CN115108820B - 一种耐高温耐磨陶瓷涂料的制备方法 - Google Patents
一种耐高温耐磨陶瓷涂料的制备方法 Download PDFInfo
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
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- C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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Abstract
本发明公开了一种耐高温耐磨陶瓷涂料的制备方法，属于涂料技术领域，本发明公开的耐磨陶瓷涂料可采用人工或机械方式涂抹在内衬或表面基底上具有极高的机械强度和刚度，密度大，无大的宏观缺陷，可有效抵御物料的冲击力和剪切应力，而结合采用聚羧酸盐凝胶，后续烧结能形成化学结合，致使其强度很高，烧结致密后，涂料中有高硬度的陶瓷晶体存在，在常温下有较高的结合强度和硬度，加入的过渡金属氧化物增黑剂，容易固溶于其中而形成固溶体，提高发射率，具有优良的韧性和抗振性，可有效防止冲击力造成的破损和剥落。由于离子键和其共价键为强结合键，键能比较高，不会产生热振损毁，不产生裂缝，耐磨性好。
Description
技术领域
本发明属于陶瓷涂料技术领域，尤其是一种耐高温耐磨陶瓷涂料的制备方法。
背景技术
高温保护材料不被氧化对世界各国都有重要的经济意义和社会意义，单只金属被氧化腐蚀后在外形、色泽以及机械性能方面都将发生变化，造成设备破坏、管道泄漏、产品污染，酿成燃烧或爆炸等恶性事故以及资源和能源的严重浪费，使国民经济受到巨大的损失。据估计，世界各发达国家每年因金属腐蚀而造成的经济损失约占其国民生产总值3.5%~4，2%，超过每年各项大灾(火灾、风灾及地震等)损失的总和。有人甚至估计每年全世界腐蚀报废和损耗的金属约为1亿吨，因此，研究新型耐磨陶瓷涂料，防护高温材料不被氧化，对经济建设有着十分重大的意义。日本东洋橡胶工业公司近年研制一项耐磨陶瓷涂料的专利产品。这种涂料的主要成膜物为环氧树脂或不饱和聚酯树脂，以陶瓷粉料为填料，固化剂所组成，再例如中国专利CN2017114572480 公开的一种改进型陶瓷防腐涂料，使用的聚合物组分并不耐高温，并不是真正意义上的陶瓷防腐涂料，而陶瓷防腐涂料别于传统的水性聚合物涂料、胶泥等防腐涂料，陶瓷防腐隔热涂料固化前可以均匀涂覆在需要防腐、防护或增强修复的基材上，固化形成一层无缝密封的涂层，其不但具有优异的防腐蚀性能，同时具有高强度、高耐磨、高附着、高绝缘、高使用寿命和阻燃性能。陶瓷涂料是一种很重要的精细化工产品，其应用已深人到国民经济的各个领域。耐磨陶瓷涂料的适用范围：可广泛应用于水泥、纲铁、火电、石化行业以及国防工业中很多物料强冲刷强腐蚀重磨损的部位。耐高温陶瓷涂料更是广泛应用于航空航天、电子，汽车，机械制造等高技术领域。适宜于水泥、国防、石油、化工行业等各种高、低温设备的关键耐磨防腐处理层，是替代现有的耐磨陶瓷片、耐磨钢的新一代理想材料，解决了各行业因风选磨蚀、冲击磨蚀、部件频繁停工检修等问题。本领域技术人员亟待开发出一种耐高温耐磨陶瓷涂料的制备方法，以满足现有的使用需求和性能要求。
发明内容
针对上述问题，本发明旨在提供一种耐高温耐磨陶瓷涂料的制备方法。
本发明通过以下技术方案实现：
一种耐高温耐磨陶瓷涂料的制备方法，包括以下步骤：
一、制备粘玻璃粉体：将CaO、Al2O3、SiO2、ZnO的均匀混合物装入坩埚中，然后在1400℃的电炉中熔融1h，玻璃熔化均匀后倒入25℃水中淬冷成细小颗粒，经烘干破碎、球磨、过筛得玻璃粉体，再加入质量分数42~43%丙烯酸共聚物水溶液，搅拌分散均匀得固含量75~80%的粘玻璃粉体；
二、准备堇青石粉体：将MgO、Al2O3和SiO2按照董青石化学计量比MgO13.8%、Al2O334.8%，SiO251.4%配料，并添加质量比例1~1.5%的增黑剂，然后将配合料置于球磨机中添加适量无水乙醇球磨24h，球磨介质为玛瑙球，烘干的配合料置于电炉中在1400~1450℃煅烧3h，将煅烧的产物球磨12~16h过筛得陶瓷粉体；
三、涂料使用前的混合：
将步骤(1)得到的粘玻璃粉体和将步骤(2)得到的陶瓷粉分别按40~50:50~60质量比例配料，再加入质量分数42~43%丙烯酸共聚物水溶液，搅拌分散均匀得固含量65~70%的耐高温耐磨陶瓷涂料。
进一步的，所述步骤一的均匀混合物为按重量百分比计的15.0~29.8%CaO、28.3~33.3%Al2O3、40.4~56.7%SiO2、1~2%ZnO的混合物。
进一步的，所述的丙烯酸共聚物为马来酸-丙烯酸共聚物或丙烯酸/衣康酸共聚物中的其中一种。
马来酸-丙烯酸共聚物耐温性能好，有较强的缓蚀阻垢分散效果，与丙烯酸/衣康酸共聚物同样应用在以往各类循环冷却水系统中。
本发明则采用丙烯酸共聚物与玻璃粉反应，制备粘玻璃粉体，涂料在室温下具有良好的涂覆粘附效果，施工效果好。
例如，
进一步的，所述的步骤三增黑剂为氧化锰、铁铬黑中的其中一种。
进一步的，包括以下步骤：
(1)涂料喷涂：处理后的金属基材预热至25~30℃后，将所述耐高温陶瓷防腐隔热涂料喷涂在基材上；
(2)烧结固化：a、烘烤阶段：以50℃/h的速度加热至600℃，保温4h；目的是彻底排除炉衬中的水分。b、半烧结阶段：以50℃/h升温至900℃，保温3h，以100℃/h升温至1200℃，保温3h；控制升温速度，防止产生裂纹。c、完全烧结阶段：高温烧结，置于1000~1080℃下氮气氛围下，烧结110~130分钟，冷却即可。高温烧结时，坩埚的烧结结构是提高其使用寿命的基础。烧结温度不同，烧结层厚度不足，使用寿命明显降低。
本发明的有益效果是：
本发明的粘玻璃粉体制备中，当丙烯酸共聚物与玻璃粉混合后，Al3+，Ca2+离子均能与聚丙烯酸反应生成聚羧酸盐，形成交联的网状结构，并将未反应的玻璃粉结合在一起，逐渐由糊状变为凝胶其中，通过静电吸引力与聚羧酸链间形成纯离子键结合，且有部分络合键，粘玻璃粉体易吸收水分，可被侵蚀和溶解。进一步与堇青石粉体混配后，涂覆后无需前处理变得坚硬和不易溶解，由于堇青石中含有A12O3组分，并能够均匀地分散于玻璃基体中，在一定的温度下玻璃组分CaO和SiO2能够与Al2O3发生界面反应生成钙长石，而且钙长石形成的速度远大于石英从玻璃中析出的速度，从而达到抑制石英析出的目的。烧结致密后，其硬度较高。涂料中有高硬度的陶瓷晶体存在，将会使得复合材料的硬度明显增加。由于堇青石和钙长石都比玻璃的硬度高，故陶瓷涂料硬度较高，本发明的耐磨陶瓷涂料是一种非金属胶凝材料，在施工现场，施工人员将该涂料均匀涂覆在金属及混凝土，在常温下有较高的结合强度和硬度，由于堇青石属于结构不紧密晶体，加入的过渡金属氧化物增黑剂，容易固溶于其中而形成固溶体，环状结构的硅酸盐，属六方晶系，过渡金属离子由于形成固溶体，造成了晶格畸变，降低了离子振动的对称性而使材料的红外辐射率提高。过渡金属离子在六元环空腔中与周围的氧离子的距离不等，偶极矩的变化较大，谱带相叠加，提高发射率。
相比现有技术本发明具有如下优点：
本发明公开的耐磨陶瓷涂料是一种非金属胶凝材料，采用人工或机械方式涂抹在内衬或表面基底上具有极高的机械强度和刚度，密度大，无大的宏观缺陷，可有效抵御物料的冲击力和剪切应力，而结合采用聚羧酸盐凝胶，后烧结能形成化学结合，致使其强度很高，环境相容性好，不会和矿渣发生反应，同时由于这种材料多为高温合成原料，晶体发育好，结构完整，环境温度不会对它造成大的影响，属环境惰性材料，因而对环境敏感性差，无环境污染，不会造成土质恶化和重金属离子污染，不会影响生态环境，是一种绿色环保型的产品。具有优良的韧性和抗振性，可有效防止冲击力造成的破损和剥落。由于离子键和其共价键为强结合键，键能比较高，低温对其影响很小，而且它的振动频率极高，常温难以对其构成威胁，不会产生热振损毁，整体性好，体积稳定，不产生裂缝，因而整体性好，另外施工为整体施工，无接缝出现，因而整体性进一步提高。耐磨性好，能够延长使用寿命，不会造成土质恶化和重金属离子污染，不影响生态环境。
具体实施方式
下面用具体实施例说明本发明，但并不是对本发明的限制。
实施例1
第一步、制备粘玻璃粉体：玻璃粉体的组成:15.0%CaO、28.3%Al2O3、56.7%SiO2、2%ZnO，原料使用化学纯度>99.0%。按组成称量的各种原料混合均匀后装入刚玉坩埚中，然后在1400℃的硅铝棒电炉中熔融1h，玻璃熔化均匀后倒入水中淬冷成细小颗粒，经烘干破碎、球磨过筛制成粒度为D50=2μm的玻璃粉体，再加入质量分数43%丙烯酸共聚物水溶液，山东泰和水处理科技股份有限公司马来酸-丙烯酸共聚物MA/AA，搅拌分散均匀得固含量75%的粘玻璃粉体。第二步、准备堇青石粉体：将纯度>99.0%的MgO，Al2O3和SiO2按照董青石化学计量比，MgO13.8%，Al2O334.8%，SiO251.4%配料，并添加质量比例1.5%的增黑剂氧化锰。然后将配合料置于球磨机中添加无水乙醇球磨24h，球磨介质为玛瑙球。烘干的配合料置于硅铝棒电炉中在1400℃煅烧3h，将煅烧的产物球磨16h得到D50=4μm的陶瓷粉体。
第三步、涂料的制备：将玻璃粉和陶瓷粉分别按40:60质量比比例配料，以无水乙醇为介质球磨16h，球磨介质为玛瑙球，再加入质量分数42%丙烯酸共聚物水溶液，山东泰和水处理科技股份有限公司马来酸-丙烯酸共聚物MA/AA，搅拌分散均匀得固含量65%的耐高温耐磨陶瓷涂料。
第四步、耐高温耐磨陶瓷涂料的涂饰：
(1)涂料喷涂：处理后的金属基材预热至25℃后，将所述耐高温陶瓷防腐隔热涂料喷涂在基材上；
(2)烘烤阶段：以50℃/h的速度加热至600℃，保温4h，目的是彻底排除炉衬中的水分。半烧结阶段：以50℃/h升温至900℃，保温3h，以100℃/h升温至1200℃，保温3h，必须控制升温速度，防止产生裂纹。完全烧结阶段：高温烧结时，坩埚的烧结结构是提高其使用寿命的基础。烧结温度不同，烧结层厚度不足，使用寿命明显降低。
产品性能：耐磨陶瓷涂料初凝时间不小于30分钟，粘接强度，Q420FRWZ35基材≥5.0MPa，LMJ10混凝土基材≥2.0MPa；耐热性，300℃，24h，漆膜不起泡、不开裂、不粘化；耐冷热交变性，300℃－23℃室温，自然冷却10次循环，不起泡、不开裂、不粉化；发射率ε≥0.923，附着力2级、无清液或分层。
实施例2
第一步、制备粘玻璃粉体：玻璃粉体的组成:29.8%CaO、28.3%Al2O3、40.4%SiO2、1%ZnO，原料使用化学纯度>99.0%。按组成称量的各种原料混合均匀后装入刚玉坩埚中，然后在1400℃的硅铝棒电炉中熔融1h，玻璃熔化均匀后倒入水中淬冷成细小颗粒，经烘干破碎、球磨过筛制成粒度为D50=2μm的玻璃粉体，再加入质量分数43%丙烯酸共聚物水溶液，搅拌分散均匀得固含量80%的粘玻璃粉体。第二步、准备堇青石粉体：将纯度>99.0%的MgO，Al2O3和SiO2按照董青石化学计量比，MgO13.8%，Al2O334.8%，SiO251.4%配料，并添加质量比例1.5%的增黑剂铁铬黑，然后将配合料置于球磨机中添加无水乙醇球磨24h，球磨介质为玛瑙球。烘干的配合料置于硅铝棒电炉中在1400℃煅烧3h，将煅烧的产物球磨14h得到D50=4μm的陶瓷粉体。
第三步、涂料的制备：将玻璃粉和陶瓷粉分别按50:50质量比比例配料，以无水乙醇为介质球磨16h，球磨介质为玛瑙球，再加入质量分数42%丙烯酸共聚物水溶液，唐山永合水处理剂有限公司的BF-211丙烯酸/衣康酸共聚物，搅拌分散均匀得固含量70%的耐高温耐磨陶瓷涂料。
第四步、耐高温耐磨陶瓷涂料的涂饰：
(1)涂料喷涂：处理后的金属基材预热至30℃后，将所述耐高温陶瓷防腐隔热涂料喷涂在基材上；(2)烘烤阶段：以50℃/h的速度加热至600℃，保温4h，目的是彻底排除炉衬中的水分。半烧结阶段：以50℃/h升温至900℃，保温3h，以100℃/h升温至1200℃，保温3h，必须控制升温速度，防止产生裂纹。完全烧结阶段：高温烧结时，坩埚的烧结结构是提高其使用寿命的基础。烧结温度不同，烧结层厚度不足，使用寿命明显降低。
产品性能：耐磨陶瓷涂料初凝时间不小于30分钟，粘接强度，Q420FRWZ35基材≥5.0MPa，LMJ10混凝土基材≥2.0MPa；耐热性，300℃，24h，漆膜不起泡、不开裂、不粘化；耐冷热交变性，300℃－23℃室温，自然冷却10次循环，不起泡、不开裂、不粉化；发射率ε≥0.937，附着力2级、无清液或分层。
将实施例1~2的陶瓷防腐隔热涂料应用性能测试，检测结果如表1所示：
表1实施例1~2的陶瓷防腐隔热涂料的应用性能进行性能测试结果
注：试验方法参考以下标准和方法进行，其中制样按YB/T5202.2进行；样品的气孔率检测按照YB/T5200进行；体积密度检测按照YB/T5200进行；抗折强度和耐压强度的检验按YB/T5201进行；磨损值的检验按GB/T18301进行；加热永久线变化的检验按YB/T5203进行；YB/T5200-1993致密耐火浇注料显气孔率和体积密度试验方法；YB/T5201-1993致密耐火浇注料常温抗折强度和耐压强度试验方法。GB/T17617-1998耐火原料和不定形耐火材料取样；YB/T5202.2-2003不定型耐火材料试样制备方法耐火浇注料；YB/T5203-1993致密耐火浇注料线变化试验方法；GB/T18301-2012耐火材料常温耐磨性试验方法；YB/T 134-2015高温红外辐射环保型涂料。
Claims (5)
1.一种耐高温耐磨陶瓷涂料的制备方法，其特征在于，包括以下步骤：
一、制备粘玻璃粉体：将CaO、Al2O3、SiO2、ZnO的均匀混合物装入坩埚中，然后在1400℃的电炉中熔融1h，玻璃熔化均匀后倒入25℃水中淬冷成细小颗粒，经烘干破碎、球磨、过筛得玻璃粉体，再加入质量分数42~43%丙烯酸共聚物水溶液，搅拌分散均匀得固含量75~80%的粘玻璃粉体；
二、准备堇青石粉体：将MgO、Al2O3和SiO2按照董青石化学计量比MgO13.8%、Al2O334.8%，SiO251.4%配料，并添加质量比例1~1.5%的增黑剂，然后将配合料置于球磨机中添加适量无水乙醇球磨24h，球磨介质为玛瑙球，烘干的配合料置于电炉中在1400~1450℃煅烧3h，将煅烧的产物球磨12~16h过筛得陶瓷粉体；
三、涂料使用前的混合：
将步骤(1)得到的粘玻璃粉体和将步骤(2)得到的陶瓷粉分别按40~50:50~60质量比例配料，再加入质量分数42~43%丙烯酸共聚物水溶液，搅拌分散均匀得固含量65~70%的耐高温耐磨陶瓷涂料。
2.根据权利要求1所述的一种耐高温耐磨陶瓷涂料的制备方法，其特征在于，所述步骤一的均匀混合物为按重量百分比计的15.0~29.8%CaO、28.3~33.3%Al2O3、40.4~56.7%SiO2、1~2%ZnO的混合物。
3.根据权利要求1所述的一种耐高温耐磨陶瓷涂料的制备方法，其特征在于，所述的丙烯酸共聚物为马来酸-丙烯酸共聚物或丙烯酸/衣康酸共聚物中的其中一种。
4.根据权利要求1所述的一种耐高温耐磨陶瓷涂料的制备方法，其特征在于，所述的步骤三增黑剂为氧化锰、铁铬黑中的其中一种。
5.一种权利要求1所述制备方法得到的耐高温耐磨陶瓷涂料的使用方法，其特征在于，包括以下步骤：
(1)涂料喷涂：处理后的金属基材预热至25~30℃后，将所述耐高温耐磨陶瓷涂料喷涂在基材上；
(2)烧结固化：a、烘烤阶段：以50℃/h的速度加热至600℃，保温4h；b、半烧结阶段：以50℃/h升温至900℃，保温3h，以100℃/h升温至1200℃，保温3h；c、完全烧结阶段：高温烧结，置于1000~1080℃下氮气氛围下，烧结110~130分钟，冷却即可。
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