw materials to obtain a mixture;
(2) distributing the mixture into a refractory kiln car;
(3) firing the mixture in the refractory kiln car at 700-750 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores;
wherein, in the firing process, an inert gas atmosphere is maintained.
As an improvement of the technical scheme, in the step (3), the raw materials are sintered according to the following temperature curve:
heating for 20-30 min from room temperature to 450 ℃;
the temperature is raised for 30-45 min from 450 ℃ to 600 ℃;
heating for 15-20 min from 600 ℃ to the firing temperature;
the temperature reduction time is 10-12 min from the firing temperature to 450 ℃;
cooling for 60-80 min from 450 ℃ to room temperature;
wherein the firing temperature is 710-730 ℃.
As an improvement of the technical scheme, in the step (1), a screw mixing device is adopted to mix the raw materials;
and (3) sintering by adopting a roller kiln.
As an improvement of the technical scheme, the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a coaming plate which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the backing plate and the coaming plate are encircled to form an accommodating cavity for accommodating the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide;
in the step (2), aluminum silicate high-temperature paper is adhered in the accommodating cavity of the refractory kiln car, and then the material is distributed.
The implementation of the invention has the following advantages:
1. according to the foamed aluminum plate, calcium carbonate powder with the particle size of 400-800 meshes is used as a foaming agent, and can be decomposed at 700-750 ℃ to generate a large amount of gas, so that the foaming effect is achieved.
2. According to the foamed aluminum plate, the high-temperature tackifier is added in the formula, and the viscosity of the aluminum melt is increased at high temperature, so that gas generated by decomposition of the calcium carbide powder does not flow at will, the adding amount of the foaming agent is reduced, the uniformity of air holes is ensured, and the air holes are prevented from penetrating to form open air holes.
3. The fluxing agent is added in the formula, and the fluxing agent reacts with alumina at 400-600 ℃ to destroy an oxide film on the surface of the aluminum powder or aluminum skimmings due to the fact that a layer of oxide film (alumina) exists on the surfaces of the aluminum powder and the aluminum skimmings, and the melting point of the alumina is 2050 ℃, so that the melting temperature of the aluminum powder or the aluminum skimmings is greatly reduced, and the energy consumption is greatly reduced.
4. In the preparation method of the foamed aluminum plate, the cooling time is controlled to be 10-12 min in the process of cooling the firing temperature to 450 ℃, namely, a quenching process is adopted; the gas generated by the foaming agent can be fixed in the melt by quenching and solidification, and the uniformity of the pores is improved. Meanwhile, the use amount of the high-temperature tackifier is reduced to a certain extent.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to specific embodiments.
The invention provides a preparation method of a foamed aluminum plate with uniform closed pores, which is mainly prepared from the following raw materials in parts by weight:
90-98 parts of base material, 0.5-5 parts of fluxing agent, 0.5-5 parts of high-temperature tackifier and 0.1-1 part of foaming agent.
The base material is aluminum powder or aluminum scraps, the particle size of the base material is 10-100 meshes, the base material in the particle size range can be fully mixed with other raw materials, and the foaming uniformity is improved. For example, the particle size of the base material is 20 to 60 mesh, 40 to 60 mesh, 20 to 80 mesh or 60 to 100 mesh, but not limited thereto. Preferably, the particle size of the base material is 40-80 meshes. Specifically, the amount of the binder is 90 to 98 parts, and is illustratively 90 parts, 92 parts, 94 parts, 96 parts, or 98 parts, but is not limited thereto. Preferably, the amount of the base material is 93-95 parts. The foamed aluminum plate has high base material consumption, high purity, excellent corrosion resistance and excellent electromagnetic shielding performance.
The foaming agent is calcium carbonate powder with the particle size of 400-800 meshes, and the calcium carbonate powder with the particle size range can be fully dispersed in the mixture, so that the foaming uniformity is ensured. Preferably, the particle size of the calcium carbonate powder is 500-600 meshes. The calcium carbonate powder is used in an amount of 0.1 to 1 part, illustratively 0.1 part, 0.15 part, 0.2 part, 0.24 part, 0.44 part, 0.5 part, 0.7 part, or 0.9 part, but is not limited thereto. Preferably, the amount of the calcium carbonate powder is 0.1-0.5 part, and the amount of the foaming agent can be effectively reduced while the foaming effect is ensured through the cooperation of the preparation process and the high-temperature tackifier.
Furthermore, the high-temperature thickening agent is 0.5-5 parts in the formula, and can improve the viscosity of the aluminum melt at high temperature, so that gas generated by decomposition of calcium carbonate powder is retained in the melt, bubbles do not move randomly, and the uniformity of the bubbles is improved while the dosage of the foaming agent is reduced. Specifically, the high-temperature tackifier may be alumina powder, mullite powder, or ceramic powder (such as daily ceramic powder, building ceramic powder, bath ceramic powder, foamed ceramic powder, etc.), but is not limited thereto. Preferably, the high-temperature tackifier is alumina powder.
Specifically, the particle size of the high-temperature tackifier is 100-325 meshes, preferably 200-300 meshes, the high-temperature tackifier with the particle size range can be uniformly mixed with the base material and the foaming agent, and the proper viscosity is given to the aluminum melt at high temperature, so that the foaming uniformity is improved.
Meanwhile, 0.5-5 parts of fluxing agent is added into the formula of the foamed aluminum plate, and because the surfaces of the aluminum powder and the aluminum skimmings are provided with a layer of oxide film (aluminum oxide), the melting point of the aluminum oxide is 2050 ℃, the added fluxing agent reacts with the aluminum oxide at 400-600 ℃ to destroy the oxide film on the surfaces of the aluminum powder or the aluminum skimmings, so that the melting temperature of the aluminum powder or the aluminum skimmings is greatly reduced, and the energy consumption is greatly reduced. Specifically, the flux may be selected from potassium fluoroaluminate and/or cryolite, but is not limited thereto. The particle size of the fluxing agent is 250-1500 meshes.
Correspondingly, the invention also discloses a preparation method for preparing the foamed aluminum plate with the uniformly opened closed cells, which comprises the following steps:
(1) providing raw materials, and uniformly mixing the raw materials to obtain a mixture.
Specifically, a ball mill, a screw mixing device, a paddle stirrer, or the like may be used for mixing, but not limited thereto. Preferably, adopt screw rod mixture device to carry out the compounding, its homogeneity that can promote the compounding, and realize the defeated material compounding of limit, promote production efficiency.
(2) Distributing the mixture into a refractory kiln car;
the refractory kiln car can be of an integrated structure, such as an integrated sagger sintered by silicon carbide or mullite, or of an assembled structure. Preferably, the refractory kiln car is of a split mounting type structure, the refractory kiln car with the split mounting type structure can be used for producing large-specification foamed aluminum plates, and the refractory kiln car can be cut and the like at the later stage according to requirements, so that the production flexibility is improved. Specifically, in one embodiment of the invention, the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a surrounding plate which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the backing plate and the surrounding plate surround to form a containing cavity for containing a mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. The refractory kiln car with the structure operates stably without vibration, so that the foamed aluminum plate can be fired in the roller kiln, and the production efficiency is improved.
Furthermore, before material distribution, aluminum silicate high-temperature paper is adhered in a containing cavity of the refractory kiln car to prevent high-temperature aluminum melt from flowing out of a gap of the assembled kiln car.
Specifically, the material distribution equipment can adopt the material distribution equipment commonly used in the field of architectural ceramics (such as ceramic tiles, foamed ceramics and the like).
(3) And firing the mixture in the refractory kiln car at 700-750 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores.
Wherein, an inert gas atmosphere is maintained in the firing process, and specifically, the inert gas can be nitrogen or argon, but is not limited thereto; preferably, the inert gas is argon, which does not consume oxygen in the mix, facilitating control of foaming. The firing process can be carried out in a tunnel kiln, a roller kiln (such as a roller kiln for sintering the lithium battery anode), and an electric furnace, but is not limited thereto. Preferably, the firing process is performed in a roller kiln to improve production efficiency.
Further, in one embodiment of the present invention, firing is performed according to the following temperature profile:
heating for 20-30 min from room temperature to 450 ℃;
the temperature is raised for 30-45 min from 450 ℃ to 600 ℃;
heating for 15-20 min from 600 ℃ to the firing temperature;
the temperature is reduced for 10-12 min from the firing temperature to 450 ℃;
cooling for 60-80 min from 450 ℃ to room temperature;
wherein the firing temperature is 710-730 ℃. According to the invention, the quenching section is arranged in the section from the sintering temperature to 450 ℃, so that the gas generated by the foaming agent is fixed in the melt, and the uniformity of air holes is improved. Meanwhile, the use amount of the high-temperature tackifier is reduced to a certain extent.
The foamed aluminum plate prepared by the preparation method has high aperture uniformity and high strength, and the foamed aluminum plate with large specification (the maximum specification is 2400mm 3000mm 200mm) can be processed as required.
Further, the preparation method of the present invention further includes the step of performing subsequent processing, such as edging, cutting, carving, etc., on the fired foamed aluminum plate, but is not limited thereto.
The invention is further illustrated by the following specific examples:
example 1
This example provides a foamed aluminum sheet with uniform closed cells, which is formulated as follows:
95 parts of industrial aluminum powder, 1 part of calcium carbonate powder, 2.5 parts of alumina powder and potassium fluoroaluminate (K) 3 AlF 6 )1.5 parts;
wherein the industrial aluminum powder has a particle size of 200-300 meshes, the calcium carbonate powder has a particle size of 500-600 meshes, the alumina powder has a particle size of 200-325 meshes, and potassium fluoroaluminate (K) 3 AlF 6 ) The particle size of the particles is 1000-1200 meshes.
The preparation method comprises the following steps:
(1) mixing the raw materials uniformly;
(2) distributing the mixture into a refractory kiln car;
the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a coaming plate which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the backing plate and the coaming plate are encircled to form a containing cavity for containing a mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered to the accommodating cavity of the refractory kiln car.
(3) Firing the mixture in the refractory kiln car at 700 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores;
wherein, the raw materials are sintered in a roller kiln, and the nitrogen atmosphere is maintained in the sintering process. The firing temperature curve is as follows:
heating for 40min (uniformly heating) from room temperature to 700 ℃;
and (4) cooling for 120min (uniformly cooling) from the sintering temperature to the room temperature.
Example 2
90 parts of industrial aluminum powder, 0.5 part of calcium carbonate powder, 4.5 parts of alumina powder and 5 parts of potassium fluoroaluminate (K3AlF 6);
wherein the industrial aluminum powder has a particle size of 200-300 meshes, the calcium carbonate powder has a particle size of 500-600 meshes, the alumina powder has a particle size of 100-180 meshes, and potassium fluoroaluminate (K) 3 AlF6) having a particle size of 300 to 600 mesh.
The preparation method is the same as that of example 1.
Example 3
This example provides a foamed aluminum sheet with uniform closed cells, which is formulated as follows:
95 parts of industrial aluminum powder, 0.6 part of calcium carbonate powder, 0.4 part of mullite powder and 4 parts of potassium fluoroaluminate (K3AlF 6);
the particle size of the industrial aluminum powder is 200-300 meshes, the particle size of the mullite powder is 200-325 meshes, the particle size of the calcium carbonate powder is 500-600 meshes, and the particle size of the potassium fluoroaluminate (K3AlF6) is 500-1000 meshes.
The preparation method is the same as that of the example 1, but the argon atmosphere is maintained in the sintering process.
Example 4
This example provides a foamed aluminum panel with uniform closed cells, having the following formulation:
97 parts of industrial aluminum powder, 0.4 part of calcium carbonate powder, 0.4 part of alumina powder and 2.2 parts of cryolite (Na3AlF 6);
wherein the particle size of the industrial aluminum powder is 200-250 meshes, the particle size of the alumina powder is 200-250 meshes, the particle size of the calcium carbonate powder is 600-700 meshes, and the particle size of the cryolite (Na3AlF6) is 500-1000 meshes.
The preparation method is the same as in example 3.
Example 5
This example provides a foamed aluminum sheet with uniform closed cells, which is formulated as follows:
92 parts of aluminum skimmings, 0.4 part of calcium carbonate powder, 4.6 parts of alumina powder and 3 parts of cryolite (Na3AlF 6);
wherein the particle size of the aluminum scraps is 10-40 meshes, the particle size of the alumina powder is 100-200 meshes, the particle size of the calcium carbonate powder is 600-700 meshes, and the particle size of the cryolite (Na3AlF6) is 500-1000 meshes.
The preparation method comprises the following steps:
(1) mixing the raw materials uniformly;
(2) distributing the mixture into a refractory kiln car;
the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a coaming plate which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the backing plate and the coaming plate are encircled to form a containing cavity for containing a mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered to the accommodating cavity of the refractory kiln car.
(3) Firing the mixture in the refractory kiln car at 720 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores;
wherein, the sintering is carried out in a roller kiln, and the argon atmosphere is maintained in the sintering process. The firing temperature curve is as follows:
heating for 22min (uniformly heating) from room temperature to 450 ℃;
heating for 40min (uniformly heating) from 450 ℃ to 600 ℃;
heating for 16min (uniformly heating) from 600 ℃ to 720 ℃;
cooling for 12min (constant speed cooling) from 720 ℃ to 450 ℃;
cooling from 450 deg.c to room temperature for 60min (constant speed cooling).
Example 6
This example provides a foamed aluminum panel with uniform closed cells, having the following formulation:
98 parts of industrial aluminum powder, 0.3 part of calcium carbonate powder, 0.2 part of alumina powder and 1.5 parts of potassium fluoroaluminate (K3AlF 6);
wherein the particle size of the industrial aluminum powder is 40-100 meshes, the particle size of the alumina powder is 250-325 meshes, the particle size of the calcium carbonate powder is 600-700 meshes, and the particle size of the potassium fluoroaluminate (K3AlF6) is 500-1000 meshes.
The preparation method comprises the following steps:
(1) mixing the raw materials uniformly;
(2) distributing the mixture into a refractory kiln car;
the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a coaming plate which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the backing plate and the coaming plate are encircled to form a containing cavity for containing a mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered to the accommodating cavity of the refractory kiln car.
(3) Firing the mixture in the refractory kiln car at 750 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores;
wherein, the sintering is carried out in a roller kiln, and the argon atmosphere is maintained in the sintering process. The firing temperature curve is as follows:
heating for 25min (uniformly heating) from room temperature to 450 ℃;
heating for 35min (uniformly heating) from 450 ℃ to 600 ℃;
heating for 18min from 600 ℃ to 750 ℃ (uniform heating);
cooling for 11min (constant speed cooling) from 750 deg.C to 450 deg.C;
cooling from 450 deg.c to room temperature for 65min (constant speed cooling).
Comparative example 1
This comparative example provides an aluminum sheet having the same formulation and preparation method as example 1. The difference is that the particle size of the calcium carbonate powder is 100-200 meshes.
Comparative example 2
This comparative example provides a foamed aluminum sheet having the same formulation and preparation method as in example 1. The difference is that the particle size of the calcium carbonate powder is 1000-1200 meshes.
Comparative example 3
This comparative example provides an aluminum sheet having the same formulation as example 1. The preparation method comprises the following steps:
(1) mixing the raw materials uniformly;
(2) distributing the mixture into a refractory kiln car;
the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a coaming plate which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the backing plate and the coaming plate are encircled to form a containing cavity for containing a mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered to the accommodating cavity of the refractory kiln car.
(3) Firing the mixture in the refractory kiln car at 700 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores;
wherein, the raw materials are sintered in a roller kiln, and the nitrogen atmosphere is maintained in the sintering process. The firing temperature curve is as follows:
heating for 30min (uniformly heating) from room temperature to 700 ℃;
and (5) cooling for 93min (uniformly cooling) from the sintering temperature to the room temperature.
Comparative example 4
This comparative example provides an aluminum sheet having the same formulation as example 1. The preparation method comprises the following steps:
(1) mixing the raw materials uniformly;
(2) distributing the mixture into a refractory kiln car;
the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a coaming plate which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the backing plate and the coaming plate are encircled to form a containing cavity for containing a mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered to the accommodating cavity of the refractory kiln car.
(3) Firing the mixture in the refractory kiln car at 1000 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores;
wherein, the raw materials are sintered in a roller kiln, and the nitrogen atmosphere is maintained in the sintering process. The firing temperature curve is as follows:
heating from room temperature to 1000 deg.C for 44.5min (uniformly heating);
and (5) cooling for 134min (uniformly cooling) from the sintering temperature to the room temperature.
Specifically, 4 pieces of each of the 2.4m × 3m × 0.15 m-sized plates were prepared according to the formulations and preparation methods of examples 1 to 6 and comparative examples 1 to 4, and then the test was performed. Wherein, 3 plates are respectively taken to test the volume weight, the heat conductivity coefficient, the compressive strength and the porosity.
The test results are shown in the following table:
as can be seen from the table, the compressive strength of the foamed aluminum plate prepared by the invention is more than or equal to 335N/cm 2 The porosity is more than or equal to 94.3 percent and the volume weight is less than or equal to 0.36g/cm 3 . In addition, as can be seen from comparison between comparative examples 1 to 4 and example 1, it is difficult to achieve the technical effects of the present invention by changing the particle size of the calcium carbide powder or the firing temperature.
In addition, in order to judge the foaming uniformity of the panel of the present invention, 2 panels obtained in each of examples and comparative examples were cut at the peripheral edges and the center thereof, respectively, 10 panels having a specification of 0.2m × 0.2m × 0.15m were obtained in each of examples/comparative examples, and the compressive strength of the panels was measured, respectively, and the specific results are shown in the following table, in which the unit of the compressive strength is N/cm 2 ：
As can be seen from the table, the foamed aluminum plate prepared by the invention has small variance of the compressive strength of each position, which shows that the foamed aluminum plate has high uniformity. Whereas the comparative example had a relatively poor uniformity.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.
Claims (10)
1. A foamed aluminum plate with uniform closed pores is characterized by being mainly prepared from the following raw materials in parts by weight:
90-98 parts of base material, 0.5-5 parts of fluxing agent, 0.5-5 parts of high-temperature tackifier and 0.1-1 part of foaming agent.
Wherein the base material is aluminum powder, aluminum scraps and/or aluminum alloy powder, and the particle size of the base material is 10-100 meshes; the foaming agent is calcium carbonate powder, and the particle size of the foaming agent is 400-800 meshes; the fluxing agent is potassium fluoroaluminate and/or cryolite; the high-temperature tackifier is one or a mixture of more of alumina powder, mullite powder and ceramic powder.
2. The foamed aluminum sheet having uniform closed cells according to claim 1, wherein the blowing agent is used in an amount of 0.1 to 0.5 parts and has a particle size of 500 to 600 mesh.
3. The foamed aluminum sheet having uniform closed cells according to claim 1, wherein the base material has a particle size of 10 to 100 mesh, the flux has a particle size of 250 to 1500 mesh, and the high temperature adhesion promoter has a particle size of 100 to 325 mesh.
4. The foamed aluminum sheet having uniform closed cells of claim 3, wherein the high temperature adhesion promoter is alumina powder having a particle size of 200 to 300 mesh.
5. The foamed aluminum sheet having uniform closed cells of claim 1, wherein the base material is aluminum powder having a particle size of 40 to 80 mesh.
6. The foamed aluminum sheet with uniform closed cells according to any one of claims 1 to 5, wherein the foamed aluminum sheet is made from the following raw materials in parts by weight:
93-96 parts of base material, 0.1-0.5 part of foaming agent, 1.5-3 parts of high-temperature tackifier and 1.5-3 parts of fluxing agent.
7. A method of making a foamed aluminium panel having uniform closed cells according to any one of claims 1 to 6, comprising:
(1) providing raw materials, and uniformly mixing the raw materials to obtain a mixture;
(2) distributing the mixture into a refractory kiln car;
(3) firing the mixture in the refractory kiln car at 700-750 ℃, and cooling to obtain a foamed aluminum plate finished product with uniform closed pores;
wherein, in the firing process, an inert gas atmosphere is maintained.
8. The method for preparing a foamed aluminum sheet having uniform closed cells according to claim 7, wherein in the step (3), the firing is performed according to the following temperature profile:
heating for 20-30 min from room temperature to 450 ℃;
the temperature is raised for 30-45 min from 450 ℃ to 650 ℃;
heating for 15-20 min from 650 ℃ to the firing temperature;
the temperature reduction time is 10-12 min from the firing temperature to 450 ℃;
cooling for 60-80 min from 450 ℃ to room temperature;
wherein the firing temperature is 710-730 ℃.
9. The method for preparing a foamed aluminum sheet having uniform closed cells according to claim 7, wherein in the step (1), the raw materials are mixed by using a screw mixing device;
and (3) sintering by adopting a roller kiln.
10. The method for preparing the foamed aluminum plate with the uniform closed pores according to claim 7, wherein the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a surrounding plate which are sequentially arranged from bottom to top, the first square beam is perpendicular to the second square beam, and the backing plate and the surrounding plate surround to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide;
in the step (2), aluminum silicate high-temperature paper is adhered in the accommodating cavity of the refractory kiln car, and then the material is distributed.
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