CN1165124A - Abradability aluminium oxide ceramics and its manufacture method - Google Patents

Abradability aluminium oxide ceramics and its manufacture method Download PDF

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CN1165124A
CN1165124A CN 97102439 CN97102439A CN1165124A CN 1165124 A CN1165124 A CN 1165124A CN 97102439 CN97102439 CN 97102439 CN 97102439 A CN97102439 A CN 97102439A CN 1165124 A CN1165124 A CN 1165124A
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alumina
ceramic
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CN1081175C (en
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大西宏司
大沼继浩
河波利夫
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Nikkato Corp
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Abstract

A aluminous ceramics capable of sintering at a low temperature, free from unevenness in characteristics and excellent in wear resistance with low-cost starting materials. 88 to 95 wt.% of Al2O3 is used as the principal component of aluminous ceramics and 3.6 to 10 wt.% SiO2, 0.2 to 2.5 wt.% MgO and 0.2 to 2.5 wt.% CaO are added by 5 to 12 wt.%, in total, as subsidiary components to the alumina. When the total amount of the SiO2, MgO and CaO is represented by 100 wt.%, the amounts of the SiO2, MgO and CaO are 72 to 85 wt.%, 3 to 25 wt.% and 3 to 25 wt.%, respectively. The amount of inevitable impurities is reduced to less than 0.5 wt.%, the amount of defects is limited to less than 5%.

Description

Abradability aluminium oxide ceramics and manufacture method thereof
Technical field
The present invention relates to a kind of abradability aluminium oxide ceramics, particularly, the present invention relates to a kind of abradability aluminium oxide ceramics and manufacture method thereof that can be used for the wear resistance component materials.
Prior art
In recent years, it has been observed that Standpoint of Ceramic Wear-resisting Function and corrosion resistance nature than metallic substance excellence, stupalith is replacing existing metal and is being used as the wear resistance component materials.As this pottery, common known have aluminum oxide, zirconium white, silicon nitride, silicon carbide etc.Wherein, alumina-ceramic big based on hardness, that have excellent erosion resistance and inexpensive aluminum oxide is being widely used.In general, alumina-ceramic is as only being made of the aluminum oxide monomer, and then its sintering character is poor, and productivity is poor, therefore, generally must add as carrying out roasting behind sintering aid or other additive.
The problem that the invention desire solves
Yet the problem that alumina-ceramic in the past exists is: owing to added a large amount of additives, A1 in the alumina-ceramic 2O 3Content reach 90-95% (weight), on the aluminum oxide crystal boundary, generate inferior looks and glassy phase beyond a large amount of alumina crystallizations thus, can not get original hardness of aluminum oxide and intensity, and can not get sufficient abrasion resistance.
In order to address this problem, to open the spy and to have proposed a kind of like this alumina-ceramic on the flat 7-206514 communique, this alumina-ceramic contains Al 2O 395-98% (weight) is a main component, adds by SiO again 2The sintering aid 2-5% (weight) that 40-85% (weight), MgO 10-55% (weight), CaO 5-50% (weight) form; In addition, the spy open proposed on the flat 7-237961 communique a kind of with Al 2O 3Reach 90-95% (weight) and be main component, add SiO again 23.0-5.0% (weight), MgO 1.0-1.5% (weight) and B 2O 3The formed alumina-ceramic of 0.5-3.5% (weight).
The problem of opening the alumina-ceramic existence that proposes on the flat 7-206514 communique the spy is: this alumina-ceramic can improve its wear resisting property by the addition that reduces sintering aid; But because wherein the content of aluminum oxide is big more, its sintering character is low more, therefore, must at high temperature carry out roasting, and the crystalline size-grade distribution under this maturing temperature broadens easily, causes the reduction of wear resistance easily.In addition, this alumina-ceramic being used for pulverize when use abrading-ball, can see that abrasion of its empty mill promptly, are only put into and pulverized with abrading-ball and water in ball mill, the wear resistance when making it to rotate demonstrates the performance of excellence.Yet in the actual abrasion when pulverizing as the powder of aluminum oxide etc., its wear resisting property still fails fully to satisfy.
Again, opening the alumina-ceramic that proposes on the flat 7-237961 communique the spy has shown and has contained Al 2O 3Reach the excellent abrasive of the alumina-ceramic same degree in the past of 90-95% (weight), but its defective is: for suppressing grain growth and reducing the B that maturing temperature adds 2O 3Under 1000 ℃, still shown suitable vapour pressure; Because easily evaporation in roasting, the easy change of the component of described alumina-ceramic like this, must make its characteristic instability; In addition, because B 2O 3Evaporation, at the inner hole that produces of pottery, cause wear resisting property low.
Therefore, the objective of the invention is, a kind of alumina-ceramic that has excellent wear-resisting property cheaply is provided, described alumina-ceramic is sintering at low temperatures, and its characteristic unstable is little.
Solve the means of problem
The present invention is that the means that achieve the above object are: to contain Al 2O 3Reach 88-95% (weight) for the main component of alumina-ceramic, add by SiO again 2The ancillary component that 72-85% (weight), MgO 3-25% (weight), CaO 3-25% (weight) form, the total amount that makes the content of each composition in this ancillary component account for alumina-ceramic is SiO 23.6-10% (weight), MgO 0.2-2.5% (weight), CaO 0.2-2.5% (weight), the total amount that the total amount of mentioned component accounts for alumina-ceramic is 5-12% (weight); Simultaneously, unavoidable impurities content is controlled at below 0.5% (weight), in addition, the ratio of defects of pottery is controlled at below 5%.
In specification sheets of the present invention, the ratio of defects of pottery is meant: use surface grinding machine by following condition pottery to be roughly ground after (cutting) processing, remake attrition process, be polished to minute surface, to do the image photography under the scanning electronic microscope through bright finished ceramic plane (hereinafter referred to as the mirror polish face) enlargement ratio fixed (being generally 500 times) having, this photographs of image analysis, by dualization this photographs is separated into defect part and non-defect part, the ratio (that is area ratio) that this defect part accounts for the area of entire image promptly refers to ratio of defects.The defective of described defect part not only comprises pore, be also included within the corase grind of making sintered compact and grinding, polishing add threshing takes place man-hour after, and the defective of the horizontal plane that the volume density value of sintered compact do not exerted an influence.
Above-mentioned mirror polish uses the diamond wheel of surface grinding machine and resin-bonded formulation to be undertaken by following.At first, on the diamond wheel of No. 140 granularities, the circumferential speed of getting emery wheel is 1500 meter per seconds, penetraction depth is 8 μ m, giving speed (giving hereinafter referred to as workpiece) about the pottery of non-grinding thing (hereinafter referred to as workpiece) is 17 meter per seconds, stop incision after the about 80 μ m of grinding, come back rotation 5 times.Then, using the diamond wheel of No. 400 granularities instead, is 1500 meter per seconds at the circumferential speed of emery wheel, and penetraction depth is 5 μ m, and it is under the condition of 13 meter per seconds that workpiece is given, and stops incision after the about 50 μ m of grinding, comes the back rotation emery wheel 10 times.Using the diamond wheel of No. 600 granularities again instead, is 1500 meter per seconds at the circumferential speed of emery wheel, and penetraction depth is 2 μ m, and it is under 10/ second the condition, to stop incision after the about 20-30 μ of the grinding m that workpiece is given, and comes the back rotation emery wheel 15 times.Thereafter, with 2.6kgf/cm 2The diamond band that pressure will be embedded with the diamond abrasive grain of 40m stresses on the grinding skin of the pottery of doing ground finish, does 3 minutes grinding; Again with 2.6kgf/cm 2Pressure will be embedded with the diamond band pressurization of the diamond abrasive grain of 6 μ m, do 5 minutes grinding; Again with 2.6kgf/cm 2Pressure will be embedded with the diamond band pressurization of the diamond abrasive grain of 3 μ m, do 15 minutes grinding; At last, with 1.3kgf/cm 2Pressure will be embedded with the diamond band pressurization of the diamond abrasive grain of 1 μ m, do 5 minutes grinding.
That is, abradability aluminium oxide ceramics of the present invention is characterised in that: described alumina-ceramic is by Al 2O 388% (weight) is above, 95% (weight) is following, SiO 23.6-10% (weight), MgO 0.2-2.5% (weight), CaO 0.2-2.5% (weight) are that unavoidable impurity is formed on the residual quality entity; Above-mentioned SiO 2, MgO and CaO the content sum be 5-12% (weight); If above-mentioned SiO 2, MgO and CaO the content sum be 100, then each components in proportions is respectively SiO 272-85% (weight), MgO 3-25% (weight), CaO 3-2 5% (weight), above-mentioned unavoidable impurities content is below 0.5% (weight), and ratio of defects is below 5%.
Al as above-mentioned main component 2O 3Content better with the scope of 90-94.5% (weight).Again, as the content of above-mentioned ancillary component with SiO 25-10% (weight), MgO 0.4-1.5% (weight), CaO 0.3-1.5% (weight) are for well; Above-mentioned each composition sum was made as 100 o'clock, and each components in proportions is respectively SiO 2The scope of 73-84% (weight), MgO 3.5-1% (weight), CaO 4-15% (weight) is for better.
In addition, in the present invention, in intensity that further improves above-mentioned alumina-ceramic and flexible while, make its microscopic structure homogeneous more, the basic composition that per 100 weight parts are made up of mentioned component adds ZrO 20.01-15 weight part is preferably the 0.05-10 weight part, is more preferably the 0.1-8 weight part.
In addition, the invention provides a kind of manufacture method of abradability aluminium oxide ceramics, it is characterized in that, with fixed ratio cooperate raw material powder, after this mixture is broken to the powder that median size is 0.5-1.0 μ m as micro mist, the micropowder (mold pressing) of gained is shaped as required shape, and obtaining volume density is 1.90-2.10g/cm 3Formed body, this formed body of roasting.At this moment, the specific surface area of the micropowder after the pulverizing is with 8-15m 2/ g is advisable, and again, the maturing temperature of formed body is good with 1350-1600 ℃.
The content of above-mentioned unavoidable impurities is made as below 0.5% (weight), still, and wherein preferably with Na 2O and K 2The content of the alkalimetal oxide of O etc. is made as below 0.45% (weight), is preferably below 0.4% (weight); Again, TiO 2Content be made as below 0.2% (weight), be preferably below 0.15% (weight).
In addition, described ratio of defects can produce very big influence to Standpoint of Ceramic Wear-resisting Function, and therefore, the ratio of defects on the mirror polish face preferably is controlled at below 5%.This be because, defective proportion surpasses 5%, then these defectives promptly become abrasive starting point, accelerate abrasion, cause the decline of wear resisting property, simultaneously, also cause the low of resistance to impact shock, so undesirable.Ratio of defects is below 3% preferably, and better is below 2%.
The working of an invention form
As previously mentioned, abradability aluminium oxide ceramics of the present invention is to cooperate raw material in foregoing ratio, ground mixt to its median size below 1.0 μ m, its specific surface area is at 8m 2More than/the g, more specifically, prepare its median size in 0.5-1.0 μ m, its specific surface area at 8-15m 2The raw material powder of/g, the raw material powder of sinter molding gained to fixed shape, obtaining volume density is 1.90-2.10g/cm 3Formed body, made at this formed body of 1350-1600 ℃ roasting temperature.Concrete manufacture method is as follows.
(1) at first, prepare than the compound of each component that will constitute alumina-ceramic, add ZrO in case of necessity by above-mentioned component 2Raw material in water or organic solvent, adopts wet method, uses and pulverizes, mixes, disperses, the preparation raw material powder as the known pulverizer of ball mill, milling machine etc.
As the alumina raw material of main component, its purity is 99.7% (weight), and specific surface area is 2m 2More than/the g, median size is preferably median size at 0.5-3.0 μ m below 3.0 μ m.In addition, this alumina raw material can be made by alum method etc., but the alumina raw material that preferably uses Bayer process to make, this raw material can make at an easy rate.
As the raw material of MgO in the ancillary component and CaO, can use the salt of oxide compound, oxyhydroxide, carbonate etc., but preferably use its median size below 3.0 μ m, be preferably the salt of median size at 0.5-3.0 μ m.Again, as SiO 2Raw material can use silica, quartz, silicon sol, tetraethyl orthosilicate etc., also can use Y 2O 3Deng rare earth element as the stablizer solid solution in clay mineral or ZrO as kaolin etc. 2In the tetragonal spheroidal zirconium.As this ZrO 2Raw material, using its median size is below the 1.0 μ m, be preferably use its median size 0.5-1.0 μ m, its specific surface area is at 5m 2/ g is above, be preferably at 5-16m 2The raw material that/g is above.Using solid solution that Y is arranged 2O 3Deng the tetragonal spheroidal zirconium of stablizer during as raw material, can improve its toughness by the stress-induced phase transformation effect.
In the raw material of above-mentioned alumina-ceramic, contain unavoidable impurities usually, for example, Fe 2O 3, Na 2O, K 2O and TiO 2Deng, still, owing to alkalimetal oxide and TiO in the unavoidable impurities 2Or generate time looks, or cause the formation of unusual particle, so, should use the least possible raw material of its unavoidable impurities content, particularly, because Na 2O and K 2Easy and the SiO of O 2Deng forming glassy phase, should select the raw material of content below 0.45% (weight) of alkalimetal oxide for use, again, because TiO 2Or the promotion crystalline growth, or become the reason that abnormal grain is grown up, so should select its content is below 0.2% (weight), be more preferably the raw material of selecting 0.15% (weight) following.
Pulverize, mix and be dispersed in water or the organic solvent and carry out with wet method, at this moment, the viscosity of mud is good with 50-1500cps.When viscosity is high, preferably suitably add dispersion agent, allotment viscosity as sodium acrylate, multi-carboxylate etc.Below 1.0 μ m, specific surface area is at 5m by the median size of the powder of pulverizing gained 2More than/the g, more particularly powder is crushed to its median size in 0.5-1.0 μ m, its specific surface area at 8-15m 2More than/the g.Desire to carry out the pulverizing of such granularity, can use, pulverized 96 hours and carry out with the oxidation aluminum abrading-ball of 20mm diameter as ball mill.
(2), obtain the powder of granulation to the as above mud drying and the granulation of gained.Drying means can be selected for use according to employed forming method, usually, when using mold pressing or CIP (isotropy cold rolling) method moulding, adopts spraying drying; In occasion or the employing extrusion molding and the injection molding occasion of cast molding and rotation granulating and forming, preferably select the moisture eliminator drying for use again.
Importantly, even also can crush under the low pressure of the powder of granulation in the moulding of its subsequent handling, the increase of the defect level that the granulation powder of crushing property difference and sintered compact are contained is relevant.Various conditions when the good granulation powder of crushing property can be handled by kind, amount and spray-dryer that suitable selection makes an addition to the tackiness agent of mud and obtaining.In addition, can use as employed in the past any tackiness agents such as polyvinyl alcohol (PVA), acrylic resin, paraffin emulsions as tackiness agent; In addition, as dispersion agent, to use sodium acrylate, multi-carboxylate etc. for well.
For example, using spray-dryer exsiccant occasion,, the tackiness agent that to its solids component (raw material powder) is 1-5% (weight) can be added wherein chippy mud in aforementioned operation.When adding tackiness agent, when the viscosity of this tackiness agent reaches 500cps when above, can add dispersion agent with its viscosity adjustment to 500cps.The mud of gained spray-dryer spraying drying under 150-250 ℃ temperature, granulation.It is 0.2-2% that the powder that this moulding is used is mixed with water ratio usually, and particle diameter is the scope of 40-100 μ m. secondly, use this powder, according to making pottery used method usually, by the method for mold pressing, CIP etc., at 500-20000kgf/cm 2Forming pressure under make the shape of setting.
Again,, also can omit the spraying drying operation, directly use mud when rotating the forming method moulding of granulation, cast molding, extrusion molding, injection molding etc., or the material powder of only using with drying and moulding.For example, when using casting moulding, use the dispersion agent of sodium acrylate, polycarboxylate etc., the viscosity of chippy mud is modulated into below the 150cps, use the plaster mould moulding as forming method.
When using the rotation granulating and forming as forming method, tackiness agent is added in the mud of pulverizing, because dry device is dry down at 80-120 ℃, in the pulverizer of spraying gun and so on, pulverized dry powder, sieve by 40-80 order mesh, obtain undersized powder, this powder is directly used in the rotation granulating and forming.
When using extrusion molding or injection molding as forming method, in moisture eliminator, the mud of 80-120 ℃ of following drying and crushing, in the pulverizer of spraying gun and so on, pulverize dry powder, sieve by 40-80 order mesh, obtain undersized powder, in this powder, the tackiness agent that adds 3-10% in the occasion of extrusion molding mixes with blender, in injection molding occasion, the tackiness agent that adds 15-30% mixes with blender, is modulated into the base soil that moulding is used, and carries out extrusion molding or injection molding.
Although aforesaid forming method is had nothing in common with each other,, the volume density of the formed body of gained all must be at 1.90g/cm 3More than, be more preferably at 1.95g/cm 3More than.When the volume density of the formed body of gained less than 1.90g/cm 3The time, then the defective in the sintered compact of gained increases, and is therefore undesirable.
At 1350-1600 ℃, be more preferably at the as above resulting formed body of 1400-1550 ℃ roasting temperature, obtain the abradability aluminium oxide ceramics of purpose product thus.
The component of the abradability aluminium oxide ceramics that the present invention is relevant is limited to the reasons are as follows in the aforesaid scope.That is Al, 2O 3Content should be 88% (weight) above, below 95% (weight), work as Al 2O 3Content during less than 88% (weight), then the amount in inner glassy phase that generates of sintered compact and time looks increases, and causes the intensity of sintered compact, hardness low, and its shock resistance and wear resisting property also reduce, thereby undesirable; Work as Al again, 2O 3Content when 95% (weight) is above, then not only very few at the inner glassy phase that generates of sintered compact, cause sintering character low, and be accompanied by the rising of maturing temperature, on the crystal boundary of aluminum oxide, easily generate the segregation of glassy phase, become the reason that abnormal grain is grown up, make its hardness, toughness and intensity low, thus also undesirable.
Again, as the SiO of above-mentioned ancillary component 2, MgO and CaO add as sintering aid, these ancillary components mainly are present on the aluminum oxide crystal boundary with glassy phase, have suppressed the growth of its crystal grain, have improved volume density and have suppressed the subsurface defect rate, have improved wear resisting property.The content of each ancillary component is limited to is based on reason as described below within the above-mentioned scope.
That is SiO, 2, MgO and CaO content be respectively SiO 2During the scope of 3.6-10% (weight), MgO 0.2-2.5% (weight), CaO 0.2-2.5% (weight), then not only they and Al 2O 3Crystalline thermal expansion difference and wettability are suitable, and the control of crystal particle diameter and distribution is easy, and aluminum oxide grain-boundary strength and toughness improve, and shock resistance and wear resistance improve.Yet, work as SiO 2, MgO and CaO the three in one of content exceed above-mentioned scope, then reduce except the aluminum oxide grain-boundary strength, generate time looks particle, and because of with the impact of other material and friction cause the coming off of crystallization particle diameter, toughness lowly outside, also have crystal to become big in the roasting stage, (excessively) that abnormal grain easily takes place grows up, and causes crystal particle diameter to lack homogeneity inevitably, shock resistance and wear resistance are descended, so get above-mentioned scope.
Particularly, work as SiO 2Content during less than 3.6% (weight), the coking property of alumina-ceramic is low; Work as SiO again, 2Content when surpassing 10% (weight), cause that the grain-boundary strength of alumina-ceramic is low, so get above-mentioned value.In addition, when the content of MgO during less than 0.2% (weight), the crystal particle diameter of alumina-ceramic lacks homogeneity; When the content of MgO during greater than 2.5% (weight), then separate out time looks, be 0.2-2.5% (weight) so get the content of MgO.Have, when the content of CaO during less than 0.2% (weight), the coking property of alumina-ceramic is low again; And when its content surpasses 2.5% (weight), then cause the growth of low and abnormal grain of the coking property of alumina-ceramic again, so the content of getting CaO is 0.2-2.5% (weight).
In addition, SiO 2, MgO and CaO the content sum, promptly, the content of ancillary component is taken as 5-12% (weight), this be because: when mentioned component content sum during less than 5% (weight), the amount that is present in the glassy phase of aluminum oxide crystal boundary reduces makes existing of glassy phase inhomogeneous, produces the decline of coking property and growing up of crystalline abnormal grain, causes the low of the shock resistance of alumina-ceramic and wear resisting property, so, should not use.On the other hand, when the content of ancillary component surpasses 12% (weight), then glassy phase generates too much, causes hardness, toughness and the intensity of alumina-ceramic low, reduces the shock resistance and the wear resisting property of alumina-ceramic, so get above-mentioned scope.
Have again, set above-mentioned SiO 2, MgO and CaO the content sum be 100 o'clock, each components in proportions is respectively SiO 2The reasons are as follows of 72-85% (weight), MgO 3-25% (weight), CaO 3-25% (weight).That is SiO in ancillary component, 2Content during less than 72% (weight), the coking property of alumina-ceramic is low; Again, SiO in ancillary component 2Content when surpassing 85% (weight), the amount of glassy phase increases, so get above-mentioned scope.In addition, when the content of MgO during less than 3% (weight), the crystal particle diameter of alumina-ceramic lacks homogeneity; When the content of MgO surpasses 25% (weight), then separate out time looks, be above-mentioned scope so get the content of MgO in ancillary component.Have, when the content of CaO in the ancillary component during less than 3% (weight), the coking property of alumina-ceramic is low again; And when its content surpasses 25% (weight), then not only cause coking property low of alumina-ceramic, and easily make crystal growth, so getting its content is above-mentioned scope.
The basic composition that abradability aluminium oxide ceramics of the present invention is formed at the mentioned component of 100 weight parts adds the ZrO of 0.01-15 weight part 2, thus, can further improve intensity and toughness, simultaneously, make the glassy phase of aluminum oxide crystal boundary do the dispersion of homogeneous; And, also can dwindle the distribution of crystal particle diameter, make the homogeneous microstructure of sintered compact.This ZrO 2Addition be taken as above-mentioned scope be because: the basic composition of per 100 weight parts being made up of mentioned component when its addition is during less than 0.01 weight part, then can not obtain effect of sufficient, if this addition surpasses 15 weight parts, then cause the low of hardness again, particularly, using the ZrO that does not add stablizer 2During powder, easily there is the oblique system zirconium in the sintered compact, tiny crack can take place, make its wear resisting property and shock resistance low, therefore, undesirable.Above-mentioned ZrO 2Addition be the 0.01-15 weight part with above-mentioned base stock for per 100 weight parts, be preferably the 0.05-10 weight part, be more preferably the 0.1-8 weight part.
At this moment, the ZrO of interpolation 2Raw material preferably uses the raw material of its median size below 1.0 μ m.This is because work as ZrO 2The median size of raw material surpasses 1.0 μ m, then easily has the oblique system zirconium in the sintered compact, and tiny crack can take place, and makes its wear resisting property and shock resistance low, and is therefore, undesirable.Again, as ZrO 2Raw material also can use solid solution that the raw material of the stablizer of rare earth element oxide compound etc. is arranged.At this moment, contain the rare earth element oxide compound, for example, contain Y 2O 3ZrO for stablizer 2Raw material preferably uses Y 2O 3The raw material of content below 5% (mole), thus, can improve toughness by the stress-induced phase transformation effect of zirconium.
As previously mentioned, according to the present invention, with the ratio set Al for principal constituent 2O 3Add the specific ancillary component of specified quantitative, simultaneously, the amount of the unavoidable impurities that is contained in the inhibition raw material, thus, can obtain having the alumina-ceramic of excellent abrasive, above-mentioned alumina-ceramic have in the scope of 1.0-5.0 μ m the average crystalline particle diameter and, 3.60g/cm 3Above volume density, and the defective of the threshing that is caused by pore and polishing processing etc. is less, is below 5%.
In addition, when the average crystalline particle diameter of sintered compact surpasses 5 μ m, cause that then the hardness of alumina-ceramic is low, wear resisting property reduces, so undesirable.The average crystalline particle diameter of this sintered compact is preferably in below the 3 μ m, is more preferably below 2.5 μ m.Again,, consider the balance of itself and wear resisting property, preferably be set in the following scope of 5 μ m in the anti-unchallenged occasion of performance of cutting.Have, when its maximum particle diameter (crystal particle diameter when cumulative volume is 100%) surpassed 10 μ m, then crystal particle diameter distributed and broadens again, and hardness is low.Its result is lowly relevant with wear resisting property, should not adopt, so preferably use maximum particle diameter below 10 μ m, is more preferably the following sintered compact of 8 μ m.
Again, volume density is taken as 3.60g/cm 3More than, this be because, when volume density less than 3.60g/cm 3, then the sintering degree is not enough, simultaneously, has the hole that much becomes defective, and this causes that not only intensity, hardness and flexible are low, and accelerated wear test, and is therefore undesirable.Volume density is got 3.65g/cm 3More than be advisable.
Alumina-ceramic of the present invention is because crystal particle diameter is little, and Jing Ti Cause is close, and defective is few and have excellent shock resistance and a wear resisting property.Therefore, compared with in the past, Al 2O 3The sintered compact of the identical level of content comes, and alumina-ceramic intensity height of the present invention, hardness are big, good toughness.The DPH of alumina-ceramic of the present invention has shown the high rigidity more than 1100 under the load 10kgf.Again, its flexural strength has shown the 40kgf/mm under 3 bending methods of JIS1601 regulation 2Above high strength.Have, alumina-ceramic of the present invention is embedded in an abrading-ball body on the superhard alloy plate when making spherical as the abrading-ball of pulverizing usefulness again, stress application, and recording ultimate compression strength is 25kgf/mm 2More than.This ultimate compression strength (σ c) can be from formula: σ c=4 * P/ ((kgf/mm of π * D2) 2) obtain.In the formula, P is strength at break (kgf), and D is sphere diameter (mm).
DPH makes its wear resistance decrease less than 1100 o'clock, so undesirable.Flexural strength is less than 40kgf/mm again 2Or ultimate compression strength is less than 25kgf/mm 2The time, can have influence on and reduce shock resistance and wear resisting property, also undesirable.Have, destruction toughness in by JIS1607 (IF method) specified test is again More than.
Embodiment 1
Each raw material is carried out fusion by the composition of table 1, table 2, obtain sintered compact, each mixture of gained is done case of wet attrition 48 hours with 92% oxidation aluminum ball mill (capacity 7.2 liters) and 92% aluminum oxide system crushing ball of 20mm diameter for 60% time in concentration, obtains containing just like the median size shown in table 3, the table 4, specific surface area at 8m 2The mud of the micropowder that/g is above.Mud to gained adds polyvinyl alcohol water solution 3-5% (weight), and as tackiness agent, adjusting viscosity is 350cps, and with the spray-dryer drying that maintains 200 ℃, granulation obtains the moulding powder.In forming pressure is 1ton f/cm 2(only the forming pressure at No. 20 and No. 38 samples is 300kgf/cm 2), be shaped to this moulding spherical and tabular with powder by the CIP method of forming.The formed body of gained obtains the spheroid of diameter 10mm and the plate of 50 * 50 * 4mm 1380-1600 ℃ of following roasting.Spheroid is used ball as pulverizing after the rotating cylinder polishing, plate then is used as the test piece of the flexural strength test usefulness of JIS1601 regulation after cut-out and ground finish.
As alumina material,, be that to have used the aggregate particle size of the cohesion that makes according to Bayer process respectively be that 45 μ m, specific surface area are 2.5m about 1-21,24-39 sample 2The purity of/g is 99.6% low sodium alumina raw material, about No. 22 samples, being to use median size is that 1.0 μ m, specific surface area are 6m 2The purity of/g is 99.8% active oxidation aluminum feedstock, about No. 23 samples, the aggregate particle size that has been to use the cohesion that makes according to Bayer process is that 55 μ m, specific surface area are 1.5m 2The purity of/g is 99.7% low sodium alumina raw material.
In addition, as the raw material of MgO and CaO, use purity is 99.5% carbonate, as SiO 2Raw material use kaolin.As ZrO 2Raw material, in 5,8,10,15 and No. 25 samples, used its median size at 1.0 μ m, its specific surface area is at 12m 2/ g, purity are 99.9% zirconium dioxide, in No. 13 samples, have used and have contained Y 2O 32.8% (mole), median size are at 0.5 μ m, and its specific surface area is 18m 2The zirconium dioxide of/g.
The ball of each pulverizing usefulness that use obtains, method is as described below carried out cut resistance test.That is, the ball of pulverizing usefulness is packed in the ball mill of oxidation aluminum (purity 92%) of 2 liters of capacity, to the volumetrical of this ball mill half, put into median size 25 μ m, specific surface area is 1.2m 20.7 liter in the alumina raw material powder 900g of/g and water are to pulverize 24 hours under the 100rpm in the ball mill speed of rotation.The weight difference ball of ball before and after the test is obtained the percentage with respect to the ball weight before the test, with it as rate of wear.Volume density, crystal particle diameter, defect level, DPH and the flexural strength of the result of gained and the ball of pulverizing usefulness, and the volume density of formed body, median size and the specific surface area of pulverizing powder are shown in table 3, table 4 together.Flexural strength uses the testing plate that is processed by plate to measure.
Table 1
Basic composition ???ZrO 2Addition (weight part)
Sample No. Principal constituent Al 2O 3(weight %) Minor component minor component (weight %) minor component is formed Impurity (weight %)
(weight %) ???SiO 2 ??MgO ???CaO ???SiO 2 ???MgO ???CaO ??Na 2O+K 2O ??TiO 2 Other Total amount (%)
????1 ????2 ????3 ????4 ????5 ????6 ????7 ????8 ????9 ????10 ????11 ????12 ????13 ????14 ????15 ????16 ????17 ????18 ????92.69 ????91.73 ????93.06 ????91.54 ????92.69 ????89.71 ????92.55 ????91.34 ????93.16 ????93.73 ????88.97 ????92.38 ????94.30 ????90.58 ????93.04 ????90.28 ????88.02 ????92.25 ????6.84 ????7.85 ????6.51 ????8.00 ????6.84 ????9.85 ????7.00 ????8.20 ????6.35 ????5.80 ????10.54 ????7.18 ????5.21 ????8.95 ????6.50 ????9.25 ????11.50 ????7.26 ???5.04 ???6.04 ???5.38 ???6.64 ???5.04 ???7.12 ???5.92 ???6.89 ???4.83 ???4.61 ???7.70 ???5.38 ???4.11 ???6.46 ???5.36 ???7.32 ???8.66 ???5.13 ??0.40 ??0.67 ??0.77 ??1.00 ??0.40 ??2.38 ??0.25 ??0.73 ??0.92 ??0.70 ??0.41 ??1.48 ??0.67 ??1.49 ??0.79 ??0.88 ??1.41 ??1.41 ???1.40 ???1.14 ???0.36 ???0.36 ???1.40 ???0.35 ???0.83 ???0.58 ???0.60 ???0.49 ???2.43 ???0.32 ???0.43 ???1.00 ???0.35 ???1.05 ???1.43 ???0.72 ???73.6 ???77.0 ???82.7 ???83.0 ???73.6 ???72.2 ???84.5 ???84.0 ???76.1 ???79.4 ???73.1 ???74.9 ???78.8 ???72.2 ???82.4 ???79.2 ???75.3 ???70.6 ???5.9 ???8.5 ???11.8 ???12.5 ???5.9 ???24.2 ???3.6 ???8.9 ???14.5 ???12.1 ???3.9 ???20.6 ???12.9 ???16.7 ???12.2 ???9.5 ???12.3 ???19.5 ???20.5 ???14.5 ???5.5 ???4.5 ???20.5 ???3.6 ???11.9 ???7.1 ???9.4 ???8.5 ???23.1 ???4.5 ???8.3 ???11.1 ???5.4 ???11.3 ???12.4 ???9.9 ????0.35 ????0.32 ????0.30 ????0.34 ????0.35 ????0.33 ????0.34 ????0.34 ????0.33 ????0.33 ????0.32 ????0.31 ????0.36 ????0.35 ????0.33 ????0.34 ????0.38 ????0.36 ??0.07 ??0.06 ??0.07 ??0.06 ??0.07 ??0.06 ??0.06 ??0.05 ??0.09 ??0.08 ??0.10 ??0.07 ??0.09 ??0.07 ??0.06 ??0.05 ??0.05 ??0.05 ???0.05 ???0.04 ???0.06 ???0.06 ???0.05 ???0.05 ???0.05 ???0.07 ???0.07 ???0.06 ???0.07 ???0.06 ???0.04 ???0.05 ???0.07 ???0.08 ???0.07 ???0.08 ???0.47 ???0.42 ???0.43 ???0.46 ???0.47 ???0.44 ???0.45 ???0.46 ???0.49 ???0.47 ???0.49 ???0.44 ???0.49 ???0.47 ???0.46 ???0.47 ???0.50 ???0.49 ????0 ????0 ????0 ????0 ????14.5 ????0 ????0 ????5.4 ????0 ????0.5 ????0 ????0 ????8.0 ????0 ????2.3 ????0 ????0 ????0
Table 2 (continuous table 1)
??19 ??20 ??21 ??22 ??23 ??24 ??25 ??26 ??27 ??28 ??29 ??30 ??31 ??32 ??33 ??34 ??35 ??36 ??37 ??38 ??39 ??94.98 ??92.30 ??90.44 ??96.51 ??91.56 ??93.32 ??90.28 ??88.07 ??90.07 ??87.60 ??92.39 ??88.82 ??93.57 ??90.00 ??90.77 ??91.54 ??88.91 ??87.14 ??91.89 ??91.50 ??92.59 ??4.58 ??7.27 ??9.09 ??3.00 ??7.98 ??5.14 ??9.25 ??11.43 ??9.49 ??11.97 ??6.63 ??10.73 ??6.00 ??9.57 ??8.76 ??7.76 ??10.66 ??12.37 ??7.51 ??8.05 ??6.95 ??3.30 ??5.89 ??7.50 ??2.53 ??6.40 ??4.33 ??7.32 ??9.2 ??6.69 ??9.80 ??4.98 ??7.74 ??5.00 ??6.80 ??7.64 ??6.57 ??7.70 ??10.50 ??6.29 ??6.08 ??5.85 ??0.64 ??0.32 ??1.39 ??0.30 ??0.83 ??0.18 ??0.88 ??0.24 ??0.36 ??0.90 ??0.43 ??0.36 ??0.81 ??2.45 ??0.83 ??0.83 ??2.59 ??0.73 ??0.47 ??0.57 ??0.35 ??0.64 ??1.06 ??0.20 ??0.17 ??0.75 ??0.63 ??1.05 ??1.99 ??2.44 ??1.27 ??1.22 ??2.63 ??0.19 ??0.32 ??0.29 ??0.36 ??0.37 ??1.14 ??0.75 ??1.40 ??0.75 ??72.0 ??81.0 ??82.5 ??84.3 ??80.2 ??84.3 ??79.2 ??80.5 ??70.5 ??81.9 ??75.1 ??72.1 ??83.4 ??71.1 ??87.2 ??84.7 ??72.2 ??84.9 ??83.8 ??75.5 ??84.2 ??14.0 ??4.4 ??15.3 ??10.0 ??10.4 ??3.5 ??9.5 ??2.1 ??3.8 ??7.5 ??6.5 ??3.4 ??13.5 ??25.6 ??9.5 ??10.7 ??24.3 ??5.9 ??6.2 ??7.1 ??5.0 ??14.0 ??14.6 ??2.2 ??5.7 ??9.4 ??12.2 ??11.3 ??17.4 ??25.7 ??10.6 ??18.4 ??24.5 ??3.1 ??3.3 ??3.3 ??4.6 ??3.5 ??9.2 ??10.0 ??17.4 ??10.8 ????0.31 ????0.32 ????0.35 ????0.35 ????0.32 ????0.31 ????0.34 ????0.37 ????0.31 ????0.32 ????0.33 ????0.33 ????0.30 ????0.31 ????0.30 ????0.55 ????0.32 ????0.34 ????0.32 ????0.34 ????0.35 ?0.08 ?0.05 ?0.06 ?0.09 ?0.07 ?0.07 ?0.05 ?0.06 ?0.07 ?0.05 ?0.58 ?0.05 ?0.06 ?0.06 ?0.10 ?0.07 ?0.06 ?0.08 ?0.07 ?0.06 ?0.07 ??0.05 ??0.06 ??0.06 ??0.05 ??0.07 ??0.05 ??0.08 ??0.07 ??0.06 ??0.06 ??0.07 ??0.07 ??0.07 ??0.06 ??0.07 ??0.08 ??0.05 ??0.06 ??0.21 ??0.05 ??0.04 ??0.44 ??0.43 ??0.47 ??0.49 ??0.46 ??0.43 ??0.47 ??0.50 ??0.44 ??0.43 ??0.98 ??0.45 ??0.43 ??0.43 ??0.47 ??0.70 ??0.43 ??0.49 ??0.60 ??0.45 ??0.46 ????0 ????0 ????0 ????0 ????0 ????0 ????16.0 ????0 ????0 ????0 ????0 ????0 ????0 ????0 ????0 ????0 ????0 ????0 ????0 ????0 ????0
Table 3
Sample No. Median size (m) Molding volume density (g/cm 3) Maturing temperature (℃) Volume density (g/cm 3) Crystal particle diameter (μ m) Defect level (%) ?????HV Flexural strength (kgF/mm 2) Wear rate (%)
Mean value Maximum value
????1 ????0.75 ????2.00 ????1520 ????3.70 ????2.3 ????4.8 ????0.9 ???1210 ????43 ????0.08
????2 ????0.81 ????2.02 ????1470 ????3.68 ????1.8 ????4.2 ????0.9 ???1200 ????44 ????0.05
????3 ????0.75 ????2.04 ????1450 ????3.69 ????1.2 ????2.8 ????0.5 ???1250 ????42 ????0.04
????4 ????0.90 ????2.10 ????1500 ????3.72 ????2.0 ????4.0 ????0.7 ???1210 ????41 ????0.05
????5 ????0.88 ????2.07 ????1450 ????3.79 ????1.3 ????2.5 ????0.6 ???1190 ????52 ????0.02
????6 ????0.76 ????2.06 ????1550 ????3.65 ????2.8 ????4.2 ????2.2 ???1180 ????41 ????0.09
????7 ????0.85 ????2.09 ????1460 ????3.68 ????1.7 ????4.3 ????1.2 ???1210 ????46 ????0.06
????8 ????0.89 ????1.99 ????1380 ????3.73 ????1.2 ????2.5 ????1.0 ???1220 ????46 ????0.03
????9 ????0.75 ????2.03 ????1480 ????3.72 ????1.7 ????3.5 ????0.9 ???1210 ????45 ????0.05
????10 ????0.73 ????1.98 ????1470 ????3.72 ????1.9 ????3.7 ????0.6 ???1220 ????42 ????0.04
????11 ????0.77 ????2.02 ????1450 ????3.68 ????1.7 ????3.9 ????2.3 ???1180 ????40 ????0.09
????12 ????0.95 ????2.00 ????1500 ????3.70 ????2.1 ????3.9 ????2.9 ???1200 ????40 ????0.07
????13 ????0.70 ????2.04 ????1400 ????3.73 ????1.5 ????2.3 ????0.9 ???1190 ????48 ????0.02
????14 ????0.85 ????1.99 ????1500 ????3.70 ????1.9 ????3.8 ????1.5 ???1200 ????43 ????0.07
????15 ????0.87 ????2.03 ????1430 ????3.72 ????1.2 ????3.0 ????0.7 ???1200 ????44 ????0.03
????16 ????0.87 ????2.01 ????1490 ????3.70 ????2.1 ????4.2 ????1.7 ???1180 ????42 ????0.05
????17 ????0.92 ????2.01 ????1430 ????3.60 ????1.3 ????3.0 ????3.9 ???1130 ????40 ????0.08
????18 ????0.91 ????2.02 ????1480 ????3.65 ????2.2 ????4.8 ????7.2 ???1010 ????37 ????0.71
Table 4 (continuous table 3)
????19 ????0.78 ????2.00 ????1530 ????3.70 ????2.4 ????7.5 ????6.0 ???1100 ????37 ????0.52
????20 ????0.70 ????1.75 ????1500 ????3.57 ????2.8 ????5.8 ????9.8 ???1080 ????32 ????0.75
????21 ????0.78 ????2.00 ????1460 ????3.65 ????2.7 ????5.2 ????6.0 ???1020 ????37 ????0.49
????22 ????0.80 ????1.92 ????1520 ????3.78 ????2.3 ????3.5 ????9.6 ???1350 ????45 ????0.21
????23 ????1.25 ????1.94 ????1470 ????3.53 ????1.1 ????3.2 ????12.0 ???980 ????35 ????3.1
????24 ????0.92 ????1.98 ????1480 ????3.68 ????2.2 ????7.8 ????8.5 ???1020 ????36 ????0.65
????25 ????0.76 ????2.04 ????1500 ????3.72 ????3.8 ????7.1 ????9.5 ???1040 ????32 ????1.7
????26 ????0.91 ????2.01 ????1500 ????3.67 ????2.8 ????7.0 ????6.8 ???1010 ????39 ????1.8
????27 ????0.75 ????2.00 ????1480 ????3.62 ????3.7 ????8.5 ????8.9 ???990 ????35 ????2.1
????28 ????0.81 ????2.09 ????1520 ????3.66 ????2.7 ????6.5 ????8.0 ???1000 ????38 ????1.0
????29 ????0.98 ????1.99 ????1530 ????3.67 ????4.0 ????10.5 ????6.2 ???1000 ????35 ????3.5
????30 ????0.95 ????1.93 ????1470 ????3.65 ????3.6 ????7.2 ????8.7 ???1100 ????34 ????1.9
????31 ????0.82 ????1.98 ????1480 ????3.64 ????2.5 ????5.9 ????5.7 ???1010 ????37 ????0.88
????32 ????0.88 ????2.02 ????1500 ????3.63 ????2.7 ????6.2 ????7.8 ???1000 ????34 ????0.90
????33 ????0.80 ????2.01 ????1470 ????3.67 ????2.3 ????5.6 ????6.3 ???1070 ????35 ????0.47
????34 ????0.77 ????2.01 ????1470 ????3.66 ????1.8 ????3.5 ????8.0 ???1130 ????39 ????0.95
????35 ????0.80 ????1.92 ????1520 ????3.66 ????3.0 ????7.0 ????9.6 ???1000 ????33 ????2.0
????36 ????0.95 ????1.93 ????1480 ????3.63 ????2.2 ????6.9 ????6.8 ???1010 ????36 ????1.3
????37 ????0.84 ????1.96 ????1550 ????3.65 ????4.5 ????9.0 ????7.8 ???1000 ????35 ????3.9
????38 ????0.75 ????1.82 ????1550 ????3.60 ????4.3 ????8.9 ????8.5 ???1100 ????36 ????3.7
????39 ????1.34 ????2.01 ????1580 ????3.62 ????5.2 ????9.5 ????7.9 ???1010 ????33 ????4.3
In table 1, table 2, ZrO 2Addition with for the expression of the addition (weight part) of basic composition 100 weight parts of forming by aluminum oxide, sintering aid and unavoidable impurities.Again, in table 1, table 2 and table 3 and table 4, the sintered compact of sample 1-17 has satisfied condition of the present invention, but sample 18-39 for do not satisfy at least one of condition given to this invention, fall within the sintered compact outside the scope of the present invention.
The average crystalline particle diameter is sintered compact to be undertaken making attrition process by the order of 40 μ m-6 μ m-3 μ m-1 μ m again on diamond wheel after the ground finish by No. 140-No. 400-No. 600 order on diamond wheel, is polished to minute surface.To this, remake thermal etching, then on scanning electronic microscope, observe the photography of taking a picture then with the crystalline enlargement ratio that can observe in the visual field more than 100.By image analysis, measure a crystalline area from this photography photo, be scaled garden of equal value diameter (D), be its crystal particle diameter with D * 1.5, so, record 100 crystalline crystal particle diameters.Calculating the crystalline volume according to this value, is that 50% o'clock crystal particle diameter is the average crystalline particle diameter with cumulative volume.
In addition, the defect level of sintered compact is following tries to achieve.The sample that is made for test during as the test of crystal particle diameter, is carried out mirror polish.This bright finished directly under scanning electronic microscope the ratio with 500 observe, the photography of taking a picture, its photo is divided into defect part and non-defect part by the image analysis dualization.Try to achieve defect part area occupied rate (%), with this defect level as sintered compact.Defective after the threshing that pore only not, this defective are taken place when being also included within sintered compact being made aforesaid grinding and grinding and polishing, and the defective of the level surface that density of sintered compact is not exerted an influence.Face after the mirror polish of alumina-ceramic of the present invention (No. 1, sample) and extraneous alumina-ceramic of the present invention (No. 22, sample), after doing the photograph photography of scanning electronic microscope, be illustrated in Fig. 1 and Fig. 2 by what the image analysis dualization was divided into defect part and non-defect part.Among the figure, black part is divided the expression defective.
Can understand that from the result of table 3, table 4 ball of the pulverizing usefulness of alumina-ceramic system of the present invention has shown rate of wear below 0.1 and outstanding wear resisting property.In addition, can understand that from the result shown in Fig. 1 and 2 defect level of alumina-ceramic of the present invention is extremely low, only be 0.5%, and by contrast, the defect level that No. 22, sample is high, is 9.6%.Can understand from the result of sample 38 and No. 39, though its one-tenth is grouped within the scope of the invention again,, but if its defect level is many, then wear resisting property is just low, and this defect level is subjected to about median size and formed body volume density institute after the pulverizing in its manufacturing processed.
Can understand from above explanation, according to the present invention, can obtain having the abradability aluminium oxide ceramics of excellent specific property, described alumina-ceramic is because a) because have excellent intensity, hardness, toughness and shock resistance, the wear resisting property under its high loading is good; B) owing to cun have the excellent abrasive energy at the parts of using as pulverizer, thus little abrasion powder sneak into by in the crushed material, and, even there is trace abrasion powder to sneak into,, seldom can damage by the homogeneity of crushed material because it is extremely trickle to wear away powder; C) its raw material can use cheap aluminum oxide.
Thereby alumina-ceramic of the present invention not only can be used as pulverizing, disperses the medium of usefulness, the inner lining material of pulverizer, and the pulverizer member of container, agitator etc. is best suited for the wear member of various industries.
The simple declaration of accompanying drawing
Figure 1 shows that alumina-ceramic of the present invention makes the explanatory view of the dualization image of mirror polish face.
Figure 2 shows that the alumina-ceramic outside the scope of the invention makes the explanatory view of the dualization image of mirror polish face.

Claims (5)

1. an abradability aluminium oxide ceramics is characterized in that, described alumina-ceramic is by Al 2O 3More than 88% (weight), 95% (weight) is following, SiO 23.6-10% (weight), MgO 0.2-2.5% (weight), CaO 0.2-2.5% (weight) and remaining are essentially unavoidable impurity and form; Above-mentioned SiO 2, MgO and CaO the content sum be 5-12% (weight); If above-mentioned SiO 2, MgO and CaO the content sum be 100 o'clock, each components in proportions is respectively SiO 272-85% (weight), MgO 3-25% (weight), CaO 3-25% (weight), above-mentioned unavoidable impurities content is below 0.5% (weight), and ratio of defects is below 5%.
2. abradability aluminium oxide ceramics as claimed in claim 1 is characterized in that, for per 100 weight parts by Al 2O 3More than 88% (weight), 95% (weight) is following, SiO 23.6-10% (weight), MgO 0.2-2.5% (weight), CaO 0.2-2.5% (weight) and remaining are essentially the essentially consist thing that unavoidable impurity is formed, and add ZrO 20.01-15 weight part.
3. abradability aluminium oxide ceramics as claimed in claim 1 is characterized in that, is below 0.2% (weight) as the content of the alkalimetal oxide of above-mentioned unavoidable impurities, TiO 2Below 0.2% (weight).
4. as each described abradability aluminium oxide ceramics of claim 1-3, it is characterized in that the average crystallite particle diameter of described alumina-ceramic is 1.0-5.0 μ m, volume density is 3.60g/cm 3More than.
5. the manufacture method of an alumina-ceramic as claimed in claim 1, it is characterized in that, with fixed ratio cooperate raw material powder, after this mixture is broken to the powder that median size is 0.5-1.0 μ m as micro mist, the micropowder (mold pressing) of gained is shaped as required shape, and obtaining volume density is 1.90-2.10g/cm 3Formed body, this formed body of roasting.
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HK1002557A1 (en) 1998-09-04

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