CN115385693A - 一种（Ti,W）C陶瓷材料的制备方法 - Google Patents

一种（Ti,W）C陶瓷材料的制备方法 Download PDF

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CN115385693A
CN115385693A CN202211121688.XA CN202211121688A CN115385693A CN 115385693 A CN115385693 A CN 115385693A CN 202211121688 A CN202211121688 A CN 202211121688A CN 115385693 A CN115385693 A CN 115385693A
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ceramic material
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刘咏
高雨阳
周承商
夏虎
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Jiangxi Yongtai Powder Metallurgy Co ltd
Central South University
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Central South University
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Abstract

本发明涉及一种(Ti,W)C陶瓷材料的制备方法；属于金属陶瓷制备技术领域。本发明以钨和/或钛的氧化物作为钛源和钨源，通过往原料中引入碱土金属二碳化物、铝粉；通过自蔓延反应得到产物；所得产物中W与Ti的摩尔比大于等于1/2。本发明首次提出以钨和/或钛的氧化物作为原料配合自蔓延制备出了硬度大于30GPa的(Ti,W)C陶瓷。本发明制备工艺简单可控，所得产品性能优越，生产过程能耗低，便于大规模工业化应用。

Description

一种(Ti,W)C陶瓷材料的制备方法
技术领域
本发明涉及一种(Ti,W)C陶瓷材料的制备方法；属于金属陶瓷制备技术领域。
背景技术
(Ti,W)C基金属陶瓷是在WC-Co系硬质合金和TiC-Ni系金属陶瓷基础上发展起来的一种新型的固溶体基金属陶瓷，相比WC-Co系硬质合金，由于(Ti,W)C固溶体中掺杂有高硬度的TiC(维氏硬度TiC：3200kg/mm2，WC：1780kg/mm2)，因此，(Ti,W)C基金属陶瓷具有更优良的硬度和耐磨性能，作为硬质合金基材具有良好的应用前景。目前制备(Ti,W)C固溶体的方法主要有：碳热还原法、燃烧合成法、机械合金化法和放电等离子烧结法等。如周永贵等采用一步碳化法制备了(Ti0.5,W0.5)C固溶体。李劲风等通过燃烧合成法制备了W/(Ti+W)比分别为0.4和0.54的两种Ti-W-C体系固溶体。在李劲风等发表的论文《Ti-W-C体系的自蔓延高温合成与反应机理》一文中就涉及到了利用自蔓延高温合成法制备(Ti,W)C。实验以Ti、W、石墨为原料，按反应式①配料：
Ti+W+C→TiC+WC/(Ti,W)C ①
分别选取W/(Ti+W)＝0.40、0.54两种配比(质量比)。均匀混合后将粉料压制成相对密度约50％，尺寸约为D20 mm×20mm的圆柱状坯体，置于SHS装置中，用钨丝点火进行SHS合成。采用燃烧前沿与冷金属块(铜块)接触的方法实现燃烧前沿的激冷淬熄以观察燃烧前沿的高温动态反应过程。通过此过程成功制备了(Ti,W)C，但在淬熄过程后，发现W/(Ti+W)＝0.54坯体的燃烧激冷淬熄处Ti粉表面有TiC层生成，且TiC层表面有0.3-0.5mm裂纹形成，这会降低材料的硬度性能。
除了周永贵、李劲风等人外，人们还做了其他的尝试，如：Genc等对含W+2％TiC粉末进行机械合金化处理，并将1％Ni作为活性剂添加到混合粉末中，最终得到W2TiC+1Ni固溶体。Liang等通过实验验证了以W、Ti、C的机械合金化混合粉末为原料，将研磨后的粉末通过后续放电等离子烧结，合成了纳米晶(Ti,W)C。
虽然目前制备(Ti,W)C基金属陶瓷的方法众多，但这些方法要么存在能耗较大，要么存在操作复杂，要么存在制得的陶瓷粉末粒度分布较宽，要么存在制备的(Ti,W)C陶瓷硬度偏低(如硬度为19-21Gpa)等问题，这些问题多会限制其在硬质合金基材领域的进一步发展。
发明内容
本发明针对现有技术的不足，首次提出以钨和/或钛的氧化物作为原料配合自蔓延制备出了硬度大于30Gpa的(Ti,W)C陶瓷。
本发明一种(Ti,W)C陶瓷材料的制备方法，所述方法以钨和/或钛的氧化物作为钛源和钨源，通过往原来料中引入碱土金属二碳化物、铝粉；通过自蔓延反应得到产物；所得产物中W与Ti的摩尔比大于等于1/2；优选为2:3～3:2。
作为优选，本发明一种(Ti,W)C陶瓷材料的制备方法；所述钛源为二氧化钛TiO2。
作为优选，本发明一种(Ti,W)C陶瓷材料的制备方法；所述钨源为三氧化钨WO3。
作为进一步的优选，本发明一种(Ti,W)C陶瓷材料的制备方法，以三氧化钨粉(35-90μm)、二氧化钛粉(5-10μm)、电石粉(20-80μm)和铝粉(-350目)为原料。选用自蔓延燃烧反应方程式如下：
6TiO2+3CaC2+6Al＝6TiC+3CaO+3Al2O3②
6WO3+3CaC2+10Al＝6WC+3CaO+5Al2O3③
按照摩尔比TiO2：WO3＝2-3:3-2配取三氧化钨粉和二氧化钛粉；然后分别按照②式和③式的系数配取电石粉和铝粉；将配取的粉末混合均匀后干燥，得到备用粉末；将备用粉末转移至碳质材料或陶瓷材质的容器内，经点火引发自蔓延燃烧合成反应；反应完成后，取出产物；破碎，分离得到(Ti,W)C。
三氧化钨粉包括黄钨粉。
作为更进一步的优选，本发明一种(Ti,W)C陶瓷材料的制备方法，按照摩尔比TiO2：WO3＝2:3配取三氧化钨粉和二氧化钛粉；或按照摩尔比TiO2：WO3＝1:1配取三氧化钨粉和二氧化钛粉；或按照摩尔比TiO2：WO3＝3:2配取三氧化钨粉和二氧化钛粉。
作为更进一步的优选，本发明一种(Ti,W)C陶瓷材料的制备方法，自蔓延燃烧所用容器优选为石墨材质的容器。
作为更进一步的优选，本发明一种(Ti,W)C陶瓷材料的制备方法，石墨材质的容器在使用前预热。
石墨材质的容器在使用前预热；预热的温度优选为400-550℃。
本发明一种(Ti,W)C陶瓷材料的制备方法，燃烧产物中同时含有钙和铝的氧化物，将产物碾碎过筛至300目以上，通过摇床重力分离和盐酸溶液酸洗(质量分数：36-38％)去除钙和铝的氧化物，得到纯(Tix，W1-x)C粉末。经摇床重力分离后得到的产物用盐酸处理。
盐酸的用量主要根据需要溶解产物的量来估计，溶解反应方程式如下：
CaO+2HCl＝CaCl2+H20
Al2O3+6HCl＝2AlCl3+3H2O
在溶解操作中，一般放入过量的盐酸溶液以保证反应完全，待反应体系内无明显反应现象时停止。
为提高(Tix，W1-x)C晶粒的结晶度，使其具有更优异的性能，对提纯后的(Tix，W1-x)C粉末进行热压烧结，所述热压烧结工艺参数为：所述热压烧结工艺参数为：烧结温度为1200-1300℃、优选为1250℃，烧结压力为45-60MPa、优选为50MPa，保温时间为15-30min、优选为20min；得到硬度大于30GPa的(Tix，W1-x)C块体。
在本发明技术探索过程中，发现：当烧结温度为1250℃(该温度算比较低的温度)，烧结压力为50MPa，保温时间为20min；得到硬度为30.2-32.8GPa的(Tix，W1-x)C块体。
原理和优势
1.本发明选用黄钨粉、二氧化钛粉、电石粉和铝粉为原料，发生②和③式燃烧反应放热量大，在取用相同原料量的情况下，本发明实验过程可达更高的绝热温度，有利于熔体中元素扩散及晶体生长；同时，本发明选择上述原料和比例，通过自蔓延燃烧合成过程得到初产物，此过程反应速度快，无需额外加热装置，能耗小。
2.本发明参考选矿分离法，通过摇床利用重力差将(Ti,W)C和其他金属氧化物(钙和铝的氧化物)分离；此过程操作简便，提纯周期短，效率高；
3.本发明通过自蔓延燃烧合成法成功制备(Ti,W)C晶粒，经提纯后，通过后续真空烧结技术(尤其是在烧结温度较低时如1250℃)得到晶型更完整，硬度性能更优良的(Ti,W)C陶瓷材料。所得产品的硬度达到30GPa及以上，经优化后，产品的硬度最高可达32.74GPa，远远优于现有(Ti,W)C的硬度(19-21Gpa)。
附图说明
附图1为实施例1-3所制备产品提纯前的XRD图；
附图2为实施例1-3所制备产品提纯后的XRD图；
附图3为实施例1-3所制备产品提纯后的SEM图；
附图4为实施例1-3所制备提纯粉末经热压烧结后所得产品的SEM图。
具体实施方式
实施例1
设计(Ti0.4，W0.6)C固溶体；选用自蔓延燃烧反应方程式如下：
6TiO2+3CaC2+6Al＝6TiC+3CaO+3Al2O3②
6WO3+3CaC2+10Al＝6WC+3CaO+5Al2O3③
按照设定的比例配取黄钨粉(35-90μm)、二氧化钛粉(5-10μm)、电石粉(20-80μm)和铝粉(-350目)，以上述配取为原料；将原料混合均匀后，转移至提前预热好的石墨坩埚内(预热至500℃)，经点火引发自蔓延燃烧合成反应，成功获得(Tix，W1-x)C固溶体(x＝0.4)。燃烧产物中同时含有钙和铝的氧化物，将产物碾碎过300目的筛，通过摇床重力分离和盐酸溶液酸洗(盐酸的质量分数：36-38％)去除钙和铝的氧化物，得到高纯(Tix，W1-x)C粉末(提纯前后的样品XRD图分别见图1和图2)。
经摇床重力分离所得产物用浓度为36-38wt％的盐酸处理，使得生成的氧化钙和三氧化二铝完全分解(在溶解操作中，一般放入过量的盐酸溶液以保证反应完全，待反应体系内无明显反应现象时停止)；然后清洗干燥，得到热压烧结备用粉末。
为提高(Tix，W1-x)C晶粒的结晶度，使其具有更优异的性能，对提纯后的(Tix，W1-x)C粉末。进行热压烧结，所述热压烧结工艺参数为：烧结温度为1250℃，烧结压力为50Mpa，保温时间为20min(烧结前后样品的SEM图分别见图3和图4)。对烧结后的块体坯进行纳米压痕测试，所述纳米压痕测试工作参数为：最大载荷20mN，加载/卸载时间25s，保载2s。本发明制备的(Ti,W)C硬度高(结果见表1)，优于现有(Ti,W)C的硬度(19-21Gpa)。
实施例2
设计(Ti0.5，W0.5)C固溶体；选用自蔓延燃烧反应方程式如下：
6TiO2+3CaC2+6Al＝6TiC+3CaO+3Al2O3②
6WO3+3CaC2+10Al＝6WC+3CaO+5Al2O3③
按照设定的比例配取黄钨粉(35-90μm)、二氧化钛粉(5-10μm)、电石粉(20-80μm)和铝粉(-350目)，以上述配取为原料；将原料混合均匀后，转移至提前预热好的石墨坩埚内(预热至500℃)，经点火引发自蔓延燃烧合成反应，成功获得(Tix，W1-x)C固溶体(x＝0.5)。燃烧产物中同时含有钙和铝的氧化物，将产物碾碎过300目的筛，通过摇床重力分离和盐酸溶液酸洗(盐酸的质量分数：36-38％)去除钙和铝的氧化物，得到高纯(Tix，W1-x)C粉末(提纯前后的样品XRD图分别见图1和图2)。
经摇床重力分离所得产物用浓度为36-38wt％的盐酸处理，使得生成的氧化钙和三氧化二铝完全分解(在溶解操作中，一般放入过量的盐酸溶液以保证反应完全，待反应体系内无明显反应现象时停止)；然后清洗干燥，得到热压烧结备用粉末。
为提高(Tix，W1-x)C晶粒的结晶度，使其具有更优异的性能，对提纯后的(Tix，W1-x)C粉末。进行热压烧结，所述热压烧结工艺参数为：烧结温度为1250℃，烧结压力为50Mpa，保温时间为20min(烧结前后样品的SEM图分别见图3和图4)。对烧结后的块体坯进行纳米压痕测试，所述纳米压痕测试工作参数为：最大载荷20mN，加载/卸载时间25s，保载2s。本发明制备的(Ti,W)C硬度高(结果见表1)，优于现有(Ti,W)C的硬度(19-21Gpa)。
实施例3
设计(Ti0.6，W0.4)C固溶体；选用自蔓延燃烧反应方程式如下：
6TiO2+3CaC2+6Al＝6TiC+3CaO+3Al2O3②
6WO3+3CaC2+10Al＝6WC+3CaO+5Al2O3③
按照设定的比例配取黄钨粉(35-90μm)、二氧化钛粉(5-10μm)、电石粉(20-80μm)和铝粉(-350目)，以上述配取为原料；将原料混合均匀后，转移至提前预热好的石墨坩埚内(预热至500℃)，经点火引发自蔓延燃烧合成反应，成功获得(Tix，W1-x)C固溶体(x＝0.6)。燃烧产物中同时含有钙和铝的氧化物，将产物碾碎过筛至300目以上，通过摇床重力分离和盐酸溶液酸洗(盐酸的质量分数：36-38％)去除钙和铝的氧化物，得到高纯(Tix，W1-x)C粉末(提纯前后的样品XRD图分别见图1和图2)。
经摇床重力分离所得产物用浓度为36-38wt％的盐酸处理，使得生成的氧化钙和三氧化二铝完全分解(在溶解操作中，一般放入过量的盐酸溶液以保证反应完全，待反应体系内无明显反应现象时停止)；然后清洗干燥，得到热压烧结备用粉末。
为提高(Tix，W1-x)C晶粒的结晶度，使其具有更优异的性能，对提纯后的(Tix，W1-x)C粉末。进行热压烧结，所述热压烧结工艺参数为：烧结温度为1250℃，烧结压力为50Mpa，保温时间为20min(烧结前后样品的SEM图分别见图3和图4)。对烧结后的块体坯进行纳米压痕测试，所述纳米压痕测试工作参数为：最大载荷20mN，加载/卸载时间25s，保载2s。
表1实施例1-3制备的(Tix，W1-x)C块体的硬度表
Figure BDA0003847384460000061
通过表1可以看出本发明制备的(Ti,W)C硬度高(结果见表1)，优于现有(Ti,W)C的硬度(19-21Gpa)。
本发明在实验中钨源曾使用过蓝钨，但此实验点火多次失败，最终选择使用黄钨。后面研究发现：由于氧含量对于燃烧合成过程尤为重要，而蓝钨晶格中容纳一定量的氧空位，是一种氧缺陷氧化钨，故在本发明中不是最优方案。
本发明技术探索初期，尝试加入铝热剂参与燃烧反应，目的是铝热剂燃烧放出大量热可以提高体系的最高燃烧温度，但加入铝热剂的反应产物中含有大量的脱碳相，会影响产物纯度，故最终并未采取此方案。铝热剂燃烧反应式如下：
3Fe3O4+8Al＝9Fe+4Al2O3。

Claims (9)

1.一种(Ti,W)C陶瓷材料的制备方法，所述方法以钨和/或钛的氧化物作为钛源和钨源，通过往原来料中引入碱土金属二碳化物、铝粉；通过自蔓延反应得到产物；所得产物中W与Ti的摩尔比大于等于1/2。
2.根据权利要求1所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：所述钛源为二氧化钛TiO2。
3.根据权利要求1所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：所述钨源为三氧化钨WO3。
4.根据权利要求1所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：以三氧化钨粉、二氧化钛粉、电石粉和铝粉为原料；选用自蔓延燃烧反应方程式如下：
6TiO2+3CaC2+6Al＝6TiC+3CaO+3Al2O3②
6WO3+3CaC2+10Al＝6WC+3CaO+5Al2O3③
按照摩尔比TiO2：WO3＝2-3:3-2配取黄钨粉和二氧化钛粉；然后分别按照②式和③式的系数配取电石粉和铝粉；将配取的粉末混合均匀后干燥，得到备用粉末；将备用粉末转移至碳质材料或陶瓷材质的容器内，经点火引发自蔓延燃烧合成反应；反应完成后，取出产物；破碎，分离得到(Ti,W)C。
5.根据权利要求4所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：按照摩尔比TiO2：WO3＝2:3配取三氧化钨粉和二氧化钛粉；
或按照摩尔比TiO2：WO3＝1:1配取三氧化钨粉和二氧化钛粉；
或按照摩尔比TiO2：WO3＝3:2配取三氧化钨粉和二氧化钛粉。
6.根据权利要求4所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：自蔓延燃烧所用容器优选为石墨材质的容器。
7.根据权利要求4所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：石墨材质的容器在使用前预热；预热的温度为400-550℃。
8.根据权利要求4所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：燃烧产物中同时含有钙和铝的氧化物，将产物碾碎过筛至300目以上，通过摇床重力分离和盐酸溶液酸洗去除钙和铝的氧化物，得到纯(Tix，W1-x)C粉末；所述盐酸是质量分数为36-38％盐酸溶液。
9.根据权利要求8所述的一种(Ti,W)C陶瓷材料的制备方法；其特征在于：对提纯后的(Tix，W1-x)C粉末进行热压烧结，所述热压烧结工艺参数为：烧结温度为1200-1300℃、优选为1250℃，烧结压力为45-60MPa、优选为50MPa，保温时间为15-30min、优选为20min；得到硬度大于30GPa的(Tix，W1-x)C块体。
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