CN116396064B - Method for preparing complex-shape abrasive particles of aluminum oxide-based composite material by spray pyrolysis deposition - Google Patents
Method for preparing complex-shape abrasive particles of aluminum oxide-based composite material by spray pyrolysis deposition Download PDFInfo
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- CN116396064B CN116396064B CN202310329076.8A CN202310329076A CN116396064B CN 116396064 B CN116396064 B CN 116396064B CN 202310329076 A CN202310329076 A CN 202310329076A CN 116396064 B CN116396064 B CN 116396064B
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- alumina
- spray pyrolysis
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- 238000005118 spray pyrolysis Methods 0.000 title claims abstract description 28
- 239000002131 composite material Substances 0.000 title claims abstract description 26
- 239000002245 particle Substances 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims abstract description 17
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 title description 9
- 238000005245 sintering Methods 0.000 claims abstract description 50
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 42
- 239000002243 precursor Substances 0.000 claims abstract description 21
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims abstract description 9
- 239000000843 powder Substances 0.000 claims description 25
- 239000000758 substrate Substances 0.000 claims description 25
- 238000005507 spraying Methods 0.000 claims description 18
- 238000000227 grinding Methods 0.000 claims description 17
- 239000000243 solution Substances 0.000 claims description 16
- 238000000151 deposition Methods 0.000 claims description 15
- 239000011259 mixed solution Substances 0.000 claims description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 9
- 230000002787 reinforcement Effects 0.000 claims description 9
- 239000000725 suspension Substances 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 239000012752 auxiliary agent Substances 0.000 claims description 6
- GVGUFUZHNYFZLC-UHFFFAOYSA-N dodecyl benzenesulfonate;sodium Chemical group [Na].CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 GVGUFUZHNYFZLC-UHFFFAOYSA-N 0.000 claims description 6
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 claims description 6
- 229910021393 carbon nanotube Inorganic materials 0.000 claims description 5
- 239000002041 carbon nanotube Substances 0.000 claims description 5
- 239000002270 dispersing agent Substances 0.000 claims description 5
- 230000000630 rising effect Effects 0.000 claims description 5
- 239000000839 emulsion Substances 0.000 claims description 4
- 239000005543 nano-size silicon particle Substances 0.000 claims description 4
- 150000003839 salts Chemical class 0.000 claims description 4
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 3
- 239000002202 Polyethylene glycol Substances 0.000 claims description 3
- 239000012298 atmosphere Substances 0.000 claims description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 3
- 239000001301 oxygen Substances 0.000 claims description 3
- 229910052760 oxygen Inorganic materials 0.000 claims description 3
- 229920001223 polyethylene glycol Polymers 0.000 claims description 3
- 239000002861 polymer material Substances 0.000 claims description 3
- 230000003014 reinforcing effect Effects 0.000 claims description 3
- 239000002904 solvent Substances 0.000 claims description 3
- XMWRBQBLMFGWIX-UHFFFAOYSA-N C60 fullerene Chemical compound C12=C3C(C4=C56)=C7C8=C5C5=C9C%10=C6C6=C4C1=C1C4=C6C6=C%10C%10=C9C9=C%11C5=C8C5=C8C7=C3C3=C7C2=C1C1=C2C4=C6C4=C%10C6=C9C9=C%11C5=C5C8=C3C3=C7C1=C1C2=C4C6=C2C9=C5C3=C12 XMWRBQBLMFGWIX-UHFFFAOYSA-N 0.000 claims description 2
- 229910010293 ceramic material Inorganic materials 0.000 claims description 2
- 229910003472 fullerene Inorganic materials 0.000 claims description 2
- 229910021389 graphene Inorganic materials 0.000 claims description 2
- 239000011261 inert gas Substances 0.000 claims description 2
- 159000000003 magnesium salts Chemical group 0.000 claims description 2
- 239000007769 metal material Substances 0.000 claims description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 2
- 239000002113 nanodiamond Substances 0.000 claims description 2
- 229920000036 polyvinylpyrrolidone Polymers 0.000 claims description 2
- 239000001267 polyvinylpyrrolidone Substances 0.000 claims description 2
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 claims description 2
- 238000000746 purification Methods 0.000 claims description 2
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 2
- 150000003376 silicon Chemical class 0.000 claims description 2
- 150000003608 titanium Chemical class 0.000 claims description 2
- 150000003754 zirconium Chemical class 0.000 claims description 2
- 229910052581 Si3N4 Inorganic materials 0.000 claims 1
- 239000003570 air Substances 0.000 claims 1
- 239000005416 organic matter Substances 0.000 claims 1
- 239000003960 organic solvent Substances 0.000 claims 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims 1
- 229910010271 silicon carbide Inorganic materials 0.000 claims 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims 1
- 239000006061 abrasive grain Substances 0.000 abstract description 4
- 238000002360 preparation method Methods 0.000 abstract description 4
- 239000000203 mixture Substances 0.000 abstract 1
- 239000000919 ceramic Substances 0.000 description 14
- 239000007921 spray Substances 0.000 description 10
- 238000001816 cooling Methods 0.000 description 9
- 239000008367 deionised water Substances 0.000 description 9
- 229910021641 deionized water Inorganic materials 0.000 description 9
- 238000003756 stirring Methods 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- 238000000889 atomisation Methods 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- 238000004663 powder metallurgy Methods 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 6
- 239000003082 abrasive agent Substances 0.000 description 6
- -1 etc. Chemical compound 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- BNGXYYYYKUGPPF-UHFFFAOYSA-M (3-methylphenyl)methyl-triphenylphosphanium;chloride Chemical compound [Cl-].CC1=CC=CC(C[P+](C=2C=CC=CC=2)(C=2C=CC=CC=2)C=2C=CC=CC=2)=C1 BNGXYYYYKUGPPF-UHFFFAOYSA-M 0.000 description 4
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 4
- PPQREHKVAOVYBT-UHFFFAOYSA-H dialuminum;tricarbonate Chemical compound [Al+3].[Al+3].[O-]C([O-])=O.[O-]C([O-])=O.[O-]C([O-])=O PPQREHKVAOVYBT-UHFFFAOYSA-H 0.000 description 4
- YIXJRHPUWRPCBB-UHFFFAOYSA-N magnesium nitrate Chemical compound [Mg+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O YIXJRHPUWRPCBB-UHFFFAOYSA-N 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 229910052786 argon Inorganic materials 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 229910052593 corundum Inorganic materials 0.000 description 3
- 239000010431 corundum Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- RAXXELZNTBOGNW-UHFFFAOYSA-N imidazole Natural products C1=CNC=N1 RAXXELZNTBOGNW-UHFFFAOYSA-N 0.000 description 3
- FYDKNKUEBJQCCN-UHFFFAOYSA-N lanthanum(3+);trinitrate Chemical compound [La+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O FYDKNKUEBJQCCN-UHFFFAOYSA-N 0.000 description 3
- 239000011858 nanopowder Substances 0.000 description 3
- 238000005498 polishing Methods 0.000 description 3
- 238000000197 pyrolysis Methods 0.000 description 3
- DUNKXUFBGCUVQW-UHFFFAOYSA-J zirconium tetrachloride Chemical compound Cl[Zr](Cl)(Cl)Cl DUNKXUFBGCUVQW-UHFFFAOYSA-J 0.000 description 3
- HSEYYGFJBLWFGD-UHFFFAOYSA-N 4-methylsulfanyl-2-[(2-methylsulfanylpyridine-3-carbonyl)amino]butanoic acid Chemical compound CSCCC(C(O)=O)NC(=O)C1=CC=CN=C1SC HSEYYGFJBLWFGD-UHFFFAOYSA-N 0.000 description 2
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 2
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 2
- 229940118662 aluminum carbonate Drugs 0.000 description 2
- MWPLVEDNUUSJAV-UHFFFAOYSA-N anthracene Chemical compound C1=CC=CC2=CC3=CC=CC=C3C=C21 MWPLVEDNUUSJAV-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- DMEGYFMYUHOHGS-UHFFFAOYSA-N cycloheptane Chemical compound C1CCCCCC1 DMEGYFMYUHOHGS-UHFFFAOYSA-N 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- ICAKDTKJOYSXGC-UHFFFAOYSA-K lanthanum(iii) chloride Chemical compound Cl[La](Cl)Cl ICAKDTKJOYSXGC-UHFFFAOYSA-K 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000012299 nitrogen atmosphere Substances 0.000 description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- IRPGOXJVTQTAAN-UHFFFAOYSA-N 2,2,3,3,3-pentafluoropropanal Chemical compound FC(F)(F)C(F)(F)C=O IRPGOXJVTQTAAN-UHFFFAOYSA-N 0.000 description 1
- KLZUFWVZNOTSEM-UHFFFAOYSA-K Aluminum fluoride Inorganic materials F[Al](F)F KLZUFWVZNOTSEM-UHFFFAOYSA-K 0.000 description 1
- 241001391944 Commicarpus scandens Species 0.000 description 1
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 1
- CZPWVGJYEJSRLH-UHFFFAOYSA-N Pyrimidine Chemical compound C1=CN=CN=C1 CZPWVGJYEJSRLH-UHFFFAOYSA-N 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- HDYRYUINDGQKMC-UHFFFAOYSA-M acetyloxyaluminum;dihydrate Chemical compound O.O.CC(=O)O[Al] HDYRYUINDGQKMC-UHFFFAOYSA-M 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229940009827 aluminum acetate Drugs 0.000 description 1
- 229940063656 aluminum chloride Drugs 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 150000003934 aromatic aldehydes Chemical class 0.000 description 1
- 150000001491 aromatic compounds Chemical class 0.000 description 1
- 150000008365 aromatic ketones Chemical class 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 1
- CZZYITDELCSZES-UHFFFAOYSA-N diphenylmethane Chemical compound C=1C=CC=CC=1CC1=CC=CC=C1 CZZYITDELCSZES-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 150000004676 glycans Chemical class 0.000 description 1
- 150000002391 heterocyclic compounds Chemical class 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 150000002603 lanthanum Chemical class 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229920002521 macromolecule Polymers 0.000 description 1
- QWDJLDTYWNBUKE-UHFFFAOYSA-L magnesium bicarbonate Chemical compound [Mg+2].OC([O-])=O.OC([O-])=O QWDJLDTYWNBUKE-UHFFFAOYSA-L 0.000 description 1
- 229910000022 magnesium bicarbonate Inorganic materials 0.000 description 1
- 235000014824 magnesium bicarbonate Nutrition 0.000 description 1
- 239000002370 magnesium bicarbonate Substances 0.000 description 1
- 229910001629 magnesium chloride Inorganic materials 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 239000012046 mixed solvent Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 150000002843 nonmetals Chemical class 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 229920001282 polysaccharide Polymers 0.000 description 1
- 239000005017 polysaccharide Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 150000003746 yttrium Chemical class 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/111—Fine ceramics
- C04B35/1115—Minute sintered entities, e.g. sintered abrasive grains or shaped particles such as platelets
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
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- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
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- C04B35/62605—Treating the starting powders individually or as mixtures
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3852—Nitrides, e.g. oxynitrides, carbonitrides, oxycarbonitrides, lithium nitride, magnesium nitride
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Abstract
A method for preparing complex-shaped abrasive particles of an alumina-based composite material by spray pyrolysis deposition comprises the steps of preparing a precursor solution, spray pyrolysis deposition and pressure sintering, wherein the precursor solution is prepared by preparing aluminum salt and the like into a mixture; the precursor solution is decomposed and deposited into a complex-shape die at high temperature by spray pyrolysis deposition, and an alumina pressed compact with a complex shape is obtained; purifying the obtained alumina pressed compact with the complex shape at high temperature and sintering under pressure to finally obtain the nano or superfine alumina-based composite material with the complex shape, which is nearly fully compact; the method can realize large-batch, low-cost, high-stability and high-quality preparation of the complex alumina abrasive grains.
Description
Technical Field
The invention relates to a method for preparing abrasive particles with complex shapes of aluminum oxide-based composite materials by spray pyrolysis deposition, belonging to the field of powder metallurgy and material preparation.
Background
Spray pyrolysis deposition (SPHD) is a technique for manufacturing metal and ceramic nanopowders. It is thermally decomposed at high temperature by spraying a pyrolysis agent, so that the powder is formed to be deposited on a substrate. Spray pyrolysis deposition is an efficient method of manufacturing nanopowders, such as alumina abrasive particles. Is widely used for manufacturing metal and ceramic nano powder, such as manufacturing electronic, medical and aviation equipment. The method has the advantages of producing the powder with high purity, high precision and high surface area, and simultaneously has the advantages of high production efficiency, low production cost and high purity of the prepared material.
Powder metallurgy techniques can be used to produce powders of a variety of materials, such as ceramics, cemented carbides, non-metals, and the like. The technology can produce high-purity, high-precision and high-surface-area powder, and is widely applied to various fields such as electronics, aviation, medical treatment, automobiles and the like. The powder metallurgy technology can also be used for preparing alumina ceramics, namely, the alumina ceramics is prepared by mixing, pressing, sintering and other substances (such as rare earth oxide, carbon nano reinforcing body and the like) of aluminum oxide or nitride to prepare ceramic composite materials, and the ceramic powder prepared by the powder metallurgy technology has the characteristics of high purity, high precision, high surface area and the like and can be used for preparing various ceramic products such as ceramic substrates, ceramic heat insulation materials and the like.
Alumina abrasive is a high hardness material commonly used in grinding operations. It has excellent properties such as high hardness, high thermal stability and wear resistance, and thus is widely used in the fields of grinding surfaces, polishing, cleaning, etc. The particle size range of the alumina abrasive is wide, and the alumina abrasive is produced from micron level to nanometer level. In grinding, factors such as the grain size and morphology of the abrasive will directly affect the machining accuracy and surface quality. In addition to conventional grinding, alumina abrasives can also be used in nano-polishing, cleaning, and plating techniques. Among these techniques, alumina abrasives can provide efficient, environmentally friendly and long-term stable processing results. But at the same time is relatively brittle and is easy to break during processing. In addition, because the alumina abrasive grain has higher hardness and density, the production and processing costs are higher.
The alumina complex-shaped abrasive particles refer to alumina particles having a different shape from common round alumina abrasive particles, and the complex-shaped alumina abrasive particles have a larger contact area and a higher surface ratio, and thus have better dispersibility and higher adhesion. The alumina abrasive grain with the complex shape can be used for grinding, polishing and other processes so as to obtain more excellent grinding effect. However, it is difficult to prepare alumina abrasive materials with complex shapes by a forming process in powder metallurgy, or the cost of the prepared abrasive materials is greatly increased, which is unfavorable for popularization and use of the abrasive materials.
Disclosure of Invention
Aiming at the problems existing in the prior art, the invention combines the advantages of spray pyrolysis deposition and powder metallurgy forming, and provides a simple and easy-to-realize preparation method of the alumina-based composite material complex-shape abrasive particles.
The technical scheme of the invention is as follows:
a method for preparing complex-shape abrasive particles of an alumina-based composite material by spray pyrolysis deposition comprises the following specific steps:
(1) Preparing an aluminum salt solubilizer into a precursor solution;
(2) Carrying out spray pyrolysis on the precursor solution, and depositing powder obtained by spraying into a die;
(3) Purifying the spray pyrolysis product at high temperature, and then performing pressure sintering to obtain the alumina-based composite material abrasive particles with complex shapes.
The aluminum salt in step (1) may be a soluble inorganic or organic salt such as aluminum nitrate, aluminum chloride, aluminum acetate, aluminum carbonate, aluminum fluoride, etc.
Adding a reinforcing precursor and/or an auxiliary agent into the precursor solution in the step (1); the reinforcement precursor may be a rare earth element-containing salt (such as yttrium salt, lanthanum salt, etc.), or an organic substance (such as aromatic compound such as benzene, naphthalene, anthracene, etc., perhydro-compound such as cyclohexane, cycloheptane, etc., imidazole, pyrimidine, etc., heterocyclic compound such as diphenylmethane and its derivative, carbonyl-containing compound such as aromatic aldehyde, aromatic ketone, etc., biological macromolecule such as polysaccharide, starch, etc.), or a nano reinforcement, the nano reinforcement specifically including carbon nanotube, graphene, carbon quantum dot, fullerene, nanodiamond, nanosilicon nitride, nanoboron nitride, nanosilicon carbide, nanotitanium carbide, etc.; the auxiliary agent is magnesium salt, zirconium salt, titanium salt, silicon salt and the like; the mass ratio of the reinforcement precursor to the aluminum salt is 1:1.001-1000; the addition amount of the auxiliary agent is 0.1-10.0% of the mass of the aluminum salt.
The precursor solution in the step (1) can be mixed solution, suspension or emulsion, and if the precursor solution is suspension or emulsion, dispersing agent accounting for 0.5-5.5% of the mass of the precursor solution is added, wherein the dispersing agent is inorganic surfactant such as sodium dodecyl benzene sulfonate or organic polymer material such as polyethylene glycol and polyvinylpyrrolidone.
The spray pyrolysis temperature in the step (2) can be low-temperature spray or high-temperature spray, and the spray temperature of the low-temperature spray is 220-450 ℃; the spraying temperature of high-temperature spraying is 450-1100 ℃; the appropriate temperature is selected according to the material being sprayed.
Depositing the powder obtained by spraying in the step (2) into a die, wherein the die is a multi-cavity honeycomb substrate grinding tool with high complexity, and the high complexity means that the geometric shape of the grinding material obtained after deposition can be designed arbitrarily, such as regular tetrahedron, triangular pyramid, triangular prism, multi-tooth form and the like, and the geometric body can be hollow or solid; the substrate of the honeycomb cavity substrate grinding tool can be ceramic material, metal material or polymer material.
The high-temperature purification temperature in the step (3) is not lower than 250 ℃, the time is not lower than 5 minutes, and the pressure is not higher than the standard atmospheric pressure.
The temperature of the pressurized sintering in the step (3) is not lower than 1100 ℃, and the pressure is not lower than 0.2MPa; the pressurized atmosphere may be an inert gas, or may be air or oxygen; the sintering temperature rising rate is not less than 10 ℃/min, and the sintering time is not more than 10 hours. The invention has the beneficial effects that:
the invention fully combines the advantages of spray pyrolysis deposition and powder metallurgy forming, prepares the alumina-based composite material with complex shape in one step, not only can realize batch production and greatly save the production and preparation cost, but also is beneficial to refining alumina grains and evenly dispersing reinforcements and improves the comprehensive performance of the alumina-based abrasive with complex shape.
Drawings
Schematic representation of a multi-cavity substrate abrasive article, i.e., a deposition substrate, made of the abrasive article steel of fig. 1;
the size schematic of the individual alumina-based abrasive grains of the design of fig. 2;
FIG. 3 is a pictorial photograph of the alumina-based abrasive material prepared.
Detailed Description
The invention will be further illustrated with reference to specific examples.
Example 1
Dissolving 1000g of aluminum ammonium sulfate into 10 liters of deionized water heated to 60 ℃, adding 20g of magnesium nitrate and 8.0g of lanthanum nitrate, fully stirring to obtain a mixed solution, placing the obtained mixed solution into spray pyrolysis equipment for atomization, wherein the spray temperature is 250 ℃, depositing the sprayed composite powder into a die made of grinding tool steel, wherein the die is a multi-cavity substrate grinding tool, the inner cavity substrate is a solid regular quadrangular pyramid honeycomb structure, the shape of the die is as shown in figure 1, single aluminum oxide-based abrasive particles expected to be obtained in the interior of the die are as shown in figure 2, and after the spraying is completed, keeping the obtained powder blank and the die at 420 ℃ for 30 minutes, and the vacuum degree is 10Pa; the obtained sample is sent into a pressurized sintering furnace, the temperature of the sintering furnace is 1350 ℃, pure argon is adopted for pressurized sintering, the pressure is 0.8MPa, the sintering heating rate is 20 ℃/min, the sintering time is 2 hours, and the alumina abrasive with the final side length of 1.5mm and the regular quadrangular pyramid shape is obtained after cooling, as shown in figure 3, the relative density is 99.1%, and the hardness is 10.2GPa.
Example 2
Dissolving 500g of aluminum nitrate into 15 liters of deionized water heated to 80 ℃, adding 10.0g of zirconium chloride and 8.0g of lanthanum chloride, fully stirring to obtain a mixed solution, placing the obtained mixed solution into spray pyrolysis equipment for atomization, wherein the spraying temperature is 850 ℃, depositing the sprayed composite powder into a corundum ceramic mold, wherein the mold is a multi-cavity substrate grinding tool, the geometry of a substrate in the inner cavity of the mold is a solid square pyramid-shaped honeycomb structure, and after spraying, keeping the obtained powder blank and the mold at 250 ℃ for 10 minutes, and the vacuum degree is 20Pa; feeding the obtained sample into a pressurized sintering furnace, wherein the temperature of the sintering furnace is 1300 ℃, the pressurized sintering is carried out under the protection of pure nitrogen atmosphere, the pressure is 3.0MPa, the sintering heating rate is 10 ℃/min, the sintering time is 2 hours, and the aluminum oxide abrasive with the final side length of 3.0mm is obtained after cooling, wherein the relative density of the aluminum oxide abrasive reaches 98.5%; the hardness reaches 9.88GPa.
Example 3
Dissolving 1000g of aluminum ammonium chloride into 20L of deionized water heated to 75 ℃, adding 30g of magnesium bicarbonate and 15.0g of carbon nanotube dispersion (the mass fraction is 10%), simultaneously adding 10g of Sodium Dodecyl Benzene Sulfonate (SDBS), fully stirring to obtain suspension, placing the obtained suspension into spray pyrolysis equipment for atomization, wherein the spray temperature is 220 ℃, depositing the sprayed composite powder into a polytetrafluoroethylene mold, wherein the mold is a multi-cavity substrate grinding tool, the geometry of a substrate in the mold is a solid regular triangular prism honeycomb structure, and after the spraying is completed, keeping the obtained powder blank and the mold at 260 ℃ for 10 minutes, and the vacuum degree is 10Pa; feeding the obtained sample into a low-pressure sintering furnace, wherein the temperature of the sintering furnace is 1400 ℃, pure argon is adopted for pressurizing, the pressure is 5.5MPa, the sintering heating rate is 12 ℃/min, the sintering time is 1.0 hour, and the alumina-based abrasive with the final side length of 3.0mm is obtained after cooling, wherein the relative density of the alumina-based abrasive reaches 98.7%; the hardness reaches 9.46GPa.
Example 4
Adding 400g of aluminum chloride and 20g of zirconium chloride into 500mL of ethanol and deionized water (volume ratio is 1:1), fully stirring to obtain a mixed solution, putting the obtained mixed solution into a spray thermal pyrolysis furnace, depositing the sprayed composite powder into a hard alloy die, wherein the die is a multi-cavity substrate grinding tool, the geometric shape of the substrate in the inner cavity of the die is a solid multi-tooth honeycomb structure, setting the temperature to 560 ℃ until the solution is completely sprayed and pyrolyzed to deposit into the die, and after spraying is completed, keeping the obtained powder blank and the die at 420 ℃ for 30 minutes, wherein the vacuum degree is 10Pa; the obtained sample is sent into a high-temperature sintering furnace, pressurized sintering is carried out under the oxygen atmosphere, the pressure is 5.5MPa, the sintering heating rate is 10 ℃/min, the sintering temperature is 1250 ℃, the sintering time is 2.5 hours, and the toothed alumina ceramic particles with the final grain size of 50-100 mu m are obtained after cooling, wherein the relative density reaches 99.5%; the hardness reaches 9.61GPa.
Example 5
Adding 2.0Kg of aluminum carbonate into 6.0L of deionized water, fully stirring, adding 0.5Kg of nano boron nitride, adding 50g of polyethylene glycol as a dispersing agent, putting the obtained mixed solution into a spray thermal pyrolysis furnace, spraying to obtain composite powder, depositing the composite powder into a ceramic mold, setting the geometric shape of the substrate of an inner cavity of the mold to be a honeycomb structure of a solid hexagonal prism, setting the temperature to 850 ℃ until the solution is completely sprayed and pyrolyzed, depositing the composite powder into the mold, and after spraying, keeping the obtained powder blank and the mold at 240 ℃ for 15 minutes and the vacuum degree to be 20Pa; the obtained sample is sent into a high-temperature sintering furnace, pressurized sintering is carried out under the argon atmosphere, the pressure is 3.5MPa, the sintering heating rate is 12 ℃/min, the sintering temperature is 1400 ℃, the sintering time is 1.0 hour, and the hexagonal prism alumina ceramic particles with the final grain size of 50-80 mu m are obtained after cooling, wherein the relative density reaches 97.8%; the hardness reaches 10.68GPa.
Example 6
Adding 320g of aluminum nitrate and 18g of lanthanum nitrate into a mixed solvent of 100mL of acetone and 1000mL of deionized water, fully stirring to obtain a mixed solution, placing the obtained mixed solution into spray pyrolysis equipment for atomization, wherein the spray temperature is 800 ℃, depositing the sprayed composite powder into a corundum ceramic mold, wherein the mold is a multi-cavity substrate grinding tool, the geometric shape of the substrate in the inner cavity of the mold is a hollow regular triangular prism-shaped honeycomb structure, and after the spraying is completed, keeping the obtained powder blank and the mold at 280 ℃ for 30 minutes, and the vacuum degree is 10Pa; feeding the obtained sample into a pressurized sintering furnace, wherein the temperature of the sintering furnace is 1520 ℃, the pressure is 6.0MPa, the sintering temperature rising rate is 20 ℃/min, the sintering time is 6 hours, and the aluminum oxide abrasive with the final side length of 3.0mm and with the relative density of 99.5% is obtained after cooling; the hardness reaches 11.33GPa.
Comparative example 1
Dissolving 1000g of aluminum ammonium sulfate into 10 liters of deionized water heated to 60 ℃, then adding 20g of magnesium nitrate and 8.0g of lanthanum nitrate, fully stirring to obtain a mixed solution, placing the obtained solution into spray pyrolysis equipment for atomization, wherein the spraying temperature is 320 ℃, depositing the sprayed composite powder into a conventional stainless steel mold, wherein an inner cavity is a conventional cavity, after spraying, continuing the mold into a vacuum furnace, and preserving the temperature for 30 minutes at 320 ℃, wherein the vacuum degree is 10Pa; the obtained sample is sent into a vacuum sintering furnace after heat treatment, the temperature of the sintering furnace is 1350 ℃, the sintering heating rate is 20 ℃/min, the sintering time is 2 hours, and the alumina abrasive is obtained after cooling, wherein the relative density of the alumina abrasive reaches 91.12%; the hardness reaches 5.20GPa.
Comparative example 2
Dissolving 500g of aluminum nitrate into 15 liters of deionized water heated to 80 ℃, adding 10.0g of zirconium chloride and 8.0g of lanthanum chloride, fully stirring to obtain a mixed solution, placing the obtained solution into spray pyrolysis equipment for atomization, wherein the spray temperature is 180 ℃, depositing the sprayed composite powder into a corundum ceramic mold, wherein the mold is a multi-cavity substrate grinding tool, the geometric shape of a substrate in the inner cavity of the mold is a regular rectangular pyramid-shaped honeycomb structure, sending the obtained sample into a pressurized sintering furnace, and pressurizing the obtained sample under the protection of pure nitrogen atmosphere at the temperature of 1300 ℃ under the pressure of 3.0MPa; the sintering temperature rising rate is 10 ℃/min, the sintering time is 2 hours, and the aluminum oxide abrasive with the final side length of 3.0mm and the regular square pyramid is obtained after cooling, wherein the relative density reaches 90.27%; the hardness reaches 3.08GPa.
Comparative example 3
Dissolving 1000g of aluminum ammonium chloride into 20L of deionized water heated to 75 ℃, then adding 30g of magnesium chloride and 15.0g of carbon nanotube dispersion (mass fraction is 10%), simultaneously adding Sodium Dodecyl Benzene Sulfonate (SDBS) accounting for 0.5% of the total mass of the aluminum ammonium chloride and the carbon nanotubes, fully stirring to obtain suspension, placing the obtained suspension into spray pyrolysis equipment for atomization, wherein the spraying temperature is 220 ℃, depositing composite powder obtained by spraying into a polytetrafluoroethylene mold, and the cavity of the mold is a conventional cavity; feeding the obtained sample into a vacuum sintering furnace, wherein the temperature of the sintering furnace is 1050 ℃, and the pressure is 5.5MPa by adopting pure argon gas for pressurizing; the sintering temperature rising rate is 12 ℃/min, the sintering time is 1.0 hour, and the alumina-based abrasive is obtained after cooling, and the relative density of the alumina-based abrasive reaches 88.11%; the hardness reaches 1.24GPa.
Claims (4)
1. A method for preparing complex-shape abrasive particles of an alumina-based composite material by spray pyrolysis deposition is characterized by comprising the following specific steps:
(1) Preparing an aluminum salt solubilizer into a precursor solution;
(2) Carrying out spray pyrolysis on the precursor solution, and depositing powder obtained by spraying into a die;
(3) Purifying the spray pyrolysis product at high temperature, and then performing pressure sintering to obtain abrasive particles with complex shapes of the alumina-based composite material;
the spray pyrolysis temperature of the step (2) is 220-1100 ℃;
the die in the step (2) is a multi-cavity honeycomb substrate grinding tool, and the geometric shape of the substrate of the multi-cavity honeycomb substrate die is regular tetrahedron, triangular pyramid, triangular prism or multi-tooth shape; the substrate material of the multi-cavity honeycomb substrate is ceramic material, metal material or polymer material;
the high-temperature purification temperature in the step (3) is not lower than 250 ℃, the time is not lower than 5 minutes, and the pressure is not higher than the standard atmospheric pressure;
the temperature of the pressurized sintering in the step (3) is not lower than 1100 ℃, the pressure is not lower than 0.2MPa, and the pressurized atmosphere is inert gas, air or oxygen; the sintering temperature rising rate is not less than 10 ℃/min, and the sintering time is not more than 10 hours.
2. The method of preparing complex shaped abrasive particles of an alumina-based composite material by spray pyrolysis deposition according to claim 1, wherein the aluminum salt in step (1) is a soluble salt and the solvent is water or an organic solvent.
3. The method for preparing complex-shaped abrasive particles of an alumina-based composite material by spray pyrolysis deposition according to claim 1, wherein a reinforcing precursor and/or an auxiliary agent are added into the precursor solution in the step (1); the reinforcement precursor is a rare earth element-containing salt, an organic matter capable of decomposing to generate a six-membered ring carbon structure or a nano reinforcement, and the nano reinforcement comprises a carbon nano tube, graphene, carbon quantum dots, fullerene, nano diamond, nano silicon nitride, nano boron nitride, nano silicon carbide and nano titanium carbide; the auxiliary agent is magnesium salt, zirconium salt, titanium salt or silicon salt; the mass ratio of the reinforcement precursor to the aluminum salt is 1:1.001-1000; the addition amount of the auxiliary agent is 0.1-10.0% of the total mass of the aluminum salt.
4. The method for preparing the complex-shaped abrasive particles of the alumina-based composite material by spray pyrolysis deposition according to claim 3, wherein the precursor solution in the step (1) is a mixed solution, a suspension or an emulsion, and if the precursor solution is the suspension or the emulsion, a dispersing agent accounting for 0.5-5.5% of the mass of the precursor solution is added, and the dispersing agent is sodium dodecyl benzene sulfonate, polyethylene glycol or polyvinylpyrrolidone.
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