GB2271562A - Binding agent for ceramic materials - Google Patents

Binding agent for ceramic materials Download PDF

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Publication number
GB2271562A
GB2271562A GB9320055A GB9320055A GB2271562A GB 2271562 A GB2271562 A GB 2271562A GB 9320055 A GB9320055 A GB 9320055A GB 9320055 A GB9320055 A GB 9320055A GB 2271562 A GB2271562 A GB 2271562A
Authority
GB
United Kingdom
Prior art keywords
binding agent
agent according
grain
ceramic material
weight
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.)
Withdrawn
Application number
GB9320055A
Other versions
GB9320055D0 (en
Inventor
Karl Riepl
Dietrich Deutschmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Veitsch Radex GmbH and Co OG
Original Assignee
Veitsch Radex GmbH and Co OG
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Veitsch Radex GmbH and Co OG filed Critical Veitsch Radex GmbH and Co OG
Publication of GB9320055D0 publication Critical patent/GB9320055D0/en
Publication of GB2271562A publication Critical patent/GB2271562A/en
Withdrawn legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303Inorganic additives

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Ceramic Products (AREA)

Description

2271562 BINDING AGENT FOR CERAMIC MATERIALS is The invention relates to a
binding agent for ceramic materials based on refractory oxides.
Various types of binding agents are known for preparing refractory ceramic materials. Sulphates, phosphates, cements, water glass, clays and/or substances containing carbon, for example, are included here. In the case mentioned last usually a "carbon bond" is aimed at; a "carbon framework structure" which forms during the pyro-process is also mentioned in some cases.
The remaining cases relate to more or less temporary binding agents, the use of which causes, amongst other things, the following problems:
Under the effect of temperature the binding agents vaporize sooner or later so that a corresponding porosity forms in the structure of the material or of the moulded part produced therefrom, which is often undesirable. An increased porosity also usually results in a reduced infiltration-resisting property and corrosion-resisting property.
The other problem is found in that the known binding agents often reduce the refractory quality of the associated material (of the moulded part) in an undesirable manner.
The underlying object of the invention in this respect is to provide a binding agent for ceramic materials based on refractory oxides, which agent, after adding to a ceramic material and possibly also after producing moulded parts, guarantees good green bonding and resistance to heat in the products. Also the further above-mentioned properties, which are specific to use, such as the infiltration-resisting property, the corrosion-resisting property etc., should be maintained as far as possible or even improved.
In achieving this obj ect one proceeds from the following consideration: conventional refractory ceramic materials, such as used in technology, consist of a granular matrix which has a largely continuous particlesize distribution curve. "Largely continuous" signifies that no larger granulation gaps exist. In terms of production technology the result is however that, proceeding from the maximum grain, no continuous particlesize distribution curve as far as "zero" is produced, rather the particlesize distribution characteristic curve terminates at a distance from the 11zero value", usually approximately 10 to 30 pm. This means that typically 96 to 98% by weight of the ceramic material lies within the above-mentioned grain upper and lower limits, whilst the remainder consists partially of impurities and partially of a random oversize and undersize.
Using this as a premise the invention proceeds from the further consideration that the binding agent should, in its granular composition, join the particle-size distribution curve of the ceramic material, in order to continue this in a continuous manner "downwards", if possible as far as "zeroft. In this case the binding agent can and should also be structured on the basis of refractory oxides so that during baking a purely ceramic bond is produced and annealing out of the thermally volatile components is prevented.
- The binding agent part, which, for example, lies between 2 and 15% by weight relative to the total material, can be produced in completely different methods in order to obtain the desired fine grain fractions.
The refractory oxides of the binding agent can, in this connection, be obtained as a re-oxidised product of vaporization with reducing meltingdown of the aluminium, chromium or magnesium carriers in electric arc furnaces.
Accordingly the invention relates to a binding agent for ceramic materials based on refractory oxides, wherein the granular structure of the material f ollows a largely continuous particle-size distribution curve, with the following features:
- the binding agent consists of at least one refractory oxide, - the binding agent has a particle-size distribution curve which joins the fine grain end of the particle-size distribution curve of the ceramic material in a substantially continuous manner and, as a result, together with the ceramic material, at least 98% by weight covers a grain spectrum of between zero and the maximum grain size of the ceramic material.
In the ideal case a continuous particle-size distribution curve from "zero" up to the maximum grain size is produced, wherein the lower range of grain size is covered by the binding agent and the upper range of grain size by the ceramic material. A value of 100 by weight represents in this respect a "theoretical" value because impurities are present in some cases and a technical limiting grain size in the fine grain range (for example below 1.0 pm) will usually be present for technical reasons.
According to an advantageous embodiment, however, a value of more than 99 by weight is aimed at within the grain spectrum mentioned.
For this purpose it is important for the performance of the binding agent, according to the invention, that it covers the grain range below the refractory oxides of the ceramic material, in order to fill up "pores" in the material, likewise with refractory oxides. In this manner an almost optimum structure-filling ratio is produced with the green bonded as well as with the fired product.
Because the binding agent also consists of refractory oxides, there is no longer the problem of shrinkage processes when drying or in the pyroprocess of ceramic materials/bodies. The binding agent itself does not contain any "volatile components" or at least none worth mentioning.
An S'02 part which is usually contained in known binding agents in amorphous form is also deliberately omitted. The disadvantage of these binding agents containing S'02 is their unfavourable effect on the resistance to heat and resistance to heat-corrosion of the ceramic products produced. theref rom. The S'02 part causes the formation of the mullite-like and/or glasslike phases in the product. From the phase system A1203S'02 it can be inferred that the f irst melting can be expected at approximately 15950 Celsius, whilst for example pure A120.. such as used for example as refractory oxide in a binding agent, according to the invention, does not melt until just above 2000 Celsius.
With the formation according to the invention of the binding agent, additives of phosphates or alkalis traditionally used as binding agents and which have a disadvantageous effect on the resistance to heat can be omitted. Additives containing phosphates or alkalis are possibly contained only in the sense of a dispersion agent and are, as a result, only in a substantially reduced supplementary amount.
In other words: because the binding agent preferably contains the same refractory oxides as the ceramic material, the binding agent assists the advantageous mechanical properties and corrosion properties as well as the inf iltration- inhibiting effect of the products formed therefrom.
The refractory oxides used in the binding agent should have densities which are as close as possible to the theoretical density so that they are subject to practically no subsequent shrinkage. The "grain size division" between the ceramic material and the binding agent is determined depending on the application. Usually the grain size division will lie at approximately 10 to 30 pm.
Corresponding to an exemplary embodiment, according to which 953% by weight of the binding agent is present in a grain fraction below the grain size division, this means that with a grain size division of, for example 30 pm, 95% by weight of the binding agent lies in a grain fraction of < 30 pm.
As explained above the binding agent should be selected in its grain fraction so that it continues the particle-size distribution curve of the associated ceramic material in a continuous manner in the fine grain range. The particle-size distribution curve of the binding agent can, as a result, also follow a Fuller curve.
A binding agent with one or several of the following refractory oxides: A1203. Cr203.Zr02P MgO, has proven to be particularly preferable.
The refractory oxides of the binding agent can as a result be identical to those of the refractory ceramic -6 material. It is also quite possible to prepare a ceramic material which contains, for example, 99% by weight A1203r the binding agent of which also consists practically exclusively (except for impurities) of A1203 powder.
i 11 However, the use of different oxides for forming mixed crystals for example of the type A1203-Cr203, also lies within the scope of the invention. In the abovementioned case the melting point increases with an increasing content of Cr203.
The behaviour of the binding agent can be optimised in that its particles are dispersed beforehand or added to the ceramic material together with a dispersing agent.
A preceding dispersion can be carried out, for example, as follows:
A dry mixture of an oxide micro-powder and a dispersing agent powder is produced in a mixing unit in that for example 0.61% phosphate disperser is added to the micro-powder and mixed for five minutes.
Sodium tripolyphosphate, for example, can be indicated as dispersing agent which is added to the binding agent. The binding agent can then be added as dry finished mixture to the refractory ceramic matrix material and the whole material is treated with water.
Depending on the area of use the binding agent can also contain a content (preferably 0.01 to 1.0 % by weight relative to the binding agent) of a flocculating agent, which is selected from such materials which are not effective until dispersion of the particles has taken place. Substances releasing calcium ions are above all suitable for this purpose.
Finally the invention also provides the addition of so-called conditioning agents which affect the setting performance of the binding agent. Setting accelerators and retarders belong to these and depend on the case of application. In order to retard setting carboxylic acids such as citric acid for example are used. Also with the aid of additives, such as cellulose derivatives, which affect the water retention value, the viscosity and the processability of the binding agent can be adjusted in a targeted manner to the particular area of application.
In the following, range limits for such dispersing agents, flocculating agents and conditioning agents are indicated, which in each case are calculated relative to the overall mass of the binding agent:
- Dispersing agent(s): 0.01% to 2.0% Flocculating agent(s): 0.01% to 2.0% - Conditioning agent(s): 0.01% to 2.0% wherein the overall quantity of additive should not exceed 6.
Further features of the invention are found in the features of the subclaims as well as the other documents of application.
The invention will be illustrated in more detail with the aid of an exemplary embodiment.
A material based on alumina with a maximum grain size of 3mm is available here. The grain spectrum of the refractory ceramic material is as follows:
3.0 1.2 0.063 < 0. 005 mm to 1. 2 mm to 0.063 mm to 0.005 mm by weight 48 by weight 14 by weight 8 by weight 100% by weight by weight of a binding agent according to the invention is now added to this material, which itself consists likewise of an alumina-micro powder, 98 by weight of which is present in a grain fraction < 0.005 mm.
The attached Figure shows that the particle-size distribution curve of the binding agent joins the particle-size distribution curve of the ceramic material in an almost interrupted manner and this continues into the very fine grain fractions (almost zero).
The advantages achieved by using the binding agen according to the invention are discussed above in detail.
n- -g-

Claims (18)

CLAIMS 1. A binding agent for ceramic materials based on refractory oxides, wherein the granular structure of the material follows a largely continuous particle-size distribution curve, characterised by the following features:
1. 1 the binding agent consists of at least one refractory oxide and 1.2 has a particle-size distribution curve which joins the fine grain end of the particle-size distribution curve of the ceramic material in a substantially continuous manner and, as a result, together with the ceramic material, at least 98 by weight covers a grain spectrum of between zero and the maximum grain size of the ceramic material.
2. A binding agent according to claim 1, in which the grain fraction of the binding agent is selected such that the binding agent with the material covers a grain spectrum of between zero and the maximum grain of the ceramic material of at least 99% by weight.
3. A binding agent according to claim 1 or 2, with a proportion of more than 95% by weight in a grain fraction below the grain size division relative to the ceramic material.
4. A binding agent according to claim 3, with a proportion of more than 95% by weight in the grain fraction < 10 pm.
5. A binding agent according to one of claims 1 to 4, the particle-size distribution curve of which follows a Fuller curve.
6. A bindIng agent accordIng to one of cla:Lms 1 to 5, with a major content of one or several of the following refractory oxides: A1,03. Cr2030' Zr029' M90 v
7. A binding agent according to one of claims 1 to 6, the refractory oxide(s) of which corresponds (correspond) to that/those of the ceramic material.
8. A binding agent according to one of claims I to 7, the refractory oxide parts of which, themselves and/or with the refractory oxides of the ceramic material, form a spinel.
9. A binding agent according to one of claims 1 to 8, with a content of one or several of the named refractory oxides in sol form or gel form.
10. A binding agent according to one of claims 1 to 9, in which the particles of the refractory oxide component were isolated beforehand using a dispersing agent.
11. A binding agent according to one of claims 1 to 9, in which the refractory oxide component is present in a homogenous mixture with a dispersing agent.
12. A binding agent according to claim 11, in which the dispersing agent consists of phosphates.
13. A binding agent according to one of claims 1 to 12, in which the refractory oxide component contains a flocculating agent.
14. A binding agent according to claim 13, in which the flocculating agent consists of calcium salts or other alkaline earth salts.
15. A binding agent according to one of claims 1 to 14, in which the refractory oxide component contains an additive (conditioning agent) affecting the setting performance.
16. A binding agent according to claim 15, in which the additive consists of cellulose derivatives and/or carboxylic acids.
17. A binding agent according to one of claims 11 to 16, in which the dispersing agent, the flocculating agent and/or the conditioning agent is (are) present in each case in a quantity of a maximum of 2.0% by weight and, together, a maximum of 6. 0 % by weight, in each case relative to the total binding agent.
18. A binding agent substantially as herein described as an exemplary embodiment.
GB9320055A 1992-10-01 1993-09-29 Binding agent for ceramic materials Withdrawn GB2271562A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE4233015A DE4233015C1 (en) 1992-10-01 1992-10-01 Binder for ceramic masses

Publications (2)

Publication Number Publication Date
GB9320055D0 GB9320055D0 (en) 1993-11-17
GB2271562A true GB2271562A (en) 1994-04-20

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ID=6469386

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GB9320055A Withdrawn GB2271562A (en) 1992-10-01 1993-09-29 Binding agent for ceramic materials

Country Status (5)

Country Link
AT (1) AT398757B (en)
DE (1) DE4233015C1 (en)
FR (1) FR2696444A1 (en)
GB (1) GB2271562A (en)
IT (1) IT1272712B (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2283740B (en) * 1993-11-15 1997-07-30 Furukawa Electric Co Ltd Method of manufacturing a porous preform for an optical fiber
DE4409078C1 (en) * 1994-03-17 1995-02-02 Veitsch Radex Ag Refractory brick

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3516840A (en) * 1964-10-22 1970-06-23 Aluminum Co Of America Production of ceramic bodies
US4125407A (en) * 1976-02-17 1978-11-14 Kurosaki Refractories Co., Ltd. Refractories which have dense-structure as well as spalling resistance and method for fabricating same
GB2007641A (en) * 1977-10-05 1979-05-23 Feldmuehle Ag Sintered material
US4310480A (en) * 1974-08-13 1982-01-12 Kurosaki Refractories Co., Ltd. Process for fabrication of dense-structure refractories which have resistance to spalling
GB2094779A (en) * 1981-03-11 1982-09-22 Atomic Energy Authority Uk Ceramic matrix material
EP0318305A2 (en) * 1987-11-26 1989-05-31 Alcan International Limited Refractory material produced from red mud
US5004039A (en) * 1981-03-23 1991-04-02 Remet Corporation Refractory material

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3272840D1 (en) * 1982-05-04 1986-10-02 Remet Corp Refractory material
AT382142B (en) * 1984-12-17 1987-01-12 Ruthner Michael Johann Dipl In METHOD AND DEVICE FOR PRODUCING CERAMIC POWDERS BASED ON ONE AND / OR MULTI-COMPONENT METAL OXIDS, AND MIXTURES THEREOF
US4678762A (en) * 1985-02-04 1987-07-07 Norton Company Very smooth and flat polycrystalline alumina substrates from direct firing
JPH01212259A (en) * 1988-02-19 1989-08-25 Shinagawa Refract Co Ltd Castable refractories for spray coating
DE3808123A1 (en) * 1988-03-11 1988-07-07 Krupp Gmbh Process for producing sintered parts of finely particulate metal or ceramic powders
DE3907022A1 (en) * 1988-03-11 1989-09-21 Krupp Gmbh Process for producing sintered parts from fine metal or ceramic powders
DE3840316C1 (en) * 1988-11-30 1990-04-19 Kernforschungszentrum Karlsruhe Gmbh, 7500 Karlsruhe, De
JPH0656506A (en) * 1992-06-05 1994-03-01 Veitscher Magnesitwerke Ag Production of ceramic material and its molding using finely powdered fire-proofing oxide

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3516840A (en) * 1964-10-22 1970-06-23 Aluminum Co Of America Production of ceramic bodies
US4310480A (en) * 1974-08-13 1982-01-12 Kurosaki Refractories Co., Ltd. Process for fabrication of dense-structure refractories which have resistance to spalling
US4125407A (en) * 1976-02-17 1978-11-14 Kurosaki Refractories Co., Ltd. Refractories which have dense-structure as well as spalling resistance and method for fabricating same
GB2007641A (en) * 1977-10-05 1979-05-23 Feldmuehle Ag Sintered material
GB2094779A (en) * 1981-03-11 1982-09-22 Atomic Energy Authority Uk Ceramic matrix material
US5004039A (en) * 1981-03-23 1991-04-02 Remet Corporation Refractory material
EP0318305A2 (en) * 1987-11-26 1989-05-31 Alcan International Limited Refractory material produced from red mud

Also Published As

Publication number Publication date
AT398757B (en) 1995-01-25
ATA192793A (en) 1994-06-15
ITMI932086A0 (en) 1993-09-30
DE4233015C1 (en) 1993-10-28
GB9320055D0 (en) 1993-11-17
IT1272712B (en) 1997-06-26
ITMI932086A1 (en) 1995-03-30
FR2696444A1 (en) 1994-04-08

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