CN115286366A - Preparation process of high-strength wear-resistant ceramic microsphere material and plunger - Google Patents
Preparation process of high-strength wear-resistant ceramic microsphere material and plunger Download PDFInfo
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- CN115286366A CN115286366A CN202211007554.5A CN202211007554A CN115286366A CN 115286366 A CN115286366 A CN 115286366A CN 202211007554 A CN202211007554 A CN 202211007554A CN 115286366 A CN115286366 A CN 115286366A
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Abstract
The invention relates to the technical field of plunger preparation, in particular to a high-strength wear-resistant ceramic microsphere material and a preparation process of a plunger. The material at least comprises the following raw materials in parts by weight: 41-58 parts of aluminum oxide, 2-8 parts of glass powder, 5-12 parts of feldspar, 11-18 parts of clay, 3-5 parts of sintering aid and 1-6 parts of grinding aid. In the invention, a sintering aid is added to form a solid solution with a sintered object, so that the crystal lattice is distorted and activated, a grinding aid is added as a surfactant to improve the crushing efficiency of the ceramic microspheres, wherein calcium oxide and sodium citrate react to generate calcium citrate, so that the absorption of the ceramic is facilitated, the expansion coefficient of the generated ceramic microspheres is adjusted, the mechanical strength of a finished product is improved, and in addition, a secondary sintering technology of high-temperature and low-temperature combination is adopted to endow the material with a fine structure and excellent mechanical properties.
Description
Technical Field
The invention relates to the technical field of plunger preparation, in particular to a high-strength wear-resistant ceramic microsphere material and a preparation process of a plunger.
Background
The mining emulsion pump station is one of key equipment of a coal mine underground modern high-yield high-efficiency fully-mechanized coal mining working face, an emulsion pump is a common plunger type reciprocating pump and is used for providing emulsion for a hydraulic support, a working principle of the mining emulsion pump is that a piston is driven by rotation of a crankshaft to reciprocate to achieve liquid suction and liquid discharge, and the emulsion pump is a power source of a hydraulic support supporting system in high-yield high-efficiency fully-mechanized coal mining supporting equipment and has a very important position in the fully-mechanized coal mining working face.
The plunger is the most important part in the emulsion pump, when the emulsion pump works, high-speed water flow flowing on the surface of the plunger can bring about serious wiredrawing erosion, and when an aqueous medium contains impurity particles, abrasive wear can be caused, the plunger respectively bears 40MPa and stress-free alternating change in the liquid and outside the liquid in the movement process, tiny defects and cracks can cause the initiation and the expansion of fatigue cracks, and finally the crack of the plunger is enlarged to fail, so that the influence of the failure of the plunger on the coal fully-mechanized mining work is reduced, and the maintenance cost is reduced, and the preparation process of the high-strength wear-resistant ceramic microsphere material and the plunger is provided.
Disclosure of Invention
The invention aims to provide a preparation process of a high-strength wear-resistant ceramic microsphere material and a plunger, which aims to solve the problems in the background technology.
In order to achieve the above object, in one aspect, the present invention provides a high-strength wear-resistant ceramic microsphere material, which at least comprises the following raw materials in parts by weight: 41-58 parts of aluminum oxide, 2-8 parts of glass powder, 5-12 parts of feldspar, 11-18 parts of clay, 3-5 parts of sintering aid and 1-6 parts of grinding aid.
As a further improvement of the technical scheme, the sintering aid comprises chromium dioxide, calcium oxide and magnesium oxide, and the grinding aid comprises triethanolamine and sodium citrate.
As a further improvement of the technical scheme, the glass powder is low-melting-point glass, and the feldspar comprises albite and celsian.
In another aspect, the present invention further provides a preparation process of the high-strength wear-resistant ceramic microsphere material plunger, including the following steps:
s1, putting aluminum oxide, glass powder, feldspar and clay into a ball mill, adding water, stirring and mixing, grinding by ball milling to form crushed materials, and forming base materials by a spray granulation mode for the crushed materials;
s2, putting the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a shaping die, and cooling to generate a blank;
s3, putting the blank into a rubber wrapping mold material at normal temperature, and carrying out static pressure forming by taking liquid as a pressure medium to generate ceramic microsphere particles;
s4, putting the ceramic microsphere particles into a grinder, adding a grinding aid and a sintering aid to fully contact the ceramic microsphere particles, and grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 8-15 microns;
s5, putting the ceramic microsphere powder into a columnar stainless steel mold, sintering and shaping the ceramic microsphere powder through hanging sintering, and taking out a slender tubular blank from the mold;
and S6, grinding and polishing the blank to produce the plunger with the appearance size, the surface finish degree and the concentricity verticality which meet the requirements of the emulsion pump.
As a further improvement of the technical scheme, in the S1, the ball mill is a high-energy planetary ball mill, and the rotating speed of the ball mill during grinding is 100-220rpm/min.
As a further improvement of this embodiment, in S2, the slurry is put into a non-porous mold, and the organic monomer is polymerized by gel casting to be cured to form a preform.
As a further improvement of the technical scheme, in the S3, the particle size of the ceramic microspheres generated under the pressure condition of 400-600MPA is 0.18-0.25mm.
As a further improvement of the technical scheme, in S4, after being ground and crushed, the ceramic microsphere particles are heated for 3-8h at the temperature of 1000-1500 ℃.
As a further improvement of the technical scheme, in S5, the stainless steel mold is provided with a thimble hole, and the sintering temperature of the blank is 260-440 ℃.
As a further improvement of the technical scheme, in S6, after the abrasion traces on the surface of the blank are removed by grinding with a diamond grinding wheel, the blank and the sleeve are paired by slight interference, and then grinding and polishing are performed.
According to the invention, a sintering aid such as chromium dioxide, calcium oxide and magnesium oxide is added to form a solid solution with a sintered product, so that lattice distortion is activated, the sintering temperature can be reduced, the diffusion and sintering speed is increased, the volume effect generated when crystal form transformation occurs in sintering is inhibited, and the sintered product with a smaller volume can be generated.
Compared with the prior art, the invention has the beneficial effects that:
in the preparation process of the high-strength wear-resistant ceramic microsphere material and the plunger, a sintering aid is added to form a solid solution with a sintered object, so that crystal lattices are distorted and activated, the diffusion and sintering speed is increased, a grinding aid is added to serve as a surfactant to improve the crushing efficiency of the ceramic microsphere, calcium oxide and sodium citrate react to generate calcium citrate so as to facilitate the absorption of ceramic, adjust the expansion coefficient of the generated ceramic microsphere and improve the mechanical strength of a finished product, and in addition, a secondary sintering technology combining high temperature and low temperature is adopted to endow the material with a fine structure and excellent mechanical properties.
Drawings
FIG. 1 is a flow chart of the preparation of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
On one hand, the present embodiment aims to provide a high-strength wear-resistant ceramic microsphere material, which at least includes the following raw materials in parts by weight: 41-58 parts of aluminum oxide, 2-8 parts of glass powder, 5-12 parts of feldspar, 11-18 parts of clay, 3-5 parts of sintering aid and 1-6 parts of grinding aid.
On the basis, in the embodiment of the invention, the sintering aid comprises chromium dioxide, calcium oxide and magnesium oxide, the grinding aid comprises triethanolamine and sodium citrate, the chromium dioxide can form a solid solution with a sintered product, the sintering temperature can be reduced, the volume effect generated when the crystal form of the chromium dioxide is changed during sintering can be inhibited by adding the calcium oxide and the magnesium oxide, and the triethanolamine and the sodium citrate are used as surfactants to increase the polarity of the ceramic surface, so that adsorption molecules are more tightly adsorbed on the ceramic surface, and the crushing efficiency of the ceramic microspheres is improved.
Furthermore, the glass powder is low-melting-point glass, the feldspar comprises albite and celsian, the low-melting-point glass has good heat resistance and chemical stability and high mechanical strength, the melting temperature can be reduced during production by adopting the low-melting-point glass, and the feldspar is an aluminosilicate mineral and can supplement aluminum-silicon components.
According to the invention, a sintering aid such as chromium dioxide, calcium oxide and magnesium oxide is added to form a solid solution with a sintered product, so that lattice distortion is activated, the sintering temperature can be reduced, the diffusion and sintering speed is increased, the volume effect generated when crystal form transformation occurs in sintering is inhibited, and the sintered product with a smaller volume can be generated.
Referring to fig. 1, an embodiment of the present invention further provides a process for preparing a high-strength wear-resistant ceramic microsphere plunger, which includes the following specific steps:
1. 41-58 parts of aluminum oxide, 2-8 parts of glass powder, 5-12 parts of feldspar and 11-18 parts of clay are put into a high-energy planetary ball mill and added with water for stirring and mixing, the mixture is ground by ball milling at the rotating speed of 100-220rpm/min to form ground materials, the ground materials form base materials in a spray granulation mode, grinding balls of the high-energy planetary ball mill perform high-speed rotary motion to mutually impact with a sample, the purpose of grinding the sample is achieved, higher mechanical energy can be conveyed to the ball-milled powder in a shorter time, the ground materials are mechanically activated in a shorter time, nanocrystalline or amorphous materials are even formed, oxidation and pollution of the materials are reduced, and the grinding effect can be weakened or lost at the too low or too high rotating speed;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to perform polymerization reaction in a gel film injection mode, solidifying, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to be solidified in situ, so that the blank with high density, high strength and good uniformity is obtained;
3. putting the blank into a rubber sheath die material at normal temperature, carrying out static pressure forming under the pressure condition of taking liquid as a pressure medium of 400-600MPA to generate ceramic microsphere particles with the particle size of 0.18-0.25mm, wherein the ceramic microsphere particles prepared by a cold isostatic pressure forming mode have high density, uniform and consistent density, and the length-diameter ratio can be not limited due to uniform density, thereby being beneficial to the subsequent production of rod-shaped, tubular and other fine and long products;
4. putting ceramic microsphere particles into a grinding machine, adding 1-6 parts of grinding aid and 3-5 parts of sintering aid to fully contact the ceramic microsphere particles, heating at 1000-1500 ℃ for 3-8h, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 8-15 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to form the subsequent ceramic microsphere powder;
5. ceramic microsphere powder is put into a columnar stainless steel die with a thimble hole, and after the ceramic microsphere powder is subjected to hanging firing, sintering and molding at 260-440 ℃, a slender tubular blank is taken out of the die, and the thimble hole is arranged to ensure that the stress at two ends is uniform, so that the coaxiality of the prepared blank, namely the concentricity and the smoothness of a plunger can be ensured, the densification of the blank can be realized in a low-temperature sintering mode, and the material in the blank is endowed with a fine structure and excellent mechanical properties;
6. the blank is ground and polished, namely after the abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out, so that a plunger with the appearance size, surface finish and concentricity verticality all meeting the requirements of an emulsion pump is produced, and elastic pressure is produced between the surfaces of parts after assembly by depending on the interference value of a shaft and a hole, thereby obtaining fastened connection, having good coaxiality, being capable of bearing larger axial force, torque and dynamic load, and having higher processing precision.
The plunger made of the high-strength wear-resistant ceramic microsphere material provided by the invention is further illustrated by the following specific examples according to the use amounts of different raw materials in the plunger and different preparation process parameters.
Example 1
1. Adding 41 parts of aluminum oxide, 2 parts of glass powder, 5 parts of feldspar and 11 parts of clay into a high-energy planetary ball mill, adding water, stirring and mixing, grinding at the rotating speed of 100rpm/min through ball milling to form ground materials, forming base materials through a spray granulation mode by the ground materials, enabling grinding balls of the high-energy planetary ball mill to rotate at a high speed to impact with a sample mutually, achieving the purpose of grinding the sample, conveying higher mechanical energy to the ball-milled powder in a shorter time, enabling the ground material to be mechanically activated in a shorter time, even forming a nanocrystalline or amorphous material, and reducing oxidation and pollution of the material, wherein the excessively low or high rotating speed can weaken or lose the grinding effect;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to perform polymerization reaction in a gel film injection mode, solidifying, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to be solidified in situ, so that the blank with high density, high strength and good uniformity is obtained;
3. the blank is put into a rubber sheath die material at normal temperature, and is subjected to static pressure forming under the pressure condition that liquid is 400MPA as a pressure medium to generate ceramic microsphere particles with the particle size of 0.18mm, the ceramic microsphere particles prepared by the cold isostatic pressure forming mode have high density, the density of the particles is uniform, and the length-diameter ratio can not be limited due to the uniform density, so that the blank is beneficial to the subsequent production of rod-shaped, tubular and other thin and long products;
4. putting ceramic microsphere particles into a grinding machine, adding 1 part of grinding aid and 3 parts of sintering aid to fully contact the ceramic microsphere particles, heating at 1000 ℃ for 3 hours, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 8 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to facilitate the formation of subsequent ceramic microsphere powder;
5. putting ceramic microsphere powder into a columnar stainless steel die with an ejector pin hole, carrying out hanging sintering molding on the ceramic microsphere powder at 260 ℃, taking out a slender tubular blank from the die, ensuring that the stress at two ends is uniform by arranging the ejector pin hole, so that the coaxiality of the prepared blank, namely the concentricity and the smooth finish of a plunger can be ensured, realizing the densification of the blank by a low-temperature sintering mode, and endowing the blank with a fine structure and excellent mechanical property;
6. the blank is ground and polished, namely after abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out to generate the plunger with the appearance size, the surface finish degree and the concentricity verticality all meeting the requirements of the emulsion pump.
Example 2
1. Adding 45 parts of aluminum oxide, 3 parts of glass powder, 7 parts of feldspar and 12 parts of clay into a high-energy planetary ball mill, adding water, stirring and mixing, grinding at a rotating speed of 130rpm/min through ball milling to form ground materials, forming base materials by spraying and granulating the ground materials, and enabling grinding balls of the high-energy planetary ball mill to perform high-speed rotary motion to impact with a sample mutually so as to achieve the purpose of grinding the sample, so that higher mechanical energy can be conveyed to the ball-milled powder in a shorter time, the ground material can be mechanically activated in a shorter time, even nanocrystalline or amorphous materials are formed, oxidation and pollution of the material are reduced, wherein the too low or too high rotating speed can weaken or lose the grinding effect;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to perform polymerization reaction in a gel film injection mode, solidifying, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to be solidified in situ, so that the blank with high density, high strength and good uniformity is obtained;
3. putting the blank into a rubber sheath die material at normal temperature, carrying out static pressure forming under the pressure condition of taking liquid as a pressure medium 450MPA to generate ceramic microsphere particles with the particle size of 0.20mm, wherein the ceramic microsphere particles prepared by the cold isostatic pressure forming mode have high density, uniform and consistent density, and uniform density, so that the length-diameter ratio can be manufactured without limitation, and the subsequent production of rod-shaped, tubular and other thin and long products is facilitated;
4. putting ceramic microsphere particles into a grinding machine, adding 2 parts of grinding aid and 3 parts of sintering aid to fully contact the ceramic microsphere particles, heating at 1200 ℃ for 4 hours, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 9 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to form the subsequent ceramic microsphere powder;
5. ceramic microsphere powder is put into a columnar stainless steel die with a thimble hole, and after the ceramic microsphere powder is subjected to hanging firing, sintering and molding at 300 ℃, a slender tubular blank is taken out of the die, and the thimble hole is arranged to ensure that the stress at two ends is uniform, so that the coaxiality of the prepared blank, namely the concentricity and the smooth finish of a plunger can be ensured, the densification of the blank can be realized in a low-temperature sintering mode, and the material in the blank is endowed with fine tissue and excellent mechanical property;
6. the blank is ground and polished, namely after the abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out, so that a plunger with the appearance size, surface finish and concentricity verticality all meeting the requirements of an emulsion pump is produced, and elastic pressure is produced between the surfaces of parts after assembly by depending on the interference value of a shaft and a hole, thereby obtaining fastened connection, having good coaxiality, being capable of bearing larger axial force, torque and dynamic load, and having higher processing precision.
Example 3
1. Adding 51 parts of aluminum oxide, 5 parts of glass powder, 9 parts of feldspar and 14 parts of clay into a high-energy planetary ball mill, adding water, stirring and mixing, grinding at the rotating speed of 170rpm/min by ball milling to form ground materials, forming base materials by spraying and granulating the ground materials, enabling grinding balls of the high-energy planetary ball mill to rotate at a high speed to impact with a sample mutually, achieving the purpose of grinding the sample, conveying higher mechanical energy to the ball-milled powder in a shorter time, enabling the ground material to be mechanically activated in a shorter time, even forming a nanocrystalline or amorphous material, and reducing oxidation and pollution of the material, wherein the excessively low or high rotating speed can weaken or lose the grinding effect;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to generate a polymerization reaction in a gel injection mode and solidify, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to solidify in situ so as to obtain the blank with high density, high strength and good uniformity;
3. the blank is put into a rubber sheath die material at normal temperature, and is subjected to static pressure forming under the pressure condition that liquid is used as a pressure medium and 500MPA to generate ceramic microsphere particles with the particle size of 0.22mm, the ceramic microsphere particles prepared by the cold isostatic pressure forming mode have high density and uniform and consistent particle density, and the length-diameter ratio can be not limited due to the uniform density, so that the blank is beneficial to the subsequent production of rod-shaped, tubular and other thin and long products;
4. putting ceramic microsphere particles into a grinder, adding 4 parts of grinding aid and 4 parts of sintering aid to fully contact the ceramic microsphere particles, heating at 1300 ℃ for 6 hours, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 11 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to facilitate the formation of subsequent ceramic microsphere powder;
5. ceramic microsphere powder is put into a columnar stainless steel die with a thimble hole, and after the ceramic microsphere powder is subjected to hanging firing, sintering and molding at 350 ℃, a slender tubular blank is taken out of the die, and the thimble hole is arranged to ensure that the stress at two ends is uniform, so that the coaxiality of the prepared blank, namely the concentricity and the smooth finish of a plunger can be ensured, the densification of the blank can be realized by a low-temperature sintering mode, and the material in the blank is endowed with fine tissue and excellent mechanical property;
6. the blank is ground and polished, namely after the abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out, so that a plunger with the appearance size, surface finish and concentricity verticality all meeting the requirements of an emulsion pump is produced, and elastic pressure is produced between the surfaces of parts after assembly by depending on the interference value of a shaft and a hole, thereby obtaining fastened connection, having good coaxiality, being capable of bearing larger axial force, torque and dynamic load, and having higher processing precision.
Example 4
1. 54 parts of aluminum oxide, 7 parts of glass powder, 11 parts of feldspar and 16 parts of clay are put into a high-energy planetary ball mill, water is added for stirring and mixing, the materials are ground by ball milling at the rotating speed of 200rpm/min to form ground materials, the ground materials form a base material in a spray granulation mode, grinding balls of the high-energy planetary ball mill perform high-speed rotary motion to mutually impact with a sample, the purpose of grinding the sample is achieved, high mechanical energy can be conveyed to the ball-milled powder in a short time, the ground material is mechanically activated in a short time, even a nanocrystalline or amorphous material is formed, oxidation and pollution of the material are reduced, and the too low or too high rotating speed weakens or loses the grinding effect;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to generate a polymerization reaction in a gel injection mode and solidify, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to solidify in situ so as to obtain the blank with high density, high strength and good uniformity;
3. putting the blank into a rubber sheath die material at normal temperature, carrying out static pressure forming under the pressure condition of taking liquid as a pressure medium 550MPA to generate ceramic microsphere particles with the particle size of 0.23mm, wherein the ceramic microsphere particles prepared by the cold isostatic pressure forming mode have high density, uniform and consistent density, and uniform density, so that the length-diameter ratio can be manufactured without limitation, and the subsequent production of rod-shaped, tubular and other thin and long products is facilitated;
4. putting ceramic microsphere particles into a grinding machine, adding 5 parts of grinding aid and 4 parts of sintering aid, fully contacting the ceramic microsphere particles, heating the mixture at 1400 ℃ for 7 hours, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 13 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to form the subsequent ceramic microsphere powder;
5. ceramic microsphere powder is put into a columnar stainless steel die with a thimble hole, and after the ceramic microsphere powder is subjected to suspension sintering and molding at 400 ℃, a slender tubular blank is taken out of the die, and the thimble hole is arranged to ensure that the stress at two ends is uniform, so that the coaxiality of the prepared blank, namely the concentricity and the smooth finish of a plunger can be ensured, the densification of the blank can be realized by a low-temperature sintering mode, and the material in the blank is endowed with fine tissue and excellent mechanical property;
6. the blank is ground and polished, namely after abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out to generate the plunger with the appearance size, the surface finish degree and the concentricity verticality all meeting the requirements of the emulsion pump.
Example 5
1. 58 parts of aluminum oxide, 8 parts of glass powder, 12 parts of feldspar and 18 parts of clay are put into a high-energy planetary ball mill, water is added for stirring and mixing, the materials are ground by ball milling at the rotating speed of 220rpm/min to form ground materials, the ground materials form base materials in a spray granulation mode, grinding balls of the high-energy planetary ball mill perform high-speed rotary motion to mutually impact with a sample, the purpose of grinding the sample is achieved, higher mechanical energy can be conveyed to the ball-milled powder in a shorter time, the ground material is mechanically activated in a shorter time, nanocrystalline or amorphous materials are even formed, oxidation and pollution of the material are reduced, and the too low or too high rotating speed can weaken or lose the grinding effect;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to perform polymerization reaction in a gel film injection mode, solidifying, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to be solidified in situ, so that the blank with high density, high strength and good uniformity is obtained;
3. the blank is put into a rubber sheath die material at normal temperature, and is subjected to static pressure forming under the pressure condition that liquid is taken as pressure medium 600MPA to generate ceramic microsphere particles with the particle size of 0.25mm, the ceramic microsphere particles prepared by the cold isostatic pressure forming mode have high density, the density of the particles is uniform, and the length-diameter ratio can not be limited because of the uniform density, thereby being beneficial to the subsequent production of rod-shaped, tubular and other thin and long products;
4. putting ceramic microsphere particles into a grinding machine, adding 6 parts of grinding aid and 5 parts of sintering aid to fully contact the ceramic microsphere particles, heating at 1500 ℃ for 8 hours, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 15 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to form the subsequent ceramic microsphere powder;
5. putting ceramic microsphere powder into a columnar stainless steel die with an ejector pin hole, carrying out hanging sintering molding on the ceramic microsphere powder at 440 ℃, taking out a slender tubular blank from the die, ensuring that the stress at two ends is uniform by arranging the ejector pin hole, so that the coaxiality of the prepared blank, namely the concentricity and the finish of a plunger piston can be ensured, realizing the densification of the blank by a low-temperature sintering mode, and endowing the blank with a fine structure and excellent mechanical property;
6. the blank is ground and polished, namely after abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out to generate the plunger with the appearance size, the surface finish degree and the concentricity verticality all meeting the requirements of the emulsion pump.
TABLE 1 comparison of the amounts of the raw materials in examples 1-5
TABLE 2 comparison of Process parameters in examples 1-5
Comparative example 1
The comparative example adopts the process of example 1, only lacks grinding aid, and the rest is unchanged, and the specific steps are as follows:
1. adding 41 parts of aluminum oxide, 2 parts of glass powder, 5 parts of feldspar and 11 parts of clay into a high-energy planetary ball mill, adding water, stirring and mixing, grinding at the rotating speed of 100rpm/min through ball milling to form ground materials, forming base materials through a spray granulation mode by the ground materials, enabling grinding balls of the high-energy planetary ball mill to rotate at a high speed to impact with a sample mutually, achieving the purpose of grinding the sample, conveying higher mechanical energy to the ball-milled powder in a shorter time, enabling the ground material to be mechanically activated in a shorter time, even forming a nanocrystalline or amorphous material, and reducing oxidation and pollution of the material, wherein the excessively low or high rotating speed can weaken or lose the grinding effect;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to perform polymerization reaction in a gel film injection mode, solidifying, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to be solidified in situ, so that the blank with high density, high strength and good uniformity is obtained;
3. putting the blank into a rubber sheath die material at normal temperature, carrying out static pressure forming under the pressure condition of taking liquid as a pressure medium 400MPA to generate ceramic microsphere particles with the particle size of 0.18mm, wherein the ceramic microsphere particles prepared by the cold isostatic pressure forming mode have high density, uniform and consistent density, and uniform density, so that the length-diameter ratio can be manufactured without limitation, and the subsequent production of rod-shaped, tubular and other thin and long products is facilitated;
4. putting ceramic microsphere particles into a grinder, adding 3 parts of sintering aid to fully contact the ceramic microsphere particles, heating at 1000 ℃ for 3h, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 8 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to facilitate the formation of the subsequent ceramic microsphere powder;
5. ceramic microsphere powder is put into a columnar stainless steel die with a thimble hole, and after the ceramic microsphere powder is subjected to hanging firing, sintering and molding at 260 ℃, a slender tubular blank is taken out of the die, and the thimble hole is arranged to ensure that the stress at two ends is uniform, so that the coaxiality of the prepared blank, namely the concentricity and the smooth finish of a plunger can be ensured, the densification of the blank can be realized by a low-temperature sintering mode, and the material in the blank is endowed with fine tissue and excellent mechanical property;
6. the blank is ground and polished, namely after the abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out, so that a plunger with the appearance size, surface finish and concentricity verticality all meeting the requirements of an emulsion pump is produced, and elastic pressure is produced between the surfaces of parts after assembly by depending on the interference value of a shaft and a hole, thereby obtaining fastened connection, having good coaxiality, being capable of bearing larger axial force, torque and dynamic load, and having higher processing precision.
Comparative example 2
The process of example 2 is adopted in the comparative example, only grinding aid is lacked, the rest is unchanged, the specific steps are similar to those of comparative example 1, and the comparative example is not repeated.
Comparative example 3
The process of example 3 is adopted in the comparative example, only the grinding aid is lacked, the rest is unchanged, the specific steps are similar to those of comparative example 1, and the comparative example is not repeated.
Comparative example 4
The process of example 4 is adopted in the comparative example, only grinding aids are lacked, the rest are unchanged, the specific steps are similar to those of comparative example 1, and the comparative example is not repeated.
Comparative example 5
The process of example 5 is adopted in the comparative example, only grinding aid is lacked, the rest is unchanged, the specific steps are similar to those of comparative example 1, and the comparative example is not repeated.
TABLE 3 comparison of the amounts of the raw materials in comparative examples 1 to 5
TABLE 4 comparison of Process parameters in comparative examples 1-5
Comparative example 6
The comparative example adopts the process of example 1, only lacks a sintering aid, and the rest is unchanged, and the specific steps are as follows:
1. adding 41 parts of aluminum oxide, 2 parts of glass powder, 5 parts of feldspar and 11 parts of clay into a high-energy planetary ball mill, adding water, stirring and mixing, grinding at the rotating speed of 100rpm/min through ball milling to form ground materials, forming base materials through a spray granulation mode by the ground materials, enabling grinding balls of the high-energy planetary ball mill to rotate at a high speed to impact with a sample mutually, achieving the purpose of grinding the sample, conveying higher mechanical energy to the ball-milled powder in a shorter time, enabling the ground material to be mechanically activated in a shorter time, even forming a nanocrystalline or amorphous material, and reducing oxidation and pollution of the material, wherein the excessively low or high rotating speed can weaken or lose the grinding effect;
2. adding the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a non-porous shaping die, enabling an organic monomer to perform polymerization reaction in a gel film injection mode, solidifying, cooling to generate a blank, and polymerizing the organic monomer in the slurry to enable the slurry to be solidified in situ, so that the blank with high density, high strength and good uniformity is obtained;
3. the blank is put into a rubber sheath die material at normal temperature, and is subjected to static pressure forming under the pressure condition that liquid is 400MPA as a pressure medium to generate ceramic microsphere particles with the particle size of 0.18mm, the ceramic microsphere particles prepared by the cold isostatic pressure forming mode have high density, the density of the particles is uniform, and the length-diameter ratio can not be limited due to the uniform density, so that the blank is beneficial to the subsequent production of rod-shaped, tubular and other thin and long products;
4. putting ceramic microsphere particles into a grinding machine, adding 1 part of grinding aid to fully contact the ceramic microsphere particles, heating at 1000 ℃ for 3h, grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 8 mu m, and heating the ceramic microsphere particles to melt and soften the ceramic microsphere particles so as to facilitate the formation of the subsequent ceramic microsphere powder;
5. ceramic microsphere powder is put into a columnar stainless steel die with a thimble hole, and after the ceramic microsphere powder is subjected to hanging firing, sintering and molding at 260 ℃, a slender tubular blank is taken out of the die, and the thimble hole is arranged to ensure that the stress at two ends is uniform, so that the coaxiality of the prepared blank, namely the concentricity and the smooth finish of a plunger can be ensured, the densification of the blank can be realized by a low-temperature sintering mode, and the material in the blank is endowed with fine tissue and excellent mechanical property;
6. the blank is ground and polished, namely after the abrasion traces on the surface of the blank are removed by grinding, the blank and the sleeve are matched in pairs by small interference, and then grinding and polishing are carried out, so that a plunger with the appearance size, surface finish and concentricity verticality all meeting the requirements of an emulsion pump is produced, and elastic pressure is produced between the surfaces of parts after assembly by depending on the interference value of a shaft and a hole, thereby obtaining fastened connection, having good coaxiality, being capable of bearing larger axial force, torque and dynamic load, and having higher processing precision.
Comparative example 7
The process of example 2 is adopted in the comparative example, only the sintering aid is lacked, the rest is unchanged, the specific steps are similar to those of comparative example 6, and the detailed description of the comparative example is omitted.
Comparative example 8
The process of example 3 is adopted in the comparative example, only the sintering aid is lacked, the rest is unchanged, the specific steps are similar to those of comparative example 6, and the detailed description of the comparative example is omitted.
Comparative example 9
The process of example 4 is adopted in the comparative example, only the sintering aid is lacked, the rest is unchanged, the specific steps are similar to those of comparative example 6, and the detailed description of the comparative example is omitted.
Comparative example 10
The process of example 5 is adopted in the comparative example, only the sintering aid is lacked, the rest is unchanged, the specific steps are similar to those of comparative example 6, and the detailed description of the comparative example is omitted.
TABLE 5 comparison of the amounts of the respective raw materials in comparative examples 6 to 10
TABLE 6 comparison of Process parameters in comparative examples 6-10
Comparative example 11
This comparative example is similar to example 1 except that the glass frit is absent as compared to comparative example 1.
Comparative example 12
This comparative example is only deficient in clay compared to comparative example 2, and is otherwise similar to example 2.
Comparative example 13
This comparative example was compared to comparative example 3 with a ball mill speed of 250rpm/min, and otherwise similar to example 3.
Comparative example 14
This comparative example was compared to comparative example 4 at a pressure of 300MPA, and otherwise similar to example 4.
Comparative example 15
This comparative example compared to comparative example 5, the ceramic microsphere particle size was 0.30mm, and the rest was similar to example 5.
Comparative example 16
This comparative example was compared to comparative example 6 with a high temperature heating temperature of 900 deg.C, and otherwise similar to example 1.
Comparative example 17
This comparative example was compared to comparative example 7 with a high temperature heating time of 9h, and otherwise similar to example 2.
Comparative example 18
This comparative example was similar to example 3 except that the ceramic microsphere powder had a particle size of 5 μm as compared with comparative example 8.
Comparative example 19
This comparative example was similar to example 4 except that the low-temperature heating temperature was 250 ℃ as compared with comparative example 9.
TABLE 7 comparison of the amounts of the respective raw materials in comparative examples 11 to 19
TABLE 8 comparison of Process parameters in comparative examples 11-19
Test example 1
The plungers prepared in examples 1 to 5 and the plungers prepared in comparative examples 1 to 19 were subjected to mechanical property examination and plunger friction coefficient test, wherein the mechanical property examination was performed by obtaining tensile strength of the plunger through a tensile test using static tensile force in a tensile testing machine, the friction coefficient test was performed by using a flat type special friction coefficient meter, the friction coefficient is a ratio of a frictional force between two surfaces to a vertical force acting on one surface thereof, an average tensile strength value and an average friction coefficient of the plunger were recorded and calculated, and data were filled in Table 9
TABLE 9 comparison of mechanical Strength and Friction coefficient of plungers prepared in examples and comparative examples
As shown in Table 9, the mechanical properties and the friction coefficients of the plungers according to examples 1 to 5 are better than those of the plungers according to comparative examples 1 to 19, the average tensile strengths of the plungers according to examples 1 to 5 are higher than 511MPA, and the average friction coefficients of the plungers are lower than 0.29, so that the tensile strengths of the plungers are decreased to various degrees and the sand fraction of the plungers is increased to various degrees when the composition is decreased to various degrees and the process conditions are changed according to comparative examples 1 to 19, thereby showing that the plungers according to the present invention have high strength and wear resistance.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and the preferred embodiments of the present invention are described in the above embodiments and the description, and are not intended to limit the present invention. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. The high-strength wear-resistant ceramic microsphere material is characterized by at least comprising the following raw materials in parts by weight: 41-58 parts of aluminum oxide, 2-8 parts of glass powder, 5-12 parts of feldspar, 11-18 parts of clay, 3-5 parts of sintering aid and 1-6 parts of grinding aid.
2. The high strength, wear resistant ceramic microsphere material of claim 1, wherein: the sintering aid comprises chromium dioxide, calcium oxide and magnesium oxide, and the grinding aid comprises triethanolamine and sodium citrate.
3. The high strength, wear resistant ceramic microsphere material of claim 1, wherein: the glass powder is low-melting-point glass, and the feldspar comprises albite and barcelsian.
4. A process for preparing a high strength, wear resistant ceramic microsphere material according to any of claims 1 to 3, comprising the steps of:
s1, putting aluminum oxide, glass powder, feldspar and clay into a ball mill, adding water, stirring and mixing, grinding by ball milling to form crushed materials, and forming base materials by spraying and granulating the crushed materials;
s2, putting the base material into a high-temperature air furnace, heating and melting to form slurry, injecting the slurry into a shaping die, and cooling to generate a blank;
s3, putting the blank into a rubber wrapping mold material at normal temperature, and carrying out static pressure forming by taking liquid as a pressure medium to generate ceramic microsphere particles;
s4, putting the ceramic microsphere particles into a grinder, adding a grinding aid and a sintering aid to fully contact the ceramic microsphere particles, and grinding and crushing the ceramic microsphere particles to generate ceramic microsphere powder with the particle size of 8-15 microns;
s5, putting the ceramic microsphere powder into a columnar stainless steel mold, sintering and shaping the ceramic microsphere powder through hanging sintering, and taking out a slender tubular blank from the mold;
and S6, grinding and polishing the blank to produce the plunger with the overall dimension, the surface finish degree and the concentricity verticality which all meet the requirements of the emulsion pump.
5. The process for preparing a high-strength wear-resistant ceramic microsphere material plunger as claimed in claim 4, wherein: in the S1, the ball mill is a high-energy planetary ball mill, and the rotation speed of the ball mill during grinding is 100-220rpm/min.
6. The process for preparing a high-strength wear-resistant ceramic microsphere material plunger according to claim 4, wherein the process comprises the following steps: in S2, the slurry is put into a non-porous mold, and the organic monomer is polymerized and cured by gel casting to form a preform.
7. The process for preparing a high-strength wear-resistant ceramic microsphere material plunger according to claim 4, wherein the process comprises the following steps: in the S3, the particle size of the ceramic microspheres generated under the pressure condition of 400-600MPA is 0.18-0.25mm.
8. The process for preparing a high-strength wear-resistant ceramic microsphere material plunger as claimed in claim 4, wherein: in S4, after being ground and crushed, the ceramic microsphere particles are heated for 3-8h at the temperature of 1000-1500 ℃.
9. The process for preparing a high-strength wear-resistant ceramic microsphere material plunger as claimed in claim 4, wherein: in S5, the stainless steel mould is provided with a thimble hole, and the sintering temperature of the blank is 260-440 ℃.
10. The process for preparing a high-strength wear-resistant ceramic microsphere material plunger as claimed in claim 4, wherein: and S6, grinding and removing the wear traces on the surface of the blank by using a diamond grinding wheel, matching the blank and the sleeve into a pair by small interference, and grinding and polishing.
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Cited By (1)
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| CN117381942A (en) * | 2023-10-10 | 2024-01-12 | 广州市恒宏生态建材有限公司 | Preparation process of environment-friendly and wear-resistant inorganic ecological stone |
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