CN116639950A - 一种大型结构陶瓷成型制备工艺及配方 - Google Patents
一种大型结构陶瓷成型制备工艺及配方 Download PDFInfo
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- 239000000919 ceramic Substances 0.000 title claims abstract description 77
- 238000002360 preparation method Methods 0.000 title claims abstract description 23
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- 239000003795 chemical substances by application Substances 0.000 claims abstract description 23
- 239000002994 raw material Substances 0.000 claims abstract description 19
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 17
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 17
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 17
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- 238000000498 ball milling Methods 0.000 claims description 14
- 239000000395 magnesium oxide Substances 0.000 claims description 13
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 13
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- ATRRKUHOCOJYRX-UHFFFAOYSA-N Ammonium bicarbonate Chemical compound [NH4+].OC([O-])=O ATRRKUHOCOJYRX-UHFFFAOYSA-N 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 2
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- 239000001099 ammonium carbonate Substances 0.000 claims description 2
- 235000012501 ammonium carbonate Nutrition 0.000 claims description 2
- 239000012876 carrier material Substances 0.000 claims description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 2
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- 229910003443 lutetium oxide Inorganic materials 0.000 claims description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 claims description 2
- 229910052863 mullite Inorganic materials 0.000 claims description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
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Abstract
本发明公开了一种大型结构陶瓷成型制备工艺及配方,以质量份数计,包括以下原料:Ai2O3‑55份,SiC‑32份,SiO2‑47份,ZrO2‑29份,黏土‑150份,高岭土‑100份,CaO‑42份,MgO‑25份,本发明配方在主要成分的选择上,充分考虑了各种物理、化学性质对陶瓷材料特性的影响,并采用了更合理的配比和成分组合,相比传统配方,本配方中添加的助熔剂含量较少,能够显著提高制品的耐腐蚀性、稳定性和致密性,本配方通过精细控制原料颗粒的尺寸、形态和组织结构,使制品的机械性能、耐磨性和抗裂性均得到明显改善,避免了制品出现气孔、裂纹、缺陷问题。
Description
技术领域
本发明涉陶瓷材料组合技术领域,尤其是一种大型结构陶瓷成型制备工艺及配方。
背景技术
大型结构陶瓷是指具有高强度、高硬度和高耐磨性等特点的陶瓷制品,广泛应用于石油化工、航天航空、机械制造等领域,其优异的性能得益于其成分配比的科学设计和加工制备工艺的精细控制,通常利用大型陶瓷来替代一些重量与尺寸较大的结构件,比如大理石等。大型陶瓷的成分通常包括A l 2O3、S i C和S iO2等,首先,A l 2O3作为主要成分,具有高强度、高硬度和抗腐蚀优秀性能,经常被用于制备大型结构陶瓷,而S i C具有优异的耐高温性和抗氧化性能,增加陶瓷的耐磨性和机械强度,S iO2和ZrO2也能够提高陶瓷制品的稳定性和高温强度,其次,黏土和高岭土是常见的助熔剂,它们能够在高温下发生部分熔融,使陶瓷颗粒之间结合更紧密,提高陶瓷的致密性和耐磨性,同时,CaO和MgO也能够改变陶瓷的化学成分,增加其机械强度和抗腐蚀性,这种大型结构陶瓷的制备过程需要严格控制原料的配比、粉末颗粒的大小和组织结构因素,以保证制得的陶瓷具有均匀的组织结构和优异的性能,其中,粉末颗粒的大小和组织结构对于陶瓷的致密性和力学性能影响尤为显著,因此需要采用精密的制备技术来控制其粒径和形貌传统配方中常常存在助熔剂含量过高的问题,这会导致制品的致密性和机械性能下降,另外,添加过多的助熔剂,还会产生一些不良反应和物质析出等问题,从而影响陶瓷制品的稳定性和耐用性,传统配方的加工制备技术通常比较简单粗糙,在生产较大体积的陶瓷结构件时,由于难以控制原料颗粒的尺寸、形态和组织结构,容易导致制品的质量存在不稳定性,出现气孔、裂纹等问题,影响陶瓷的机械性能和耐用性,因此,急需一种大型结构陶瓷成型制备工艺及配方。
发明内容
本发明为了解决上述存在的技术问题,提供一种大型结构陶瓷成型制备工艺及配方。
本发明的技术方案是这样实现的:一种大型结构陶瓷成型制备配方,提供一种Ai2O3、S i C、S iO2、ZrO2为主,再添加黏土、高岭土、CaO、MgO做为助熔剂具有不同的化学性质和晶体结构,在高温下相互作用,形成陶瓷材料结构大型结构陶瓷配方。
为了解决上述问题,本发明提供一种大型结构陶瓷配方,以质量分数计,包括以下原料:
Ai2O3-55份
S i C-32份
S i O2-47份
ZrO2-29份
黏土-150份
高岭土-100份
CaO-42份
MgO-25份
本发明要解决的另一个技术方案是,提供上述一种大型结构陶瓷成型制备工艺,目前尚未有将上述Ai2O3、S i C、S iO2、ZrO2为主,再添加黏土、高岭土、CaO、MgO结合制备一种大型结构陶瓷成型制备工艺。
为了解决上述问题,本发明提供了上述一种大型结构陶瓷成型制备工艺,包括以下步骤:
S1:颗粒堆积烧结法,颗粒堆积烧结法是利用颗粒的堆积烧结而形成的三维网络结构;
S2:通过添加与原料组分相同的细微颗粒与助烧剂,利用其在高温下易于产生液相的特点,将大颗粒连接起来,颗粒堆积烧结工艺可通过调整颗粒的粒度级配来控制的孔的结构,以粒径3~12mm的轻质陶粒为骨料;
S3:以水泥为粘结剂,把陶粒(约80wt%)、水泥、粉煤灰和增塑剂和适量的水混合均匀;
S4:制品的显气孔率为38~48%,添加的添加剂Lu2O3可制备出显气孔率为50%,抗压强度达到188MPa的高纯度多孔S i3N4陶瓷;
S5:添加造孔剂法是在配料过程中,在陶瓷浆料中添加一定量的造孔剂;
S6:通过球磨工艺使其均匀分散在浆料中,成型、干燥后,造孔剂在陶瓷生坯中占据体积;
S7:所添加的造孔剂在高温烧结过程中应易于排除且不能与陶瓷基体发生反应,被用作造孔剂的原料有碳酸铵、碳粉、淀粉、甲基丙烯酸甲酯、木屑物质;
S8:在高温条件下,造孔剂被燃烧,在烧结制品中留下气孔,制备成多孔陶瓷。
所述述步骤S1中利用其在高温下易于产生液相的特点,在高温温度下,将大颗粒连接起来,颗粒堆积烧结工艺可通过调整颗粒的粒度级配来控制的孔的结构。
所述步骤S2中将酸浸后的煤矸石与介质无水乙醇按一定的比例混合,在星型球磨机中球磨4h,80℃干燥,然后将煤矸石粉研磨均匀后过200目筛,即得预处理过得陶瓷骨料。
所述步骤S4中利用可燃烧的多孔载体吸附陶瓷料浆,经干燥、烧结后,载体材料被烧尽后在坯体内留下气孔,从而获得孔隙分布均匀的多孔陶瓷,气孔率最高可达到95%。
所述步骤S5以煤矸石中所含有的有机质为造孔剂制备多孔陶瓷的烧结工艺;再添加淀粉造孔剂进一步提高多孔陶瓷的显气孔率,并利用莫来石纤维改善了多孔陶瓷的高温收缩特性;最后以煤矸石为主要原料,配以适量氧化铝和氧化镁。
所述步骤S6对煤矸石进行破碎、球磨和过筛处理,是其得以资源化利用的前提条件,通过破碎、球磨可以使煤矸石的表面能增加,使其在高温烧结时,反应活性增大,通过过筛处理获得粒径和成分均匀的粉末。
有益效果
本发明配方在主要成分的选择上,充分考虑了各种物理、化学性质对陶瓷材料特性的影响,并采用了更合理的配比和成分组合,相比传统配方,本配方中添加的助熔剂含量较少,能够显著提高制品的耐腐蚀性、稳定性和致密性,本配方通过精细控制原料颗粒的尺寸、形态和组织结构,使制品的机械性能、耐磨性和抗裂性均得到明显改善,避免了制品出现气孔、裂纹、缺陷问题。
附图说明
图1是本发明的一种大型结构陶瓷成型制备工艺示意图。
具体实施方式
本发明的有益效果是:一种大型结构陶瓷成型制备配方,以质量份数计,包括以下原料:Ai2O3-55份,S i C-32份,SiO2-47份,ZrO2-29份,黏土-150份,高岭土-100份,CaO-42份,MgO-25份,本发明还进一步地提供了上述一种大型结构陶瓷成型制备工艺,包括S1至S8步骤,通过本发明制备获得的多孔陶瓷材料的孔径分布范围从纳米到毫米,显气孔率最低20%,最高可达95%以上,使用温度可高达1600℃,针对制备出机械强度高、耐酸碱腐蚀以及寿命长具有优异性能且区别于传统陶瓷材料的多孔陶瓷材料,以煤矸石为原料,以0.075mm方孔筛的细煤矸石5%CaO+3%A l2O3+2%MgO混合料为助烧剂,在不同烧结温度的作用下,考察显气孔率和抗压强度的变化,结果表明5%CaO+3%A l2O3+2%MgO混合料的助烧效果明显优于细煤矸石,以混合料为助烧剂、1250℃烧结的样品,其抗压强度和显气孔率分别为20.71MPa和34.97%,而添加细煤矸石的样品,抗压强度和显气孔率分别为为0.75MPa和50.75%。
具体实施方式为使本发明的目的、技术方案及优点更加清楚明白,以下结合实施例,对本发明进行进一步的详细说明。
此处所描述的具体实施例仅用于解释本发明,并不用于限定发明。
实施例1一种大型结构陶瓷成型制备配方为:Ai2O3-55份,Si C-32份,Si O2-47份,ZrO2-29份,黏土-150份,高岭土-100份,CaO-42份,MgO-25份;
进一步地提供了上述一种大型结构陶瓷成型制备工艺:
S1、将上述材料按照质量分数比例进行预混合;
S2、将预混合后的材料置于球磨机中进行4小时的球磨,使其达到更均匀的颗粒大小和颗粒分布,球磨机参数:转速600r/mi n,球磨体积60%;
S3、将球磨后的材料取出,加入适量的水和粘结剂,并进行充分混合,粘结剂用量为原材料总重量的1%;
S4、在压力机中将混合后的材料放入模具中进行压制,形成坯体。压制压力为200MPa,压制时间为5mi n;
S5、对坯体进行干燥处理,在200℃下进行12小时干燥,使其完全干燥;
S6、施加脱脂和高温烧结处理,最终得到大型结构陶瓷制品,烧结温度为1650℃,保温时间为3小时,降温速率为5℃/mi n。
实施例2一种大型结构陶瓷成型制备配方为:Ai2O3-75份,Si C-44份,Si O2-63份,ZrO2-31份,黏土-150份,高岭土-100份,CaO-47份,MgO-36份;
进一步地提供了上述一种大型结构陶瓷成型制备工艺:
S1、将上述材料按照质量分数比例进行预混合;
S2、将预混合后的材料置于星型球磨机中进行3小时的球磨,使其达到更均匀的颗粒大小和颗粒分布。球磨机参数:转速100r/mi n,球磨体积50%;
S3、将球磨后的材料取出,加入适量的水和粘结剂,并进行充分混合,粘结剂用量为原材料总重量的1.5%;
S4、在压力机中将混合后的材料放入模具中进行压制,形成坯体,压制压力为220MPa,压制时间为6mi n;
S5、对坯体进行干燥处理,在220℃下进行10小时干燥,使其完全干燥;
S6、施加脱脂和高温烧结处理,最终得到大型结构陶瓷制品,烧结温度为1600℃,保温时间为4小时,降温速率为3℃/mi n。
实施例3一种大型结构陶瓷成型制备配方为:Ai2O3-64份,Si C-32份,Si O2-41份,ZrO2-37份,黏土-150份,高岭土-100份,CaO-55份,MgO-23份;
进一步地提供了上述一种大型结构陶瓷成型制备工艺:
S1、将上述材料按照质量分数比例进行预混合;
S2、将预混合后的材料置于球磨机中进行5小时的球磨,使其达到更均匀的颗粒大小和颗粒分布,球磨机参数:转速800r/mi n,球磨体积55%;
S3、将球磨后的材料取出,加入适量的水和粘结剂,并进行充分混合。粘结剂用量为原材料总重量的2%;
S4、在压力机中将混合后的材料放入模具中进行压制,形成坯体。压制压力为230MPa,压制时间为7mi n;
S5、对坯体进行干燥处理,在240℃下进行8小时干燥,使其完全干燥;
S6、施加脱脂和高温烧结处理,最终得到大型结构陶瓷制品,烧结温度为1700℃,保温时间为2小时,降温速率为4℃/mi n。
本发明提供的一种大型结构陶瓷成型制备工艺及配方制备获得的多孔陶瓷材料的孔径分布范围从纳米到毫米,显气孔率最低20%,最高可达95%以上,使用温度可高达1600℃,针对制备出机械强度高、耐酸碱腐蚀以及寿命长具有优异性能且区别于传统陶瓷材料的多孔陶瓷材料。本发明的技术方案不限于上述具体实施例的限制,凡是根据本发明的技术方案做出的技术变形,均落入本发明的保护范围之内。
Claims (9)
1.一种大型结构陶瓷成型制备配方,其特征在于:以质量分数计,
包括以下原料:Ai2O3-55份,SiC-32份,SiO2-47份,ZrO2-29份,黏土-150份,高岭土-100份,CaO-42份,MgO-25份。
2.根据权利要求1所述的一种大型结构陶瓷成型制备配方,其特征在于,包括以下原料:Ai2O3-75份,SiC-44份,SiO2-63份,ZrO2-31份,黏土-150份,高岭土-100份,CaO-47份,MgO-36份。
3.根据权利要求1所述的一种大型结构陶瓷成型制备配方,其特征在于,包括以下原料:Ai2O3-64份,SiC-32份,SiO2-41份,ZrO2-37份,黏土-150份,高岭土-100份,CaO-55份,MgO-23份。
4.根据权利要求1-3所述的一种大型结构陶瓷成型制备工艺,其特征在于,包括以下步骤:
S1:颗粒堆积烧结法,颗粒堆积烧结法是利用颗粒的堆积烧结而形成的三维网络结构;
S2:通过添加与原料组分相同的细微颗粒与助烧剂,利用其在高温下易于产生液相的特点,将大颗粒连接起来,颗粒堆积烧结工艺可通过调整颗粒的粒度级配来控制的孔的结构,以粒径3~12mm的轻质陶粒为骨料;
S3:以水泥为粘结剂,把陶粒(约80wt%)、水泥、粉煤灰和增塑剂和适量的水混合均匀;
S4:制品的显气孔率为38~48%,添加的添加剂Lu2O3可制备出显气孔率为50%,抗压强度达到188MPa的高纯度多孔Si3N4陶瓷;
S5:添加造孔剂法是在配料过程中,在陶瓷浆料中添加一定量的造孔剂;
S6:通过球磨工艺使其均匀分散在浆料中,成型、干燥后,造孔剂在陶瓷生坯中占据体积;
S7:所添加的造孔剂在高温烧结过程中应易于排除且不能与陶瓷基体发生反应,被用作造孔剂的原料有碳酸铵、碳粉、淀粉、甲基丙烯酸甲酯、木屑物质;
S8:在高温条件下,造孔剂被燃烧,在烧结制品中留下气孔,制备成多孔陶瓷。
5.根据权利要求4所述的一种大型结构陶瓷成型制备工艺,其特征在于:所述述步骤S1中利用其在高温下易于产生液相的特点,在高温温度下,将大颗粒连接起来,颗粒堆积烧结工艺通过调整颗粒的粒度级配来控制的孔的结构。
6.根据权利要求4所述的一种大型结构陶瓷成型制备工艺,其特征在于:所述步骤S2中将酸浸后的煤矸石与介质无水乙醇按一定的比例混合,在星型球磨机中球磨4h,80℃干燥,然后将煤矸石粉研磨均匀后过200目筛,即得预处理过得陶瓷骨料。
7.根据权利要求4所述的一种大型结构陶瓷成型制备工艺及配方,其特征在于:所述步骤S4中利用可燃烧的多孔载体吸附陶瓷料浆,经干燥、烧结后,载体材料被烧尽后在坯体内留下气孔,从而获得孔隙分布均匀的多孔陶瓷,气孔率最高可达到95%。
8.根据权利要求4所述的一种大型结构陶瓷成型制备工艺,其特征在于:所述步骤S5以煤矸石中所含有的有机质为造孔剂制备多孔陶瓷的烧结工艺;再添加淀粉造孔剂进一步提高多孔陶瓷的显气孔率,并利用莫来石纤维改善了多孔陶瓷的高温收缩特性;最后以煤矸石为主要原料,配以适量氧化铝和氧化镁。
9.根据权利要求4所述的一种大型结构陶瓷成型制备工艺,其特征在于:所述步骤S6对煤矸石进行破碎、球磨和过筛处理,是其得以资源化利用的前提条件,通过破碎、球磨可以使煤矸石的表面能增加,使其在高温烧结时,反应活性增大,通过过筛处理获得粒径和成分均匀的粉末。
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