CN1872793A - 氧化物结合碳化硅质材料 - Google Patents
氧化物结合碳化硅质材料 Download PDFInfo
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- CN1872793A CN1872793A CNA2006100825480A CN200610082548A CN1872793A CN 1872793 A CN1872793 A CN 1872793A CN A2006100825480 A CNA2006100825480 A CN A2006100825480A CN 200610082548 A CN200610082548 A CN 200610082548A CN 1872793 A CN1872793 A CN 1872793A
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- Prior art keywords
- silicon carbide
- oxide
- carbide material
- bonded
- bonded silicon
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 229910010271 silicon carbide Inorganic materials 0.000 title claims abstract description 142
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 title claims abstract description 121
- 239000000463 material Substances 0.000 title claims abstract description 88
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 60
- 239000002245 particle Substances 0.000 claims abstract description 36
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 30
- 235000012239 silicon dioxide Nutrition 0.000 claims abstract description 30
- 239000013078 crystal Substances 0.000 claims abstract description 13
- 230000005484 gravity Effects 0.000 claims abstract description 10
- 239000011148 porous material Substances 0.000 claims abstract description 5
- 229960001866 silicon dioxide Drugs 0.000 claims description 29
- 239000004615 ingredient Substances 0.000 claims description 14
- 150000001875 compounds Chemical class 0.000 claims description 13
- 239000000470 constituent Substances 0.000 claims description 13
- 238000000465 moulding Methods 0.000 claims description 12
- 229910052723 transition metal Inorganic materials 0.000 claims description 11
- 150000003624 transition metals Chemical class 0.000 claims description 11
- 210000000981 epithelium Anatomy 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 229910010293 ceramic material Inorganic materials 0.000 abstract description 4
- 238000005452 bending Methods 0.000 abstract description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 abstract 1
- 239000011819 refractory material Substances 0.000 abstract 1
- 230000000052 comparative effect Effects 0.000 description 40
- 230000009970 fire resistant effect Effects 0.000 description 12
- 230000035939 shock Effects 0.000 description 7
- 238000005245 sintering Methods 0.000 description 7
- 230000003647 oxidation Effects 0.000 description 6
- 238000007254 oxidation reaction Methods 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 238000005266 casting Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 210000001519 tissue Anatomy 0.000 description 4
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 3
- 229910004298 SiO 2 Inorganic materials 0.000 description 3
- 229920002125 Sokalan® Polymers 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 150000001735 carboxylic acids Chemical class 0.000 description 3
- 239000000839 emulsion Substances 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- 239000004584 polyacrylic acid Substances 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910052602 gypsum Inorganic materials 0.000 description 2
- 239000010440 gypsum Substances 0.000 description 2
- -1 metal oxide compound Chemical class 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229910021654 trace metal Inorganic materials 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
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Abstract
本发明提供一种氧化物结合碳化硅质材料,该材料与目前主要使用的高强度陶瓷材料(例如氧化铝、Si浸透型SiC或再结晶型SiC质耐火材料)相比,强度毫不逊色,而且容易提高批量生产性以及制造大型制品,并且不仅容易地制作形状复杂的制品,还可以大幅度减少制造成本。其为实质上由碳化硅构成,具有碳化硅晶粒、其晶界以及气孔,并且具有以主成分为二氧化硅的氧化物结合碳化硅晶粒的结构的氧化物结合碳化硅质材料。在常温和高温时的弯曲强度大于等于100MPa,并且松比重大于等于2.65。
Description
技术领域
本发明涉及氧化物结合碳化硅质材料。
背景技术
以往,碳化硅(SiC)质耐火材料由于具有优异的耐热性和耐火性而在工业上占据着重要的位置,例如较多地用于陶瓷器烧成用塔板(安装器)、支撑板、套、安装器支柱、梁或辊、其他窑具等。作为这种SiC质耐火材料的一种,已知有所谓的氧化物结合SiC质耐火材料,也就是通过将SiC粒子与微量金属氧化物等一起混练并成型后,在氧化性气氛中烧成而使SiC粒子部分氧化,根据其部分氧化而生成的二氧化硅(SiO2)来结合SiC粒子。该氧化物结合SiC质烧结体由于廉价,因此被广泛地用作为陶瓷器烧成用窑具(参照特许第3373312号公报)。
但是,氧化物结合SiC质耐火材料与将SiC粒子用由氮化硅等构成的结合材料结合而形成的所谓Si浸透型SiC或再结晶型SiC质耐火材料相比,由于强度级别低、耐蠕变性也差,因此通常寿命短。
另外,最近为了提高生产效率和节能等,进行迅速烧成的情况较多,对于窑具的负荷也变大。从这种背景来看,要求氧化物结合SiC质耐火材料的耐裂性、耐氧化性、耐蠕变性等特性的改善,但是这些诸特性的改善存在着较多相反的要素,难以互相兼顾着提高。
为了解决上述问题,揭示了例如使用相对于最大粒径为4mm或4mm以下的SiC粉末添加0.01~0.7质量%的V2O5、0.01~0.7质量%的CaO以及0.01~5质量%的粘土而得到的粉体所制作的氧化物结合SiC质窑具及其制造方法(参照特许第3373312号公报)。
但是,上述氧化物结合SiC质耐火材料与Si浸透型SiC或再结晶型SiC质耐火材料相比,由于强度低,因此用作为制品时不仅要求厚重,而且在耐蠕变性和耐热冲击性方面也并不充分。
发明内容
本发明鉴于上述以往技术中存在的问题而完成,其目的在于,提供一种氧化物结合碳化硅质材料,该材料与目前主要使用的高强度陶瓷材料(例如氧化铝、Si浸透型SiC或再结晶型SiC质耐火材料)相比,强度毫不逊色,而且由于烧成引起的制品膨胀收缩也小,因此容易提高批量生产性以及制造大型制品,容易地制作形状复杂的制品,并且由于能够在大气氛围下烧成,从而可以大幅度减少制造成本。
为了实现上述目的,本发明提供如下的氧化物结合碳化硅质材料。
[1]一种氧化物结合碳化硅质材料,其为实质上由碳化硅构成,具有所述碳化硅晶粒、其晶界以及气孔,并且具有以主成分为二氧化硅的氧化物结合所述碳化硅晶粒的结构的氧化物结合碳化硅质材料,在常温时和高温时的弯曲强度为100MPa~300MPa,并且松比重为2.65~2.90。
[2]上述[1]所述的氧化物结合碳化硅质材料,其特征为,所述碳化硅晶粒实质上是含有粒径大的骨材和由微细的碳化硅晶粒构成的微粒的混合粒子,并且骨材的最大粒径为50~200μm,同时微粒的最大粒径为0.05μm~10μm。
[3]上述[1]或[2]所述的氧化物结合碳化硅质材料,其特征为,在所述骨材的周围均匀地分散有微粒,并且结合部具有微粒和以二氧化硅为主成分的氧化物同时混杂的结构。
[4]上述[1]~[3]中的任一项所述的氧化物结合碳化硅质材料,其特征为,结合碳化硅晶粒的结合部,由以二氧化硅为主成分的氧化物构成,并且在结合部含有从原子序号22~29的过渡金属元素中选择的至少一种作为微量成分。
[5]上述[1]~[4]中的任一项所述的氧化物结合碳化硅质材料,其特征为,碳化硅为85~99.5质量%,二氧化硅为0.45~10质量%,作为微量成分含有换算成氧化物为0.05~5.0质量%的从原子序号22~29的过渡金属元素中选择的至少一种。
[6]上述[1]~[5]中的任一项所述的氧化物结合碳化硅质材料,其特征为,在表面形成含有从原子序号22~29的过渡金属元素中选择的至少一种且以二氧化硅为主成分的皮膜。
[7]上述[1]~[6]中的任一项所述的氧化物结合碳化硅质材料,其特征为,浇铸成型作为氧化物结合碳化硅质材料前驱体的成型体后,在大气氛围下进行烧成。
本发明的氧化物结合碳化硅质材料,与目前主要使用的高强度陶瓷材料(例如氧化铝、Si浸透型SiC或再结晶型SiC质耐火材料)相比,强度毫不逊色,并且容易提高批量生产性以及制造大型制品,还容易制作形状复杂的制品,并且能够大幅度减少制造成本。
附图说明
图1是表示本发明的氧化物结合碳化硅质材料的微观结构的SEM(扫描电子显微镜)照片。
图2是表示以往的氧化物结合碳化硅质材料的微观结构的SEM(扫描电子显微镜)照片。
具体实施方式
下面,说明本发明的实施方式,但本发明并不限于以下的实施方式,在不脱离本发明宗旨的范围内,可以根据本领域技术人员的常识进行适当的方案变更和改良等。
图1是表示本发明的氧化物结合碳化硅质材料的微观结构的SEM(扫描电子显微镜)照片,图2是表示以往的氧化物结合碳化硅质材料的微观结构的SEM(扫描电子显微镜)照片。
本发明涉及的氧化物结合碳化硅质材料,为实质上由碳化硅构成,具有所述碳化硅晶粒、其晶界以及气孔,并且具有以主成分为二氧化硅的氧化物结合碳化硅晶粒的结构的氧化物结合碳化硅质材料,在常温时和高温时的弯曲强度大于等于100MPa,并且松比重大于等于2.65。
这里,本发明的氧化物结合碳化硅质材料的主要特征为,如图1所示,与以往的氧化物结合碳化硅质材料(参照图2)相比,能够控制碳化硅晶粒和二氧化硅的组织,致密地进行烧结,因此可以实现4倍或4倍以上的在常温时和高温时的弯曲强度。
即,本发明的氧化物结合碳化硅质材料,优选在常温时和高温时的弯曲强度大于等于100MPa(更优选为120~300MPa,进一步优选为150~300MPa)。这是由于,作为控制碳化硅晶粒和二氧化硅的组织,致密地烧结而将微观结构组织控制在最佳状态的结果,在常温时和高温时的弯曲强度会大于等于100MPa,当组织控制或致密烧结的微观结构组织不适当时,将不足100MPa,因此并非优选。优选上限300MPa是以现状的发明产品的构成可以现实实现的上限,事实上超过该上限的情况产生的问题少。
另外,本发明的氧化物结合碳化硅质材料,优选松比重大于等于2.65(优选为2.65~2.90,进一步优选为2.65~2.85)。松比重超过优选上限2.90时,在烧成过程中氧的浸透少,在结合部不会充分地生成二氧化硅,因此并非优选。
进而,本发明的氧化物结合碳化硅质材料,从实际上用作制品的角度考虑,优选耐热冲击温度大于等于600℃。
接着,本发明的氧化物结合碳化硅质材料的另一特征为,碳化硅晶粒实质上是含有粒径大的骨材和由微细的碳化硅晶粒构成的微粒的混合粒子,并且骨材的最大粒径为50~200μm,同时微粒的最大粒径为10μm或10μm以下。
此时,本发明的氧化物结合碳化硅质材料,优选在骨材的周围均匀地分散有微粒,并且结合部具有微粒和以二氧化硅为主成分的氧化物同时混杂的结构。
这里,在本发明中使用的骨材的最大粒径优选为50~200μm(更优选为50~120μm)。这是因为,如果骨材的最大粒径超过200μm,碳化硅晶粒会发生破坏,在常温时和高温时的弯曲强度会下降。另一方面,当骨材的最大粒径小于50μm时,碳化硅粒子的填充密度下降,所得到的制品的密度下降。如果密度下降,则气孔率会增大,导致比表面积增大。如果比表面积增大,则在高温氧化性氛围中使用时,与氧的接触面积增大而容易使碳化硅氧化,导致寿命变短。另外,还容易引起烧成时的氧化,因此并非优选。
另外,在本发明中使用的微粒优选必须含有实质上小于等于10μm(优选0.05~10μm,进一步优选小于等于1μm)的微粉。如果低于优选下限,则SiC粒子的填充恶化,制造的材料自身的比重会降低,从而并非优选。由此,粒子可以填充到作为骨材的晶粒的晶界空隙中,实现最密填充,因此有利于作为骨材的碳化硅晶粒间的结合。即,含有骨材和微粒的混合粒子(微细的碳化硅)在烧成时被氧化,作为二氧化硅(氧化物)形成将骨材间相互结合的结合部,有利于所得到的氧化物结合碳化硅质材料在常温时和高温时的弯曲强度的高强度化。
特别是,本发明的氧化物结合碳化硅质材料,通过作为上述骨材配合100~200μm的碳化硅粒子20~55质量%、50~100μm的碳化硅粒子2~18质量%,同时作为上述微粒配合1~10μm的碳化硅粒子10~35质量%、小于等于1μm(更优选为0.05~1μm)的碳化硅粒子15~45质量%,可以最大限度地发挥本发明的特性。
另外,本发明的氧化物结合碳化硅质材料,结合碳化硅晶粒的结合部由主成分为二氧化硅的氧化物构成。二氧化硅主要起到结合碳化硅晶粒的作用,但如果二氧化硅的含量过多(超过10质量%),则氧化物结合碳化硅质材料的耐蠕变性就会下降,另一方面,如果二氧化硅的含量过少(低于0.45质量%),则结合碳化硅晶粒的作用下降,在常温时和高温时的弯曲强度下降。
进而,本发明的氧化物结合碳化硅质材料,优选结合碳化硅晶粒的结合部由主成分为二氧化硅的氧化物构成,并且在结合部含有从原子序号22~29的过渡金属元素中选出的至少一种作为微量成分。
特别是优选碳化硅为85~99.5质量%,二氧化硅为0.45~10质量%,作为微量成分含有换算成氧化物为0.05~5.0质量%的从原子序号22~29的过渡金属元素中选出的至少一种。
即,本发明的氧化物结合碳化硅质材料,在构成结合碳化硅晶粒的结合部的二氧化硅中,添加从原子序号22~29的过渡金属元素中选出的至少一种作为微量成分。
此时,如果微量成分的添加量过多(超过5质量%),则高温时的弯曲强度下降,耐氧化性和耐蠕变性也会下降,另一方面,如果微量成分的添加量过少(低于0.05质量%),则耐氧化性下降。
另外,本发明的氧化物结合碳化硅质材料,优选在表面形成含有从原子序号22~29的过渡金属元素中选出的至少一种且以二氧化硅为主成分的皮膜。这是因为,通过在碳化硅表面形成皮膜,可以回避在制品的使用过程中产生的氧化,或者与碳化硅直接接触时产生的反应等问题。
接着,本发明的氧化物结合碳化硅质材料的主要特征为,(1)适当地调节碳化硅和二氧化硅的粒度配合及微量成分或水等的添加,制作泥浆,(2)浇铸成型后,对作为氧化物结合碳化硅质材料前驱体的成型体进行干燥,(3)在大气氛围下进行烧成。优选将在步骤(1)制作的泥浆的水添加量调节在8~16质量%,这样可以将烧成后的制品的尺寸膨胀抑制在0~0.5%。
另外,在步骤(1)制作的泥浆中优选添加分散材料和/或粘合剂。此时,在步骤(1)制作的泥浆优选添加分散材料,但并不一定要添加粘合剂。作为分散材料没有特别限制,可以适宜地使用聚羧酸铵、丙烯酸酯共聚物、聚乙烯亚胺、硅酸钠。另外,作为粘合剂没有特别限制,可以适宜地使用聚丙烯酸乳液、羧甲基纤维素或聚乙烯醇。
这里,本发明的氧化物结合碳化硅质材料,要将在步骤(1)制作的泥浆浇铸成型为作为氧化物结合碳化硅质材料前驱体的成型体,这是重要的。由此,本发明的氧化物结合碳化硅质材料,控制烧成时的碳化硅晶粒和二氧化硅的组织,致密地烧结,因此与以往的氧化物结合碳化硅质材料相比,可以实现4倍或4倍以上的在常温时和高温时的弯曲强度。另外,本发明的氧化物结合碳化硅质材料,通过使用浇铸成型,与目前主要使用的高强度陶瓷材料(例如氧化铝、Si浸透型SiC或再结晶型SiC质耐火材料)相比,强度毫不逊色,而且由于烧成引起的制品膨胀收缩也小,因此容易提高批量生产性以及制造大型制品,容易地制作形状复杂的制品。另外,通过使用廉价的浇铸成型,生产时不需要投资大型的加压装置或挤压成型机等。并且,在制造Si浸透型SiC或再结晶型SiC质耐火材料时,氛围调节炉是不可缺少的,但是本发明的氧化物结合碳化硅质材料,由于能够在大气氛围下烧成,因此不需要昂贵的设备,能够大幅度削减制造成本。
这里,浇铸成型是将陶瓷等粉体分散到水等液体中制成浆液状,将其注入成型模具内进行固化,从而将粉体成型为规定形状的方法,其优点在于,将所得成型品的成型体密度确保在必要水平的同时,能够比较容易地制造出形状复杂的成型体。
实施例
下面,根据实施例具体地说明本发明,但本发明并不限于这些实施例。
实施例1~8、比较例1~3
将SiC和SiO2调制成烧成后成为如表1所示的组成,同时作为微量成分添加换算成氧化物为1质量%的表1所示的添加剂,进而添加分散材料(物质名:聚羧酸铵)、粘合剂(物质名:聚丙烯酸乳液)及水,将50kg得到的混合物利用球磨机混合24小时,分别得到泥浆。将得到的泥浆在真空中脱泡处理30分钟后,用在石膏模具中浇注泥浆的浇铸成型法,分别得到成型体。将得到的成型体在大气氛围下在1400℃烧成,得到作为氧化物结合碳化硅质材料的烧结体(尺寸:400mm×400mm×10mm)。分别测定所得到的烧结体的特性(松比重、在常温及1300℃时的弯曲强度、在1300℃时的耐氧化性、耐蠕变性及耐热冲击温度),将其结果示于表1中。
这里,所得到的烧结体的密度(松密度)及弯曲强度按照以下方法测定。
(1)烧结体的密度(松密度)的测定
根据“JIS R 2205耐火砖的表观气孔率、吸水率、比重的测定方法”测定密度(松密度)。
(2)烧结体的弯曲强度试验
根据“JIS R 1601微细陶瓷的弯曲强度试验方法”中的四点弯曲强度进行测定。
表1
组成(质量%) | 添加剂 | 配合 | 密度 | 弯曲强度[MPa] | 1300℃耐氧化性[ppm/hr] | 耐蠕变性[mm] | 耐热冲击温度(℃) | |||||
SiC | SiO2 | 微量成分原子序号 | 微量成分 | 最大粒径(μm) | 有无10μm≥的粒子 | 松比重 | 常温 | 1300℃ | ||||
实施例1 | 95 | 4 | 22 | Ti | 100 | 有 | 2.73 | 244 | 235 | 0.7 | 0.5 | 650 |
实施例2 | 95 | 4 | 23 | V | 100 | 有 | 2.75 | 213 | 221 | 0.9 | 0.4 | 750 |
实施例3 | 95 | 4 | 24 | Cr | 100 | 有 | 2.74 | 185 | 203 | 0.5 | 0.3 | 650 |
实施例4 | 95 | 4 | 25 | Mn | 100 | 有 | 2.75 | 167 | 175 | 0.7 | 0.4 | 700 |
实施例5 | 95 | 4 | 26 | Fe | 100 | 有 | 2.75 | 194 | 189 | 0.6 | 0.5 | 600 |
实施例6 | 95 | 4 | 27 | Co | 100 | 有 | 2.75 | 175 | 182 | 0.8 | 0.6 | 650 |
实施例7 | 95 | 4 | 28 | Ni | 100 | 有 | 2.75 | 234 | 210 | 0.8 | 0.3 | 700 |
实施例8 | 95 | 4 | 29 | Cu | 100 | 有 | 2.74 | 226 | 230 | 0.7 | 0.3 | 650 |
比较例1 | 95 | 4 | 19 | K | 100 | 有 | 2.63 | 150 | 10 | 10.1 | 5 | 325 |
比较例2 | 95 | 4 | 21 | Sc | 100 | 有 | 2.61 | 65 | 31 | 15.3 | 3 | 300 |
比较例3 | 95 | 4 | 30 | Zn | 100 | 有 | 2.61 | 62 | 34 | 9.5 | 4 | 300 |
*添加剂:换算成氧化物添加1质量%
考察:实施例1~8、比较例1~3
如表1所示,对于实施例1~8,通过在泥浆中添加原子序号22~29的过渡金属元素Ti、V、Cr、Mn、Fe、Co、Ni、Cu作为微量成分,所得到的烧结体的所有特性(在常温及1300℃时的弯曲强度、在1300℃时的耐氧化性、耐蠕变性及耐热冲击温度)良好。另一方面,对于比较例1~3,所得到的烧结体的特性不充分。
实施例9~21、比较例4~28
将具有表2所示的粒子配合的SiC、SiO2及V2O5调制成烧成后成为如表2所示的组成,进而添加分散材料(物质名:聚羧酸铵)、粘合剂(物质名:聚丙烯酸乳液)及水,将50kg得到的混合物利用球磨机混合24小时,分别得到泥浆。将得到的泥浆在真空中脱泡处理30分钟后,用在石膏模具中浇注泥浆的浇铸成型法,分别得到成型体。将得到的成型体在大气氛围下在1400℃烧成,得到作为氧化物结合碳化硅质材料的烧结体(尺寸:400mm×400mm×10mm)。分别测定所得到的烧结体的特性(松比重、在常温及1300℃时的弯曲强度、在1300℃时的耐氧化性、耐蠕变性及耐热冲击温度),将其结果示于表2中。这里,实施例17与实施例2相同。
表2
组成(质量%) | SiC粒子配合 | 密度 | 弯曲强度[MPa] | 1300℃耐氧化性[ppm/hr] | 耐蠕变性[mm] | 耐热冲击温度(℃) | |||||
SiC | SiO2 | V2O5 | 最大粒径(μm) | 有无10μm≥的粒子 | 松比重 | 常温 | 1300℃ | ||||
实施例9 | 85 | 10 | 5 | 100 | 有 | 2.65 | 165 | 172 | 0.8 | 0.5 | 650 |
实施例10 | 87 | 8 | 5 | 100 | 有 | 2.77 | 213 | 211 | 0.7 | 0.7 | 775 |
实施例11 | 90 | 9.95 | 0.05 | 100 | 有 | 2.75 | 179 | 180 | 0.8 | 0.8 | 700 |
实施例12 | 90 | 9.9 | 0.1 | 100 | 有 | 2.75 | 181 | 182 | 0.1 | 0.6 | 725 |
实施例13 | 90 | 9 | 1 | 100 | 有 | 2.76 | 200 | 203 | 0.9 | 0.5 | 750 |
实施例14 | 93 | 6.5 | 0.5 | 100 | 有 | 2.70 | 189 | 179 | 0.7 | 0.5 | 700 |
实施例15 | 95 | 4 | 1 | 100 | 有 | 2.75 | 210 | 211 | 0.7 | 0.4 | 725 |
实施例16 | 95 | 4 | 1 | 200 | 有 | 2.74 | 153 | 149 | 0.7 | 0.6 | 675 |
实施例17 | 95 | 4 | 1 | 100 | 有 | 2.75 | 213 | 221 | 0.9 | 0.4 | 750 |
实施例18 | 95 | 4 | 1 | 50 | 有 | 2.70 | 257 | 267 | 0.9 | 0.6 | 725 |
实施例19 | 95 | 4 | 1 | 30 | 有 | 2.65 | 312 | 310 | 0.7 | 0.6 | 700 |
实施例20 | 99 | 0.8 | 0.2 | 100 | 有 | 2.73 | 190 | 193 | 0.7 | 0.7 | 675 |
实施例21 | 99.5 | 0.45 | 0.05 | 100 | 有 | 2.76 | 135 | 145 | 0.6 | 0.7 | 700 |
比较例4 | 70 | 29 | 1 | 100 | 有 | 2.43 | 132 | 95 | 1.3 | 4.5 | 375 |
比较例5 | 70 | 15 | 15 | 100 | 有 | 2.41 | 151 | 31 | 16.1 | 2.8 | 350 |
比较例6 | 80 | 13 | 7 | 100 | 有 | 2.49 | 131 | 42 | 5.9 | 2.5 | 325 |
比较例7 | 80 | 19 | 1 | 100 | 有 | 2.51 | 153 | 118 | 2.1 | 3.1 | 350 |
比较例8 | 80 | 19.98 | 0.02 | 100 | 有 | 2.51 | 131 | 120 | 20.1 | 3.8 | 350 |
比较例9 | 80 | 17 | 3 | 100 | 有 | 2.53 | 133 | 38 | 3.0 | 2.9 | 375 |
比较例10 | 84 | 14 | 2 | 100 | 有 | 2.55 | 142 | 131 | 2.3 | 2.3 | 300 |
比较例11 | 84 | 9 | 7 | 100 | 有 | 2.55 | 154 | 35 | 5.4 | 1.5 | 375 |
比较例12 | 88 | 6 | 6 | 100 | 有 | 2.70 | 183 | 62 | 3.3 | 1.6 | 375 |
比较例13 | 90 | 0.3 | 9.7 | 100 | 有 | 2.71 | 78 | 48 | 13.1 | 1.3 | 325 |
比较例14 | 90 | 0.5 | 9.5 | 100 | 有 | 2.70 | 136 | 50 | 10.3 | 1.4 | 325 |
比较例15 | 90 | 1 | 9 | 100 | 有 | 2.73 | 188 | 57 | 10.1 | 1.4 | 350 |
比较例16 | 90 | 4 | 6 | 100 | 有 | 2.71 | 184 | 66 | 5.1 | 1.5 | 350 |
比较例17 | 90 | 10 | 0 | 100 | 有 | 2.77 | 177 | 44 | 30.5 | 0.5 | 375 |
比较例18 | 90 | 9.97 | 0.03 | 100 | 有 | 2.70 | 167 | 153 | 11.3 | 0.5 | 300 |
比较例19 | 90 | 4 | 6 | 100 | 有 | 2.70 | 200 | 50 | 3.1 | 1.3 | 350 |
比较例20 | 90 | 3 | 7 | 100 | 有 | 2.69 | 214 | 45 | 5.3 | 1.2 | 350 |
比较例21 | 95 | 4 | 1 | 1000 | 有 | 2.81 | 43 | 42 | 0.9 | 0.5 | 325 |
比较例22 | 95 | 4 | 1 | 700 | 有 | 2.75 | 52 | 53 | 0.6 | 0.4 | 375 |
比较例23 | 95 | 4 | 1 | 500 | 有 | 2.72 | 68 | 66 | 0.7 | 0.6 | 375 |
比较例24 | 95 | 4 | 1 | 200 | 无 | 2.43 | 50 | 49 | 1.3 | 0.5 | 325 |
比较例25 | 95 | 4 | 1 | 100 | 无 | 2.35 | 53 | 50 | 1.2 | 0.5 | 300 |
比较例26 | 95 | 4 | 1 | 50 | 无 | 2.27 | 55 | 53 | 1.5 | 0.6 | 300 |
比较例27 | 95 | 4 | 1 | 20 | 有 | 2.55 | 151 | 149 | 2.1 | 0.5 | 325 |
比较例28 | 99.8 | 0.1 | 0.1 | 100 | 有 | 2.75 | 50 | 46 | 0.8 | 0.7 | 350 |
考察:实施例9~21、比较例4~28
从表2的结果可以知道,对于实施例9~21,通过对在最大粒径50~200μm的骨材粒子中添加了最大粒径为10μm或10μm以下的微细粒子的SiC、以及调制成烧成后的组成为0.05~5.0质量%的SiO2和0.05~5.0质量%的V2O5的泥浆,进行浇铸成型,然后烧成,所得到的烧结体的所有特性(在常温及1300℃时的弯曲强度、在1300℃时的耐氧化性、耐蠕变性及耐热冲击温度)良好。另一方面,在比较例4~28中,所得的烧结体的特性都不充分。
实施例2、比较例29
用SEM(扫描电子显微镜)观察在实施例2中得到的氧化物结合碳化硅质材料(烧结体)的微观结构。将其结果示于图1中。另一方面,在比较例29中,用SEM(扫描电子显微镜)观察日本碍子株式会社在市场上销售的商品名为“カタロン”的氧化物结合碳化硅质材料(烧结体)的微观结构。将其结果示于图2中。
考察:实施例2、比较例29
在实施例2得到的氧化物结合碳化硅质材料(烧结体)的微观结构,如图1所示,可以控制烧成时作为骨材的碳化硅晶粒与作为结合部的二氧化硅的组织,以致密地烧结。另一方面,在比较例29中,如图2所示,在烧成时构成骨材SiC粒子间的结合部的二氧化硅与SiC微粒部是存在非常多的气孔的状态,难以致密地烧结。
因此,在实施例2中在常温时的弯曲强度为213MPa、在1300℃时的弯曲强度为221MPa,相反在比较例29中,在常温时的弯曲强度为50MPa、在1300℃时的弯曲强度为30MPa。
如上所述,可以确认本发明的氧化物结合碳化硅质材料(实施例2),与以往的氧化物结合碳化硅质材料(比较例29)相比,可以将在常温时和高温时的弯曲强度提高4倍或4倍以上。
产业上的利用可能性
本发明的氧化物结合碳化硅质材料,可以适宜地用于例如陶瓷器烧成用塔板(安装器)、支撑板、套、安装器支柱、梁或辊、其他窑具,以及其他SiC特有的耐磨耗材料等领域。
Claims (7)
1.一种氧化物结合碳化硅质材料,其为实质上由碳化硅构成,具有所述碳化硅晶粒、其晶界以及气孔,并且具有以主成分为二氧化硅的氧化物结合所述碳化硅晶粒的结构的氧化物结合碳化硅质材料,在常温和高温时的弯曲强度为100MPa~300MPa,并且松比重为2.65~2.90。
2.权利要求1所述的氧化物结合碳化硅质材料,其特征为,所述碳化硅晶粒实质上是含有粒径大的骨材和由微细的碳化硅晶粒构成的微粒的混合粒子,并且所述骨材的最大粒径为50~200μm,同时所述微粒的最大粒径为0.05μm~10μm。
3.权利要求1或2所述的氧化物结合碳化硅质材料,其特征为,在所述骨材的周围均匀地分散有所述微粒,并且所述结合部具有所述微粒和所述以二氧化硅为主成分的氧化物同时混杂的结构。
4.权利要求1~3中的任一项所述的氧化物结合碳化硅质材料,其特征为,所述结合碳化硅晶粒之间的结合部由所述以二氧化硅为主成分的氧化物构成,并且在所述结合部含有从原子序号22~29的过渡金属元素中选择的至少一种作为微量成分。
5.权利要求1~4中的任一项所述的氧化物结合碳化硅质材料,其特征为,碳化硅为85~99.5质量%,二氧化硅为0.45~10质量%,作为微量成分含有换算成氧化物为0.05~5.0质量%的从原子序号22~29的过渡金属元素中选择的至少一种。
6.权利要求1~5中的任一项所述的氧化物结合碳化硅质材料,其特征为,在表面形成含有从原子序号22~29的过渡金属元素中选择的至少一种且以二氧化硅为主成分的皮膜。
7.权利要求1~6中的任一项所述的氧化物结合碳化硅质材料,其特征为,浇铸成型作为所述氧化物结合碳化硅质材料前驱体的成型体后,在大气氛围下进行烧成。
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CN101423412B (zh) * | 2008-11-27 | 2012-07-11 | 中钢集团洛阳耐火材料研究院有限公司 | 低温烧成制备高性能氧化硅结合碳化硅耐火材料的方法 |
CN104987097A (zh) * | 2015-07-30 | 2015-10-21 | 武汉科技大学 | 一种氮化硅结合碳化硅耐火材料及其制备方法 |
CN105236947A (zh) * | 2009-12-31 | 2016-01-13 | 哈利伯顿能源服务公司 | 具有受控的孔和/或微球分布和/或尺寸的陶瓷颗粒及其制法 |
CN109803942A (zh) * | 2016-09-30 | 2019-05-24 | 圣戈本陶瓷及塑料股份有限公司 | 陶瓷部件及其形成方法 |
CN115551804A (zh) * | 2020-05-27 | 2022-12-30 | 松下知识产权经营株式会社 | 无机结构体及其制造方法 |
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US11292749B2 (en) * | 2017-01-18 | 2022-04-05 | The University Of North Carolina At Charlotte | Composite carbide compositions and methods of making the same |
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US11285242B1 (en) | 2019-12-20 | 2022-03-29 | The University Of North Carolina At Charlotte | Processing and bioactivation of a novel SiC medical device |
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- 2006-05-30 DE DE200660008217 patent/DE602006008217D1/de active Active
- 2006-05-30 EP EP20060114683 patent/EP1728774B8/en not_active Expired - Fee Related
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101423412B (zh) * | 2008-11-27 | 2012-07-11 | 中钢集团洛阳耐火材料研究院有限公司 | 低温烧成制备高性能氧化硅结合碳化硅耐火材料的方法 |
CN105236947A (zh) * | 2009-12-31 | 2016-01-13 | 哈利伯顿能源服务公司 | 具有受控的孔和/或微球分布和/或尺寸的陶瓷颗粒及其制法 |
CN104987097A (zh) * | 2015-07-30 | 2015-10-21 | 武汉科技大学 | 一种氮化硅结合碳化硅耐火材料及其制备方法 |
CN109803942A (zh) * | 2016-09-30 | 2019-05-24 | 圣戈本陶瓷及塑料股份有限公司 | 陶瓷部件及其形成方法 |
CN115551804A (zh) * | 2020-05-27 | 2022-12-30 | 松下知识产权经营株式会社 | 无机结构体及其制造方法 |
Also Published As
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JP2006335594A (ja) | 2006-12-14 |
CN100393668C (zh) | 2008-06-11 |
JP4704111B2 (ja) | 2011-06-15 |
EP1728774B8 (en) | 2009-11-18 |
DE602006008217D1 (de) | 2009-09-17 |
EP1728774B1 (en) | 2009-08-05 |
EP1728774A1 (en) | 2006-12-06 |
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