CN116120044B - Energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material - Google Patents
Energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material Download PDFInfo
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- CN116120044B CN116120044B CN202211658576.8A CN202211658576A CN116120044B CN 116120044 B CN116120044 B CN 116120044B CN 202211658576 A CN202211658576 A CN 202211658576A CN 116120044 B CN116120044 B CN 116120044B
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- 239000000463 material Substances 0.000 title claims abstract description 69
- 238000005266 casting Methods 0.000 title claims abstract description 67
- 229910052593 corundum Inorganic materials 0.000 title claims abstract description 46
- 239000010431 corundum Substances 0.000 title claims abstract description 46
- 239000002131 composite material Substances 0.000 title claims abstract description 15
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 76
- 239000000654 additive Substances 0.000 claims abstract description 36
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 30
- 230000000996 additive effect Effects 0.000 claims abstract description 28
- 239000002002 slurry Substances 0.000 claims abstract description 22
- 239000000835 fiber Substances 0.000 claims abstract description 20
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 17
- 238000002360 preparation method Methods 0.000 claims abstract description 16
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000010703 silicon Substances 0.000 claims abstract description 14
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 14
- 239000004568 cement Substances 0.000 claims abstract description 12
- 239000002994 raw material Substances 0.000 claims abstract description 12
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 12
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims abstract description 11
- 238000000227 grinding Methods 0.000 claims abstract description 9
- -1 grinding Substances 0.000 claims abstract description 7
- 239000000843 powder Substances 0.000 claims description 32
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims description 30
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 30
- 239000011230 binding agent Substances 0.000 claims description 20
- 239000004793 Polystyrene Substances 0.000 claims description 16
- 229920002223 polystyrene Polymers 0.000 claims description 16
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 12
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 12
- 229910021389 graphene Inorganic materials 0.000 claims description 12
- 239000004576 sand Substances 0.000 claims description 12
- 229910052845 zircon Inorganic materials 0.000 claims description 12
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 12
- VHSHLMUCYSAUQU-UHFFFAOYSA-N 2-hydroxypropyl methacrylate Chemical compound CC(O)COC(=O)C(C)=C VHSHLMUCYSAUQU-UHFFFAOYSA-N 0.000 claims description 10
- 229910052851 sillimanite Inorganic materials 0.000 claims description 10
- 238000003756 stirring Methods 0.000 claims description 10
- 238000010891 electric arc Methods 0.000 claims description 9
- 239000008188 pellet Substances 0.000 claims description 9
- 239000004033 plastic Substances 0.000 claims description 9
- 229920003023 plastic Polymers 0.000 claims description 9
- 239000000377 silicon dioxide Substances 0.000 claims description 9
- 239000000243 solution Substances 0.000 claims description 9
- 229910052849 andalusite Inorganic materials 0.000 claims description 7
- 239000011259 mixed solution Substances 0.000 claims description 7
- 235000012239 silicon dioxide Nutrition 0.000 claims description 7
- 238000005245 sintering Methods 0.000 claims description 7
- 238000002791 soaking Methods 0.000 claims description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 6
- 238000000498 ball milling Methods 0.000 claims description 6
- 239000011324 bead Substances 0.000 claims description 6
- 239000007767 bonding agent Substances 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 6
- 230000008018 melting Effects 0.000 claims description 6
- 229910052760 oxygen Inorganic materials 0.000 claims description 6
- 239000001301 oxygen Substances 0.000 claims description 6
- 238000007599 discharging Methods 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 4
- 238000002156 mixing Methods 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 239000004698 Polyethylene Substances 0.000 claims description 3
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 claims description 3
- 238000000137 annealing Methods 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 238000001914 filtration Methods 0.000 claims description 3
- 239000011812 mixed powder Substances 0.000 claims description 3
- 229920000573 polyethylene Polymers 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 229910001388 sodium aluminate Inorganic materials 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims description 2
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims description 2
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 2
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 2
- 230000035939 shock Effects 0.000 abstract description 12
- 238000004519 manufacturing process Methods 0.000 abstract description 7
- 238000011282 treatment Methods 0.000 abstract description 2
- 230000000052 comparative effect Effects 0.000 description 18
- 238000011056 performance test Methods 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 238000000034 method Methods 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 239000011819 refractory material Substances 0.000 description 5
- 238000010304 firing Methods 0.000 description 4
- 230000008859 change Effects 0.000 description 2
- 239000000084 colloidal system Substances 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 150000002500 ions Chemical class 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000009991 scouring Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- 229910001093 Zr alloy Inorganic materials 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 150000004645 aluminates Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- XTYUEDCPRIMJNG-UHFFFAOYSA-N copper zirconium Chemical compound [Cu].[Zr] XTYUEDCPRIMJNG-UHFFFAOYSA-N 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 239000003792 electrolyte Substances 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000011859 microparticle Substances 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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Abstract
The invention discloses an energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material and a production method thereof, wherein the casting material comprises the following raw materials: the preparation method of the zirconia corundum aggregate, silicon carbide, organic fibers, silicon micropowder, pure calcium aluminate cement, a water reducer and an additive, and the casting material comprises the following steps: grinding, preparing slurry and preparing hollow sphere casting materials. The invention provides an energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material, which is prepared by strictly adjusting the proportion of casting raw materials, grinding, slurry preparation, hollow sphere casting material preparation and other series of treatments, has good thermal shock performance and strong wear resistance, and has the advantages of simple proportion of raw material components and cost saving; the manufacturing process is simple and is easy for industrialized production.
Description
Technical Field
The invention relates to the technical field of casting materials, in particular to an energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material.
Background
In the application of refractory materials, the unshaped refractory material has the advantages of low investment, energy consumption saving, good thermal shock stability of the whole lining body, good air tightness, capability of repairing furnace lining and the like, so that the unshaped refractory material has wider application compared with qualitative refractory materials such as refractory bricks and the like. The casting material is an unshaped refractory material which is most widely produced and used at present, is mainly used in the cement fields of blast furnaces, hot blast stoves, garbage incinerators, chemical industry and the like, and can also be used for constructing integral structures such as heating furnace linings and the like; the high-quality variety can also be used for smelting furnaces, and refractory castable materials commonly used in industry mainly comprise aluminate castable materials, water glass castable materials, phosphate castable materials and the like.
At present, the common high-aluminum castable is found to have poor thermal shock performance and anti-scouring performance in the use process, so that the service life is seriously influenced; in addition, the existing common castable is relatively low in strength and poor in wear resistance, and related requirements cannot be met.
Therefore, an energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material is designed to solve the problems.
Disclosure of Invention
In order to solve the technical problems, the invention provides an energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material.
The technical scheme of the invention is as follows: the energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material comprises the following raw materials in parts by weight: 60-70 parts of zirconia corundum aggregate, 11-15 parts of silicon carbide, 4-6 parts of organic fiber, 4-6 parts of silicon micropowder, 7-12 parts of pure calcium aluminate cement, 1-2 parts of water reducer and 1-3 parts of additive;
further, the zirconia corundum aggregate comprises the following components in percentage by mass: 41.5-42.5% of zircon sand, 48.5-50.5% of alumina powder, 4.0-5.5% of zirconia, 0.3-0.7% of sillimanite powder, 0.5-1.0% of graphene and 0.1-0.5% of binding agent.
Description: the zirconia corundum composite hollow sphere casting material with wear-resistant property can be prepared by using zirconia corundum aggregate, silicon carbide, organic fiber, silicon micropowder, pure calcium aluminate cement, water reducer and additive, and the zirconia corundum aggregate with excellent high temperature resistance, thermal shock resistance and high wear resistance by using zircon sand, alumina powder, sillimanite powder, graphene and binding agent.
Further, the water reducing agent is one or more of sodium aluminate, sodium hexametaphosphate or sodium tripolyphosphate.
Description: when the casting material is prepared, the water reducing agent is added, the mixing water consumption can be obviously reduced under the condition of keeping the flowing value of the casting material basically unchanged, the water reducing agent is electrolyte substances, and charged ions can be dissociated after the water reducing agent is dissolved in water, and the ions can be adsorbed by solid particles (or colloid particles) in suspension, so that the repulsive force among the particles is increased, the particles are uniformly dispersed, and free water wrapped in an aggregation structure formed by microparticles is released, so that the flowing value of the casting material can be improved, and the operation performance is improved.
Further, the organic fiber is any one of polyethylene fiber and polypropylene fiber.
Description: the addition of organic fiber in preparing casting material can strengthen the toughness of casting material, raise its stress-strain resistance, raise heat shock resistance and reduce cracking and peeling of casting material.
Further, the additive comprises, in mass fraction: 75-85% of andalusite micropowder and 15-25% of HPMA.
Description: the andalusite fine powder and the silicon carbide can be matched to prepare a casting material with high thermal stability, high slag erosion resistance, and the high thermal stability, low creep and high fire resistance, and HPMA is added into the casting material, so that the strength and apparent porosity of the casting material under the condition of normal temperature are increased, the volume density is reduced, and the high-temperature flexural strength and the thermal shock resistance are obviously improved.
Further, the preparation method of the zirconia corundum aggregate comprises the following steps:
1) Uniformly mixing zircon sand, alumina powder, zirconia and graphene by a mixer, adding a bonding agent, soaking for 15-23 hours, adding the soaked mixture into an electric arc furnace, melting by long electric arc for 70-85 minutes, and then introducing oxygen into the solution to obtain a mixed solution;
2) Adding sillimanite into the mixed solution, melting by long-time electric arc for 25-30 minutes, and then introducing oxygen to obtain a solution;
3) And carrying out heat preservation annealing on the solution, and then carrying out cutting and grinding processing to obtain the zirconia corundum aggregate.
Description: the zirconia corundum aggregate prepared by the method has excellent high temperature resistance, corrosion resistance and thermal shock resistance.
Further, the bonding agent comprises the following components in percentage by mass: 20% -30% of silicon dioxide, 1% -8% of glycerol and the balance of water.
Description: when the mixed solution of silicon dioxide and glycerol is used as a binding agent, the flow value of the zirconia corundum is increased, the silicon dioxide adopts nano silica colloid, the specific surface area is large, the adsorptivity is strong, ionization occurs in water, the binding agent has the same negative charge, and rejection occurs among particles, so that the zirconia corundum adopting the binding agent has excellent flow performance.
Further, the preparation method of the zirconia-corundum composite hollow sphere casting material comprises the following steps:
s1, grinding:
firstly adding zirconia corundum aggregate into a ball mill for ball milling for 10-15 minutes to prepare fine powder, then sequentially adding silicon carbide and organic fibers for ball milling for 15-20 minutes to obtain mixed powder which is sieved by a 200-mesh sieve, and then adding silicon micropowder into the ball mill to obtain mixed micropowder which is sieved by a 500-mesh sieve;
s2, preparing slurry:
adding the mixed micro powder, the pure calcium aluminate cement, the silicon micro powder and the water reducing agent into water which is 2 times of the total weight of the four components, continuously heating and stirring, when the temperature is 60-70 ℃, starting to add 0.05-0.15 part of additive/+1deg.C and stirring, when the temperature is 70-80 ℃, adding all the rest additives, and keeping the temperature and stirring for 8-10 minutes to prepare slurry;
s3, preparing a hollow sphere casting material:
taking polystyrene beads as templates, and fully soaking a plurality of polystyrene beads in the slurry; filtering the slurry mixed with the polystyrene spheres through a screen, drying, repeating the above actions until the surface of the polystyrene spheres has slurry with a certain uniform thickness, and finally performing plastic discharging and sintering on the polystyrene spheres to obtain the hollow sphere casting material.
Description: the casting material prepared by the method improves thermal shock performance and scouring resistance, reduces the phenomena of local cracking and collapse of the casting material in the use process, has small shrinkage change at high temperature, and has the characteristics of high strength, high wear resistance and the like.
Further, the plastic discharging temperature is 300-550 ℃ and the time is 2.5-3.5 hours, and the sintering temperature is 1670-1740 ℃.
Description: and (3) carrying out high-temperature plastic discharge and sintering operation to enable the polystyrene pellets to disappear so as to obtain the hollow sphere casting material.
The beneficial effects of the invention are as follows:
the invention provides an energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material, which is prepared by strictly adjusting the proportion of casting raw materials, grinding, slurry preparation, hollow sphere casting material preparation and other series of treatments, has good thermal shock performance and strong wear resistance, and has the advantages of simple proportion of raw material components and cost saving; the manufacturing process is simple and is easy for industrialized production.
Detailed Description
The invention will be described in further detail with reference to the following embodiments to better embody the advantages of the invention.
Example 1
The energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material comprises the following raw materials in parts by weight: 65 parts of zirconia corundum aggregate, 13 parts of silicon carbide, 5 parts of organic fiber, 5 parts of silicon micropowder, 10 parts of pure calcium aluminate cement, 1.5 parts of water reducer and 2 parts of additive;
the zirconia corundum aggregate comprises the following components in percentage by mass: 42% zircon sand, 49.5% alumina powder, 5% zirconia, 0.5% sillimanite powder, 1.0% graphene, 0.6% binder;
the water reducing agent is sodium aluminate; the organic fiber is polyethylene fiber;
the additive comprises the following components in percentage by mass: andalusite micropowder 80% and HPMA 20%;
the preparation method of the zirconia corundum aggregate comprises the following steps:
1) Uniformly mixing zircon sand, alumina powder, zirconia and graphene by a mixer, adding a bonding agent, soaking for 19 hours, adding the soaked mixture into an electric arc furnace, melting by long electric arc for 80 minutes, and then introducing oxygen into the solution to obtain a mixed solution;
2) Adding sillimanite into the mixed solution, melting by long-time electric arc for 28 minutes, and then introducing oxygen to obtain a solution;
3) And carrying out heat preservation annealing on the solution, and then carrying out cutting and grinding processing to obtain the zirconia corundum aggregate.
The binding agent comprises the following components in percentage by mass: 25% of silicon dioxide, 4% of glycerol and the balance of water;
the preparation method of the zirconia-corundum composite hollow sphere casting material comprises the following steps:
s1, grinding:
firstly adding zirconia corundum aggregate into a ball grinder, ball-milling for 13 minutes to prepare fine powder, then sequentially adding silicon carbide and organic fibers, ball-milling for 18 minutes to obtain mixed powder which is sieved by a 200-mesh sieve, and then adding silicon micro powder into the ball grinder to obtain mixed micro powder which is sieved by a 500-mesh sieve;
s2, preparing slurry:
adding the mixed micro powder, the pure calcium aluminate cement, the silicon micro powder and the water reducing agent into water which is 2 times of the total weight of the four components, continuously heating and stirring, when the temperature is 65 ℃, starting to add 0.1 part of additive with the temperature of/+1 ℃ and stirring, when the temperature is 75 ℃, adding all the rest additives, keeping the temperature and stirring for 9 minutes, and preparing slurry;
s3, preparing a hollow sphere casting material:
taking polystyrene beads as templates, and fully soaking a plurality of polystyrene beads in the slurry; filtering out redundant slurry mixed with polystyrene pellets through a screen, drying the slurry, repeating the actions until the surface of the polystyrene pellets has slurry with uniform thickness of 2mm, and finally performing plastic discharge and sintering on the polystyrene pellets to obtain the hollow pellet casting material;
the plastic discharging temperature is 400 ℃, the time is 3 hours, and the sintering temperature is 1700 ℃.
Example 2
This example is substantially the same as example 1, except that the castable comprises, in parts by weight: 60 parts of zirconia corundum aggregate, 11 parts of silicon carbide, 4 parts of organic fiber, 4 parts of silicon micropowder, 7 parts of pure calcium aluminate cement, 1 part of water reducer and 1 part of additive.
Example 3
This example is substantially the same as example 1, except that the castable comprises, in parts by weight: 70 parts of zirconia corundum aggregate, 15 parts of silicon carbide, 6 parts of organic fiber, 6 parts of silicon micropowder, 12 parts of pure calcium aluminate cement, 2 parts of water reducer and 3 parts of additive.
Example 4
This example is substantially the same as example 1, except that the additive comprises, in mass fraction: 75% of andalusite micropowder and 15% of HPMA.
Example 5
This example is substantially the same as example 1, except that the additive comprises, in mass fraction: 85% andalusite micropowder and 25% HPMA.
Example 6
The present example is basically the same as example 1, except that in the preparation method of zirconia-corundum aggregate, in step 1), zircon sand, alumina powder, zirconia and graphene are mixed uniformly by a mixer, and then added with a bonding agent to be soaked for 15 hours.
Example 7
The present example is basically the same as example 1, except that in the preparation method of zirconia-corundum aggregate, in step 1), zircon sand, alumina powder, zirconia and graphene are mixed uniformly by a mixer, and then added with a binder to soak for 23 hours.
Example 8
The embodiment is basically the same as the embodiment 1, except that the zirconia corundum aggregate comprises the following components in percentage by mass: 41.5% of zircon sand, 48.5% of alumina powder, 4.0% of zirconia, 0.3% of sillimanite powder, 0.5% of graphene and 0.2% of a binding agent.
Example 9
The embodiment is basically the same as the embodiment 1, except that the zirconia corundum aggregate comprises the following components in percentage by mass: 42.5% zircon sand, 50.5% alumina powder, 5.8% zirconia, 0.7% sillimanite powder, 1.5% graphene, 1.0% binder.
Example 10
This example is substantially the same as example 1, except that the binder comprises, in mass fraction: 20% of silicon dioxide, 1% of glycerol and the balance of water.
Example 11
This example is substantially the same as example 1, except that the binder comprises, in mass fraction: 30% of silicon dioxide, 8% of glycerol and the balance of water.
Example 12
This example is substantially the same as example 1 except that in step S2, when the temperature is raised to 60 ℃, 0.05 parts/+1deg.C of the additive is started and stirred, and when the temperature is raised to 70 ℃, the rest of the additive is completely added and the temperature is maintained and stirred for 8 minutes to prepare a slurry.
Example 13
This example is substantially the same as example 1 except that in step S2, when the temperature is raised to 70 ℃, 0.15 parts/+1deg.C of the additive is started and stirred, and when the temperature is raised to 80 ℃, the rest of the additive is completely added and the temperature is maintained and stirred for 10 minutes to prepare a slurry.
Example 14
This example is substantially the same as example 1, except that the plastic discharge temperature is 300℃for 2.5 hours and the firing temperature is 1670 ℃.
Example 15
This example is substantially the same as example 1, except that the plastic discharge temperature is 550℃for 3.5 hours and the firing temperature is 1740 ℃.
Experimental example
For the casting materials prepared in each example, 5 samples of each example were taken to test the performance of the copper-zirconium alloy wire, and the performance measurement results of the 5 samples of each example were averaged to obtain the performance measurement results of the example, and specifically studied as follows:
1. the influence of the raw material proportion of different casting materials on the casting materials is explored.
Examples 1, 2 and 3 were used as experimental examples for comparison, while comparative example 1 was set, and comparative example 1 is: no additive is added into the raw materials, and other conditions are unchanged; the results are shown in Table 1:
table 1 performance test table of castable under each formulation
As can be seen from the results in table 1, the proportions of different zirconia corundum aggregates, silicon carbide, organic fibers, silicon micropowder, pure calcium aluminate cement, water reducer and additives have a certain influence on the performance of the casting material, wherein the casting material in example 1 is better in thermal shock stability and wear resistance;
meanwhile, as can be seen from comparison of comparative example 1 and example 1, when no additive is added in the preparation of the castable, the performance of the prepared castable is obviously reduced, and therefore, the additive of the application obviously improves the performance of the castable.
2. The influence of different proportions of the additive on the casting material is explored.
Comparative examples 1, 4, 5 were used as experimental examples, while comparative example 2 was set, comparative example 2 being: no HPMA exists in the additive, and other conditions are unchanged; the results are shown in Table 2:
table 2 performance test table of casting materials with different additive ratios
As can be seen from the results in table 2, different andalusite micropowder and HPMA proportions have a certain influence on the performance of the casting material, wherein the casting material of example 1 has better thermal shock stability and wear resistance;
meanwhile, as can be seen from comparison of comparative example 2 and example 1, the performance of the prepared casting material is obviously reduced when HPMA is not added into the additive, so that the performance of the casting material is obviously improved by the HPMA.
3. The effect of different soak times in the binder on the castable was investigated.
Comparative examples 1, 6 and 7 were used as experimental examples, and the results are shown in table 3:
TABLE 3 Performance test Table of castable under different soak times
As can be seen from the results of Table 3 above, when preparing the zirconia-corundum aggregate, different soaking times in the binder have a certain effect on the performance of the castable, wherein example 7 is optimal, but the performance of example 7 is almost unchanged from that of example 1, whereas the preparation time of example 7 is longer, and the performance of the castable of example 1 is relatively better from the viewpoints of production cost and the like.
4. The influence of the raw material proportion of different zirconia-corundum aggregates on the casting material is explored.
Comparative examples 1, 8 and 9 are shown in Table 4:
table 4 performance test table of castable under different raw material ratios of zirconia-corundum aggregates
As can be seen from the results of table 4 above, the proportions of the zircon sand, alumina powder, zirconia, sillimanite powder, graphene and binder, which are different, have a certain effect on the performance of the casting material, wherein the casting material of example 1 has better performance.
5. The influence of different proportions of the binding agent on the casting material is explored.
Comparative examples 1, 10, 11 were used as experimental examples, while comparative example 3 was set, comparative example 3 being: no glycerol is added into the binding agent, and other conditions are unchanged; the results are shown in Table 5:
table 5 performance test table for castable with different proportions of binder
As can be seen from the results of table 5 above, the different proportions of silica, glycerol and water have a certain effect on the performance of the casting material, wherein the casting material of example 1 has better performance;
meanwhile, as can be seen from comparison of comparative example 3 with example 1, the performance of the prepared casting material is obviously reduced when no glycerol is added into the bonding agent, so that the performance of the casting material is obviously improved by the glycerol.
6. The influence of the addition amounts of the additives at different temperatures on the casting material was investigated.
Comparative examples 1, 12, 13 were used as experimental examples, while comparative example 3 was set, comparative example 4 being: when the temperature is raised to 70 ℃, adding the additive and stirring, and keeping other conditions unchanged; the results are shown in Table 6:
table 6 performance test table of casting materials with different addition amounts of additives
As can be seen from the results of table 6 above, the addition of different amounts of additives between different temperatures has a certain effect on the performance of the casting material, wherein the casting material of example 1 has better performance;
meanwhile, as can be seen from comparison of comparative example 4 with example 1, the additive was applied by the addition method of this example 1, and the performance of the finally prepared casting material was better.
7. The influence of different firing temperatures on the casting material was investigated.
Comparative examples 1, 14 and 15 are shown in Table 7:
TABLE 7 Performance test Table of castable at firing temperature
As can be seen from the results of Table 7 above, the addition of different amounts of additives between different temperatures has a certain effect on the performance of the castable, wherein the thermal shock stability of example 15 is optimal, the linear change rate and wear resistance of example 1 are optimal, the performance of example 15 is almost indistinguishable from that of example 1, the preparation cost of example 15 is higher, and the performance of the castable of example 1 is relatively better from the standpoint of production cost and the like.
Claims (1)
1. The energy-saving wear-resistant zirconia-corundum composite hollow sphere casting material is characterized by comprising the following raw materials in parts by weight: 60-70 parts of zirconia corundum aggregate, 11-15 parts of silicon carbide, 4-6 parts of organic fiber, 4-6 parts of silicon micropowder, 7-12 parts of pure calcium aluminate cement, 1-2 parts of water reducer and 1-3 parts of additive;
the zirconia corundum aggregate comprises the following components in percentage by mass: 41.5 to 42.5 percent of zircon sand, 48.5 to 50.5 percent of alumina powder, 4.0 to 5.5 percent of zirconia, 0.3 to 0.7 percent of sillimanite powder, 0.5 to 1.2 percent of graphene and 0.2 to 1.0 percent of binding agent, which are 100 percent in total;
the water reducing agent is one or more of sodium aluminate, sodium hexametaphosphate or sodium tripolyphosphate;
the organic fiber is any one of polyethylene fiber and polypropylene fiber;
the additive comprises the following components in percentage by mass: 75-85% of andalusite micropowder and 15-25% of HPMA;
the preparation method of the zirconia corundum aggregate comprises the following steps:
1) Uniformly mixing zircon sand, alumina powder, zirconia and graphene by a mixer, adding a bonding agent, soaking for 15-23 hours, adding the soaked mixture into an electric arc furnace, melting by long electric arc for 70-85 minutes, and then introducing oxygen into the solution to obtain a mixed solution;
2) Adding sillimanite powder into the mixed solution, melting by long-time electric arc for 25-30 minutes, and then introducing oxygen to obtain a solution;
3) Carrying out heat preservation annealing on the solution, and then carrying out cutting and grinding processing to obtain zirconia corundum aggregate;
the binding agent comprises the following components in percentage by mass: 20-30% of silicon dioxide, 1-8% of glycerol and the balance of water;
the preparation method of the zirconia-corundum composite hollow sphere casting material comprises the following steps:
s1, grinding:
firstly adding zirconia corundum aggregate into a ball mill for ball milling for 10-15 minutes to prepare fine powder, then sequentially adding silicon carbide and organic fibers for ball milling for 15-20 minutes to obtain mixed powder which is sieved by a 200-mesh sieve, and then adding silicon micropowder into the ball mill to obtain mixed micropowder which is sieved by a 500-mesh sieve;
s2, preparing slurry:
adding the mixed micro powder, the pure calcium aluminate cement, the silicon micro powder and the water reducing agent into water which is 2 times of the total weight of the four components, continuously heating and stirring, starting to add 0.05-0.15 part of additive with the temperature of/+1 ℃ when the temperature is 60-70 ℃, stirring, adding all the rest additives when the temperature is 70-80 ℃, and keeping the temperature and stirring for 8-10 minutes to prepare slurry;
s3, preparing a hollow sphere casting material:
taking polystyrene beads as templates, and fully soaking a plurality of polystyrene beads in the slurry; filtering out redundant slurry mixed with polystyrene pellets through a screen, drying the slurry, repeating the actions until the surface of the polystyrene pellets has slurry with a certain uniform thickness, and finally performing plastic discharging and sintering on the polystyrene pellets to obtain the hollow pellet casting material;
the plastic discharging temperature is 300-550 ℃ and the time is 2.5-3.5 hours, and the sintering temperature is 1670-1740 ℃.
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