CN115304374B - 一种电熔陶瓷砂及其制备方法 - Google Patents
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- 238000002844 melting Methods 0.000 claims abstract description 26
- 230000008018 melting Effects 0.000 claims abstract description 26
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- 238000003723 Smelting Methods 0.000 claims abstract description 12
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims abstract description 10
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 claims abstract description 10
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- 229910052814 silicon oxide Inorganic materials 0.000 claims description 3
- 238000007711 solidification Methods 0.000 claims description 2
- 230000008023 solidification Effects 0.000 claims description 2
- 238000010891 electric arc Methods 0.000 claims 1
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- 150000004706 metal oxides Chemical class 0.000 abstract description 4
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- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 3
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- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 2
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- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
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- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 1
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Abstract
本发明提供了一种电熔陶瓷砂及其制备方法,属于电熔材料技术领域。本发明的电熔陶瓷砂以增韧剂、二氧化硅和添加剂为原料,并将原料混合后进行熔融制备而成。本发明在熔融过程中,添加了一定比例的氧化铁、氧化钴、氧化铬、氧化镍、氧化锰等金属氧化物,作为增塑剂,其同时具有着色剂的作用,这些金属氧化物的添加,大幅降低了原料成本,熔融过程中熔液熔点低、熔融后密度大、熔液粘度变小,喷吹以后陶瓷砂韧性增强、陶瓷砂球形度达到96%以上,陶瓷砂外观呈现一种光洁的黑、黑灰或黑棕色,有效避免了处理深色塑胶产品时良品率的下降问题。
Description
技术领域
本发明涉及电熔材料技术领域,尤其涉及一种电熔陶瓷砂及其制备方法。
背景技术
电熔陶瓷砂(或简称喷砂、陶瓷丸、喷丸)做为一种喷砂介质材料,凭借以下优点被广泛应用于航空航天器材的强化和喷丸成型、模具行业的清洁和维护、塑料和电子产品的线路板去毛刺和表面美工效果、汽车工业的抗疲劳、强化处理等领域。
电熔陶瓷砂具有硬度高、弹性好、变形小、寿命长的特点;其硬度可达600~800HV,可抵御高压喷砂过程中超高冲击力,弹性好、变形小保证了弹丸在冲击撞击时的形状不变、不破损,增加了介质的使用寿命例如相比于玻璃喷砂,陶瓷砂的寿命是其20-30倍。同时较小的破损率也避免了喷砂过程中粉尘的产生,改善了操作环境,使用寿命的增长又可有效减少更换料的次数、降低工人成本。所以陶瓷砂无论是用在干喷丸,湿喷丸或是抛丸工序里,都是能够带来高效益。
中国专利CN1108228A公开了一种熔融陶瓷球,其采用在氧化锆、氧化硅中添加氧化钇、氧化铈这类无机非金属稀土氧化物的方法,来增强熔融陶瓷球耐压强度,并严格限制了各成分之间的添加比例。
中国专利CN101219895B公开了一种酸锆陶瓷喷砂珠,其原料包括ZrO2、HfO2、SiO2、Al2O3、CaO,当使用CaO作为稳定剂时,使其有更好的稳定性,其用量至少占3%,但不可超过10%,超过10%的CaO足够将所有的硅酸锆转变为立方相,导致内部结构不稳定,硬度增加、韧性降低、容易破碎。过多的CaO不会进一步提高力学强度,并且会出现其他的不需要的相。
上述现有技术中,存在以下劣势:
1、全部采用无机非金属氧化物为原料,为了达到产品需要的高密度、高强度,就必须采用大量昂贵的氧化锆、氧化钇等材料,生产成本的增加降低了产品的竞争力。
2、氧化锆、氧化钇等无机非金属氧化物熔点高,例如:氧化锆熔点在2800度,氧化钇熔点在2400度,即使采用硅酸锆类含锆原料,它的熔点也高达2500度,造成熔融成本增加。
3、氧化锆、氧化硅等组分比例较高时,熔融后熔液黏度较大,在喷吹生产喷丸时,容易造成喷丸球形度下降,降低产品的成品率。
4、采用目前已知技术生产的陶瓷砂为白色,在处理一些黑色塑胶产品时,喷砂镶嵌进入塑胶或缝隙,会产生明显的产品缺陷,造成废品率上升。
发明内容
有鉴于此,本发明的目的是提供一种电熔陶瓷砂,具有韧性高、密度高、球形度好的特点。
本发明制备的一种电熔陶瓷砂,包括以下重量百分比的原料:
增韧剂 0-40%,
二氧化硅 0-40%,
添加剂 20-70%,以上原料的重量百分比之和为100%;
所述增韧剂为氧化铁、氧化钴、氧化铬、氧化镍、氧化锰中的一种或几种。
优选的,所述添加剂为氧化铝、氧化锆、氧化铈、氧化钇中的一种或几种。
优选的,所述电熔陶瓷砂的颜色为黑色、黑灰色或者黑褐色。
本发明的另一目的是提供一种电熔陶瓷砂的制备方法,包括以下步骤:
(1)按比例称取上述原料;
(2)将上述原料加入熔炼设备中进行熔炼,对熔炼后的熔液进行冷却,利用凝固前表面张力形成球体,得到所述电熔陶瓷砂。
优选的,步骤(2)所述的熔炼设备为电弧炉、感应炉、等离子熔炼炉中的任意一种。
优选的,步骤(2)所述熔炼的电压为260V,电流3000~5000A,熔化温度为1800~2800度,熔化时间为30~120分钟。
优选的,步骤(2)所述冷却的方式为自由落体快速冷却、压缩空气了冷却或者高压水喷吹冷却中的任意一种。
本发明制备的陶瓷砂主要用于干、湿法的喷抛丸表面处理喷砂介质。
与现有技术相比,本发明具有以下有益效果:
本发明制备了一种电熔陶瓷砂,在熔融过程中,添加了一定比例的氧化铁、氧化钴、氧化铬、氧化镍、氧化锰等金属氧化物,作为增塑剂,其同时具有着色剂的作用,这些金属氧化物的添加,大幅降低了原料成本,熔融过程中熔液熔点低、熔融后密度大、熔液粘度变小,喷吹以后陶瓷砂韧性增强、陶瓷砂球形度达到96%以上,陶瓷砂外观呈现一种光洁的黑、黑灰或黑棕色,有效避免了处理深色塑胶产品时良品率的下降问题。制备的电熔陶瓷砂广泛用于去毛刺、除锈、消除内应力、模具清理等行业的电熔喷砂介质材料领域。
具体实施方式
下面结合实施例对本发明作进一步说明。
实施例1
一种电熔陶瓷砂,有以下重量百分比的原料组成:
锆英砂:76%,
氧化铁:18%,
氧化铝:6%。
所述电熔陶瓷砂的制备方法,步骤如下:
(1)按比例称取上述原料;
(2)将上述原料放入三相电弧炉中,电压为260V,电流3000~5000A,熔化温度2100~2300度,融化时间70分钟,采用压缩空气喷吹冷却,用120目筛网进行筛分,得到一个堆积密度2.478g/cm3,真密度4.02g/cm3,维氏硬度768HV的黑色陶瓷砂,对比现有产品无论真密度、韧性和硬度都取得理想的结果。
实施例2
一种电熔陶瓷砂,有以下重量百分比的原料组成:
氧化锆:55%,
氧化铁:11.5%,
氧化铝:8%,
氧化硅:22%,
氧化锰:3.5%。
所述电熔陶瓷砂的制备方法,步骤如下:
(1)按比例称取上述原料;
(2)将上述原料放入三相电弧炉中进行熔化,电压为300V,电流3000~5000A,熔化温度2200~2400度,融化时间75分钟,采用压缩空气喷吹冷却,用120目筛网进行筛分,得到一个堆积密度2.306g/cm3,真密度3.89g/cm3,维氏硬度743HV的黑色陶瓷砂,对比现有产品无论真密度、韧性和硬度都取得理想的结果。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (4)
1.一种电熔陶瓷砂,其特征在于,由以下重量百分比的原料组成:
氧化锆:55%,
氧化铁:11.5%,
氧化铝:8%,
氧化硅:22%,
氧化锰:3.5%;
所述的电熔陶瓷砂的制备方法,步骤如下:
(1)按比例称取上述原料;
(2)将上述原料加入熔炼设备中进行熔炼,对熔炼后的熔液进行冷却,利用凝固前表面张力形成球体,得到所述电熔陶瓷砂;所述熔炼的电压为300V,电流为3000~5000A,熔化温度为2200~2400度,熔化时间为75分钟。
2.根据权利要求1所述的电熔陶瓷砂,其特征在于,步骤(2)所述的熔炼设备为三相电弧炉。
3.根据权利要求1所述的电熔陶瓷砂,其特征在于,步骤(2)所述冷却的方式为压缩空气喷吹冷却。
4.根据权利要求1所述的电熔陶瓷砂的应用,其特征在于,所述陶瓷砂用于干、湿法的喷抛丸表面处理喷砂介质。
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