CN115304374B - 一种电熔陶瓷砂及其制备方法 - Google Patents
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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
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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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