TWI465319B - Alumina sintered, abrasive, and abrasive - Google Patents

Alumina sintered, abrasive, and abrasive Download PDF

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Publication number
TWI465319B
TWI465319B TW100139361A TW100139361A TWI465319B TW I465319 B TWI465319 B TW I465319B TW 100139361 A TW100139361 A TW 100139361A TW 100139361 A TW100139361 A TW 100139361A TW I465319 B TWI465319 B TW I465319B
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Taiwan
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alumina
sintered body
powder
content
compound
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TW100139361A
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TW201240773A (en
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Shinichiro Tomikawa
Hirokazu Miyazawa
Takeshi Iemura
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Showa Denko Kk
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    • C04B35/10Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
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Description

氧化鋁質燒結體、研磨粒、及磨具
本發明係關於一種氧化鋁質燒結體、使用該氧化鋁質燒結體所成之研磨粒、以及使用該研磨粒所成之磨具。
氧化鋁質燒結體,係發揮高硬度、高強度、高耐熱性、高耐磨耗性及高耐藥品性等優異的特徵,而在各種產業領域中使用。特別是在鋼鐵產業中作為重研削磨具的原料(研磨粒)使用。
此外,以汽車為中心的輸送用機器或者是構成產業用機械之零件的材料,大多使用特殊合金。此等特殊合金,由於相較於一般的SUS304等較硬,因此以往所沒有的高「研削比」之重研削磨具為市場所需。在此,所謂「研削比」,係指表示磨具的性能之指標,且由以下的式子來表示。
研削比=被削材料被削減的量(研削量)/磨具之磨耗量
一般而言,雖只要是能以較少的磨具來削減較多的被削材料者便能判斷為性能良好,但磨具的研削比,會受到該磨具所使用的研磨粒之「硬度」與「破壞韌性」影響。有關於「研削比與硬度」、及「研削比與破壞韌性」之間,係具有如下所述的關係:
(1)若研磨粒的硬度變高,則研磨量會增加,因此研削比會變大。
(2)若破壞韌性變高,則研磨粒的磨耗量會變少,因此研削比會變大。
若考慮上述(1)及(2),則研削比之式子中,分子部分會因研削量而受到影響,而分母部分會因磨耗量而受到影響。為了使磨具的研削比提高,硬度及破壞韌性兩者皆高係較為理想。
在此,以往之重研削磨具用的研磨粒,已知有:使氧化鋁質之微粉原料經燒結而成之研磨粒(例如,參照專利文獻1~3)、或熔融氧化鋁氧化鋯研磨粒(例如,參照專利文獻4)、在高純度微粒氧化鋁粉末中,添加有氧化鎂等之晶粒成長抑制劑的研磨粒(例如,參照專利文獻5)等。
此外,提案有以氧化鋁作為主材料並添加有TiO2 而成之燒結材料(例如,參照專利文獻6)。再者,提案有:添加有可固溶於氧化鋁結晶中之Ti、Mg、Fe等之金屬化合物的氧化鋁燒結體,作為具有高硬度及高破壞韌性之耐磨耗性優異的氧化鋁燒結體(例如,參照專利文獻7)。
[先前技術文獻] [專利文獻]
[專利文獻1]日本特公昭39-4398號公報
[專利文獻2]日本特公昭39-27612號公報
[專利文獻3]日本特公昭39-27614號公報
[專利文獻4]日本特公昭39-16592號公報
[專利文獻5]日本特公昭52-14993號公報
[專利文獻6]日本特開平3-97661號公報
[專利文獻7]日本特開平11-157962號公報
但,專利文獻1~5中皆無具體揭示有關:高硬度且低破壞韌性、或者是低硬度且高破壞韌性、高硬度且破壞韌性高的研磨粒。雖於專利文獻6中之燒結材料,係有針對硬度作評估,但針對破壞韌性卻完全沒有考慮到。此外,專利文獻7之氧化鋁燒結體,係僅揭示Ti與Mg的組合、及Fe與Mg的組合,針對其他的組合並無具體揭示。
本發明係於上述的狀況下所完成者,其目的為提供一種作出高硬度且破壞韌性優異的研磨粒之氧化鋁質燒結體、使用該氧化鋁質燒結體所成之研磨粒及使用該研磨粒所成之磨具。
本發明者們,為了達成上述目的屢次精心研究的結果發現,作為氧化鋁質燒結體所含有之化合物,可著眼於鈦化合物(特別是鈦氧化物)及鐵化合物(特別是鐵氧化物),並藉由控制此等之合計量(分別換算成氧化物之含有量的合計量),而使氧化鋁質燒結體之特性提昇。本發明係根據上述見解而完成者。
亦即,本發明係如下所述。
[1]一種氧化鋁質燒結體,其係包含鈦化合物及鐵化合物之氧化鋁質燒結體,其特徵為:鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量與氧化鋁之含有量之合計量為98質量%以上,鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量之合計量為5~13質量%,鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量之質量比(TiO2 :Fe2 O3 )為0.85:1.15~1.15:0.85。
[2]如上述[1]之氧化鋁質燒結體,其中鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量之合計量為7~10質量%。
[3]一種研磨粒,其係由如上述[1]或[2]之氧化鋁質燒結體所構成。
[4]一種磨具,其係將具有如上述[3]之研磨粒之層作為作用面。
依據本發明,係可供一種作出高硬度且破壞韌性優異的研磨粒之氧化鋁質燒結體、使用該氧化鋁質燒結體所成之研磨粒及使用該研磨粒所成之磨具。
[實施發明之最佳形態] [氧化鋁質燒結體]
本發明之氧化鋁質燒結體,係包含鈦化合物及鐵化合物,且使鈦化合物換算成TiO2 之含有量(以下稱為「TiO2 換算含有量」)與鐵化合物換算成Fe2 O3 之含有量(以下稱為「Fe2 O3 換算含有量」)與氧化鋁之含有量之3成分合計量成為98質量%以上。
此外,TiO2 換算含有量與Fe2 O3 換算含有量之2成分合計量係成為5~13質量%,且以成為7~10質量%為佳。
再者,於本發明之氧化鋁質燒結體中,為了得到高硬度且高破壞韌性之燒結體,使TiO2 換算含有量、與Fe2 O3 換算含有量之質量比(TiO2 :Fe2 O3 )成為0.85:1.15~1.15:0.85。
上述比(TiO2 :Fe2 O3 ),係以0.90:1.10~1.10:0.90者為佳,且以0.95:1.05~1.05:0.95者為更佳。
在此,針對TiO2 換算含有量及Fe2 O3 換算含有量之2成分合計量與硬度的關係,雖具有合計量越多硬度越低的關係,但只要2成分合計量在本發明之範圍內,則作為硬度指標之平均維氏硬度會成為例如16GPa以上,實用上也會具有優異的硬度。
另一方面,針對2成分合計量與破壞韌性的關係,雖不如上述硬度那樣的關係,但本發明者們發現,2成分合計量在特定的範圍中,破壞韌性會顯著地提高。亦即,只要2成分合計量在本發明之範圍內,則破壞韌性值會成為例如3.0MPa‧m1/2 以上。
在此,針對推測會得到如上所述之效果的機制進行說明。
首先,在僅由氧化鋁所構成之燒結體的情況,係如第3圖所示,龜裂的傳遞方式,係會沿著氧化鋁粒子12的晶界朝箭頭Y方向進行。接著,依據衝擊的大小,如第4圖(B)之SEM相片所示,係沿著晶界而產生直線性的龜裂。另外,第4圖,係後述之比較例1的燒結體之SEM相片;第4圖(A),係顯示施加衝擊之前的結晶組織之狀態;第4圖(B),係顯示施加衝擊之後龜裂延伸的狀態。
另一方面,藉由使其含有鈦化合物及鐵化合物,如第1圖所示,而於氧化鋁粒子12的晶界,生成破壞韌性值高的複合金屬氧化物之結晶相(例如FeTiAlO5 粒子10)。由於該FeTiAlO5 粒子10存在於氧化鋁粒子12的晶界,因此即使在施加衝擊時所發生的龜裂進行,也會因龜裂以該粒子10為起點在箭頭X方向迂迴地偏向,故衝擊力不會在一個方向而會分散、緩和。因此認為整體而言破壞韌性值提高。
上述情事,係可由第2圖所示之顯示衝擊試驗之結果的SEM相片得知。亦即,如第2圖(A)之SEM相片所示,若於氧化鋁粒子的晶界存在FeTiAlO5 粒子的狀態下施加衝擊,則如第2圖(B)所示,龜裂會以FeTiAlO5 粒子為起點迂迴地進行。
另外,第2圖係後述之實施例3的燒結體之SEM相片,該圖中,位於氧化鋁粒子之晶界的三相點處之灰色部分(顏色較淡的部分),相當於FeTiAlO5 粒子。
此外,如後述之氧化鋁質燒結體的製造方法中所說明般,就製造成本之觀點而言,作為含有Ti與Fe的原料,係以使用鈦鐵礦(鈦鐵礦:FeTiO3 )者為佳。
於本發明之氧化鋁質燒結體中,在由剛玉結晶所構成的主結晶相之晶界,存在已述之含有Ti、Fe及Al之複合金屬氧化物的結晶相,具體而言為FeTiAlO5 粒子。由於此FeTiAlO5 粒子的存在,而成為一種作出高硬度且破壞韌性優異之研磨粒的氧化鋁質燒結體。特別是FeTiAlO5 粒子,係藉由所謂破壞韌性較剛玉相更高的作用,而可得到高硬度且破壞韌性優異的氧化鋁質燒結體。由FeTiAlO5 粒子所構成之結晶相的存在及平均結晶的尺寸,係可依據後述之實施例所記載的方法而加以確認。
就高破壞韌性化的觀點而言,含有Ti、Fe及Al的複合金屬氧化物之結晶相(FeTiAlO5 粒子)的平均結晶尺寸,係以3.4~7.0μm者為佳,3.7~6.5μm者為更佳。平均結晶尺寸為3.4~7.0μm者,抑制破壞時所產生之龜裂的進行之效果會變大。此乃由於平均結晶尺寸在該範圍內,因此可良好地保持因該FeTiAlO5 粒子所得之龜裂的偏向效果。
此外,為了得到具有更高破壞韌性的燒結體,本發明之氧化鋁燒結體,係以含有作為TiO2 、Fe2 O3 、Al2 O3 以外之金屬化合物的矽化合物及/或鈣化合物者為佳。
矽化合物換算成SiO2 之含有量(以下稱為「SiO2 換算含有量」)與鈣化合物換算成CaO之含有量(以下稱為「CaO換算含有量」)之合計量,係以成為2質量%以下者為佳,以成為0.5~2質量%者為更佳。
矽化合物及鈣化合物,係被認為是作為晶粒成長劑而作用,且將此等以氧化物換算為存在2質量%以下,藉此使氧化鋁之剛玉結晶的形狀、尺寸不均一,並使龜裂的偏向產生。也就是說,認為:藉由特定量的鈦化合物及鐵化合物、以及特定量的矽化合物及鈣化合物的存在,以將各個作用作組合而使龜裂的偏向有效率地產生,而得到更高破壞韌性化的效果。
在此,氧化鋁的含有量、或TiO2 換算含有量、Fe2 O3 換算含有量、SiO2 換算含有量、CaO換算含有量、其他金屬化合物之金屬氧化物換算含有量,係可藉由螢光X射線元素分析法而求得。具體而言,係以下述方式求得。
首先,為了進行測量,執行元素的組成為已知的標準氧化物試料之濕式分析。以所得之濕式分析值作為基準值,而作成測量時必要的校準曲線。樣品的定量分析,係以該作成的校準曲線為基準來執行。測量機器,係可使用Panalytical公司製之「PW2400型」。此外,測量,係以在管球:銠管球、特性X射線:Kα射線的條件下實施者為佳。管電壓及管電流,係以在各元素不同的條件下執行測量者為佳。於下述表1中顯示管電壓與管電流的條件之一例示。
另外,於本說明書中,求得各金屬氧化物換算含有量時之成為分母之整體量,係成為將氧化鋁質燒結體所包含之全部的金屬元素,換算成氧化物並經合計的量。
[表1]
表1 各金屬氧化物之管電壓及管電流值
[氧化鋁質燒結體之製造方法]
接著,針對已述之本發明的氧化鋁質燒結體之製造方法進行說明。
(原料)
於本發明之氧化鋁質燒結體之製造方法中,係使用氧化鋁、鈦化合物、鐵化合物作為原料。視需要進一步使用矽化合物及/或鈣化合物。此等亦可含有2種以上之複合氧化物。
此等之原料的形態,雖可列舉粉末、金屬粉末、漿體、水溶液等,但於本發明中,就作業時之處理的容易度等之觀點而言,以使用粉末的原料為佳。於使用粉末原料的情況下,為了得到均質的混合粉末,氧化鋁粉末、鈦化合物粉末、鐵化合物粉末、矽化合物粉末、以及鈣化合物粉末的累積質量50%徑(d50 ),係以分別使用3μm以下者為佳,以使用1μm以下者為更佳。
在此,各種粉末的累積質量50%徑(d50 ),係可藉由雷射繞射法來進行測量。
於所得到的氧化鋁質燒結體中,由於氧化鋁粉末為用來形成由剛玉結晶所構成之主結晶相的原料,因此以高純度者為佳,且以使用例如以貝爾(Bayer)法所形成之氧化鋁等者為佳。
作為鈦化合物粉末及鐵化合物粉末,係各自為高純度之TiO2 粉末及高純度之Fe2 O3 粉末亦可,或將鈦、鐵、氧化鋁的全部或者是此等當中的2種形成複合氧化物者亦可。作為複合氧化物,係可列舉:鈦鐵礦(鈦鐵礦:FeTiO3 )粉末、鈦酸鋁粉末、FeTiAlO5 粉末等。鈦鐵礦粉末,係因較高純度之TiO2 粉末及高純度之Fe2 O3 粉末更低價,故可抑制研磨粒的製造成本。因此,以使用鈦鐵礦粉末者為佳。
在此,鈦鐵礦係也稱為釔鈦鐵礦,且以天然產的鐵及鈦的氧化礦物,而組成係以FeTiO3 來表示。產地,係澳洲、挪威、俄羅斯烏拉山地區、印度、加拿大、美國、馬來西亞等,依據產地而化學組成不同。FeTiO3 之Fe2+ 的一部分,為可經Mg2+ 置換者。
構成鈦鐵礦(澳洲昆士蘭產)的成分當中,於下述表2中顯示氧化鋁成分與鐵化合物、鈦化合物、矽化合物及鈣化合物換算成氧化物時各別的化學組成。
[表2]
表2 鈦鐵礦中之氧化鋁、及換算成氧化物時之各成分的含有量(質量%)
使用鈦鐵礦粉末時,鈦鐵礦粉末相對於氧化鋁粉末之質量混合比(鈦鐵礦粉末:氧化鋁粉末),係以設為0.05:0.95~0.16:0.84者為佳,且以設為0.08:0.92~0.12:0.88者為更佳。藉由將質量混合比設為0.05:0.95~0.16:0.84,而可將TiO2 換算含有量與Fe2 O3 換算含有量之2成分合計量設為5~13質量%。
此外,使用矽化合物或鈣化合物時,矽化合物換算成SiO2 之含有量與鈣化合物換算成CaO之含有量,為合計2質量%以下,較佳為使其成為0.5~2質量%。藉由使用該等而可使破壞韌性值更為提昇。
作為矽化合物粉末、鈣化合物粉末,係各自為高純度之SiO2 粉末及高純度之CaO粉末、碳酸鈣粉末等亦可,或將二氧化矽、氧化鈣、氧化鋁的全部或者是此等當中的2種已形成複合氧化物者亦可。複合氧化物,係可列舉富鋁紅柱石、沸石、膨土、鈣鋁黃長石、鈣長石等之粉末。
(混合物之調製)
於本發明之製造氧化鋁質燒結體的方法中,對調製原料之混合物的方法並無特別限制,但可適當地採用例如下述之方法。
首先,於含有聚乙烯醇之水性溶劑中,分別添加特定量之以貝爾法所得到之氧化鋁粉末、鈦鐵礦粉末(或者是TiO2 粉末與Fe2 O3 粉末)。其後,使用例如:超音波分散器、行星型球磨機、球磨機、混砂機等之使用有介質之分散器、ULTIMAIZER(商品名)、NANOMIZER(商品名)等之Medialess分散器而得到均質的漿體。接著,在將該漿體乾燥處理過後,加以粉碎,而調製累積質量50%徑(d50 )3μm以下,較佳為1μm以下之混合物(粉末)。
(混合物之燒結)
將如上述方式所調製的原料之混合物的成形體進行燒結,而得到相對密度95%以上,較佳為97%以上之本發明之氧化鋁質燒結體。藉由相對密度為95%以上,而可抑制因燒結體中之氣孔、空隙所引起之燒結體硬度及破壞韌性的下降。另外,相對密度,係可以阿基米德法所測量出的燒結體積密度,除以真密度而求得。
此外,燒結時,係使用眾所周知的成形手段,例如:藉由模壓、冷間靜水壓、澆鑄成形、射出成形、擠製成形等而成形為任意的形狀,接著將該成形體,藉由眾所周知的燒結法,例如:熱壓法、常壓煅燒法、氣體加壓煅燒法、微波加熱煅燒法等各種的燒結手法來進行燒結。
如上述方式所得到的本發明之氧化鋁質燒結體,係具有高硬度且優異的破壞韌性,且適合作為例如:研削材料、切削材料、研磨材料等之研削、切削、研磨等之工具,並進一步適合在鋼鐵產業中作為重研削用磨具的研磨粒。
[研磨粒]
本發明之研磨粒,係由本發明之氧化鋁質燒結體所構成。本發明之氧化鋁質燒結體,係藉由依序施行粉碎處理、揉合處理、成形處理、乾燥處理、燒結處理所得。
[磨具]
本發明之磨具,係將具有本發明之研磨粒之層作為作用面。
本發明之磨具的研磨粒之對於作用面的固定方法,係可列舉:樹脂結合、玻璃熔結、金屬黏結、電鍍等。
此外,基底金屬的材質,係可列舉:鋼鐵、不鏽鋼合金、鋁合金等。
樹脂結合,係銳利度良好,但耐久性低。玻璃熔合,係銳利度佳,且耐磨耗性也良好,但會在研磨粒發生內部應力,而容易使研磨粒破裂、或缺損。電鍍,係形狀的自由度大,且銳利度也良好。
鑑於上述之情事,於磨具中,係視其用途而選擇研磨粒之固定方法。
具體而言,例如,於樹脂結合磨具的情況下,藉由將酚樹脂、聚醯亞胺樹脂等之接著劑的粉末與研磨粒混合、或將接著劑塗佈在研磨粒上,並填充至模具予以加壓成形的方法;或者是將環氧樹脂、不飽和聚酯樹脂等之液狀的接著劑與研磨粒混合,並灌入模型中使其硬化的方法,而得到將研磨粒層固定在基底金屬的作用面所成之本發明之磨具。
針對本發明之磨具的形狀並無特別限制,只要視磨具之用途,而從直條型或杯型等形狀適當選擇即可。
[實施例]
以下,雖藉由實施例來進一步詳細地說明本發明,但本發明並不受該等例示所限制。
另外,於各例示中之諸多特性,係依據下述所示的方法求得。
(1)原料粉末之累積質量50%徑(d50 )之測量
原料粉末的累積質量50%徑(d50 ),係可藉由雷射繞射法(NIKKISO CO.,LTD.製MICROTRACK HRA)來進行測量。
(2)氧化鋁質燒結體之平均維氏硬度之測量
裝置,係使用(股)AKASHI製、機種名「MVK-VL、Hardness Tester」;測量,係以負載0.98N、壓頭的打入時間10秒的條件,且以15點測定值之平均值作為維氏硬度。平均維氏硬度只要在16GPa以上實用上便無問題。
(3)氧化鋁質燒結體之平均破壞韌性值
裝置,係使用松澤精機(股)製、機種名「DVK-1」;測量,係在最大負載9.81N、壓頭的打入速度50μm/sec、壓頭的打入時間15秒的條件下,以15點之平均值作為平均破壞韌性值。計算式係如以下所述。此外,平均破壞韌性值只要在3.0MPa‧m1/2 以上實用上便無問題。
KIC =0.026*E1/2 *P1/2 *a/c3/2
KIC :破壞韌性值(MPa‧m1/2 )
E:楊氏模數(Pa)
P:最大負載(N)
a:壓痕尺寸(m)
c:龜裂的尺寸(m)
另外,於本發明中,上述楊氏模數E,係使用氧化鋁之值(3.9×1011 Pa)。
(4)於氧化鋁質燒結體之各晶相的平均結晶尺寸之測量
裝置,係使用日本電子(股)製、機種名「JSM-6510V」來拍攝SEM相片。根據所得到的SEM相片來測量各結晶相之平均結晶尺寸。平均結晶尺寸,係藉由直徑法來測量於各結晶(50個)之同一方向的最大長度,並算出平均而求出。
(5)氧化鋁質燒結體之含有Ti、Fe及Al的金屬氧化物結晶相的組成分析
裝置,係使用Panalytical公司製、機種名「X’pert PRO」,並在特性X射線:CuKα線、管電壓40kV、管電流40mA的條件下,進行上述金屬氧化物結晶相之組成分析。
(6)相對密度
相對密度,係可以阿基米德法所測量出的燒結體之體積密度,除以真密度而求得。
此時,假設已添加的鐵化合物與鈦化合物完全反應而成為FeTiAlO5 ,而且,以氧化鋁之真密度為3.98、FeTiAlO5 之真密度為4.28,而算出以可生成之FeTiAlO5 之比例與剩餘部分的氧化鋁之比例為基礎的真密度。
如上所述,燒結體之原料的形態,係可列舉:粉末、金屬粉末、漿體、水溶液等。於本實施例中,就作業時處理之容易度等的觀點而言,認為以使用粉末之原料者為佳,而使用了原料粉末。在此,於下述表3~6顯示作為原料所使用的氧化鋁粉末、鈦鐵礦粉末、氧化鐵粉末及氧化鈦粉末之化學組成(氧化鋁之含有量、TiO2 換算含有量、Fe2 O3 換算含有量、SiO2 換算含有量、CaO換算含有量)。
[表3]
表3 氧化鋁粉末中之氧化鋁、及換算成氧化物時之各成分的化學組成(質量%)
上述氧化鋁粉末,係昭和電工(股)製「AL-160SG-3」,該累積質量50%徑(d50 )為0.6μm。
[表4]
表4 鈦鐵礦(FeTiO3 )粉末中之氧化鋁、及換算成氧化物時之各成分的化學組成(質量%)
上述鈦鐵礦粉末,係將在澳洲出產,澳洲的CRL(Consolidated Rutile Limited)公司製者,粉碎成累積質量50%徑(d50 ):0.75μm,而加以利用。
[表5]
表5 氧化鐵(Fe2 O3 )粉末中之氧化鋁、及換算成氧化物時之各成分的化學組成(質量%)
上述氧化鐵粉末,係利根產業(股)製、紅鐵粉(Bengala)SR-570,該累積質量50%徑(d50 )為0.5μm。
[表6]
表6 氧化鈦(TiO2 )粉末中之氧化鋁、及換算成氧化物時之各成分的化學組成(質量%)
上述氧化鈦粉末,係Showa Titanium(股)製「SUPER-TITANIA(註冊商標)G系列」,該累積質量50%徑(d50 )為0.6μm。
(實施例1~5及比較例1~7)
以使所形成之氧化鋁燒結體中之TiO2 及Fe2 O3 的各含有量成為表7所示之值的方式,來將累積質量50%徑(d50 )0.6μm之上述氧化鋁粉末、與累積質量50%徑(d50 )0.75μm之上述鈦鐵礦粉末加以混合,而得到各種混合物。
於各種混合物中,分別添加600g之含有5質量%之聚乙烯醇的水溶液300g與純水,且以球磨機進行粉碎、混合處理(實施例1~5及比較例1~6為4小時、比較例7為8小時),而調製出混合物濃度約25質量%之均值的各種漿體。
接著,分別將上述各種漿體在120℃下進行24小時乾燥處理之後,以研缽來進行分解粉碎處理,而得到累積質量50%徑(d50 )300μm以下之各種粉碎品。分別將上述各種粉碎品,在100MPa之壓力下模壓成形之後,進一步在150MPa之壓力下施以流體靜壓處理而製造出各種成形體。
其後,為了使相對密度成為95%以上,將上述各種成形體,在電爐(大氣環境)下煅燒4小時,藉此得到各種氧化鋁質燒結體。針對此等,進行已述的試驗(評估)。將結果顯示於下述表7。
此外,於第2圖中顯示對於實施例3之氧化鋁質燒結體之衝擊試驗前後的SEM相片,於第4圖中顯示對於比較例1之氧化鋁質燒結體之衝擊試驗前後的SEM相片。另外,上述圖中,(A)係顯示衝擊試驗前之結晶組織的狀態;(B)係顯示衝擊試驗後之龜裂延伸的狀態。
(實施例6、7及比較例8、9)
以使所形成之氧化鋁質燒結體中之TiO2 及Fe2 O3 的各含有量成為表7所示之值的方式,來將累積質量50%徑(d50 )0.6μm之上述氧化鋁粉末、累積質量50%徑(d50 )0.5μm之氧化鐵粉末、與累積質量50%徑(d50 )0.6μm之氧化鈦粉末加以混合,而得到各種混合物。
於各種混合物中,分別添加600g之含有5質量%之聚乙烯醇的水溶液300g與純水,且以球磨機進行粉碎、混合處理(處理時間:4小時),而調製出混合物濃度約25質量%之均質的各種漿體。
接著,分別將上述各種漿體在120℃下進行24小時乾燥處理之後,以研缽來進行分解粉碎處理,而得到累積質量50%徑(d50 )300μm以下之各種粉碎品。分別將上述各種粉碎品,在100MPa之壓力下模壓成形之後,進一步在150MPa之壓力下施以流體靜壓處理而製造出各種成形體。
其後,為了使相對密度成為95%以上,將上述各種成形體,在電爐(大氣環境)下燒結4小時,藉此得到各種氧化鋁質燒結體。針對此等,進行已述的試驗(評估)。將結果顯示於下述表7。
[表7]
於實施例1~7及比較例3~9之氧化鋁質燒結體中,在由剛玉結晶所構成的主結晶相之晶界,存在的含有Ti、Fe及Al之金屬氧化物的結晶相,係藉由X射向繞射測量而確認為由FeTiAlO5 所構成之結晶相。
另外,於第5圖中顯示實施例4之氧化鋁質燒結體的X射線繞射測量的結果。
X射線繞射測量的資料解析,係使用PANalytical公司製的解析軟體「X’Pert High Score Plus」來進行。
於該解析軟體中,FeTiAlO5 的結構,係根據1982年Tiedemann等所發表的文獻來決定結晶結構。
將實驗樣品的結果與藉由上述方式所得之圖型作對照,判斷出峰值乃起因於FeTiAlO5
10‧‧‧FeTiAlO5 粒子
12‧‧‧氧化鋁粒子
X‧‧‧顯示龜裂之進行方向的箭頭
Y‧‧‧顯示龜裂之進行方向的箭頭
[第1圖]係說明對於本發明之氧化鋁質燒結體的衝擊之傳遞方式之作用說明圖。
[第2圖]係對於本發明之氧化鋁質燒結體的衝擊試驗前後之SEM相片;(A)係顯示衝擊試驗前之結晶組織的狀態(熱蝕刻處理完畢);(B)係顯示衝擊試驗後之龜裂延伸的狀態(未經熱蝕刻處理)。
[第3圖]係說明對於僅由氧化鋁所構成之燒結體的衝擊之傳遞方式之作用說明圖。
[第4圖]係對於僅由氧化鋁所構成之燒結體的衝擊試驗前後之SEM相片;(A)係顯示衝擊試驗前之結晶組織的狀態(熱蝕刻處理完畢);(B)係顯示衝擊試驗後之龜裂延伸的狀態(未經熱蝕刻處理)。
[第5圖]係顯示實施例4之氧化鋁質燒結體的組成分析(X射線繞射測量)結果之X射線繞射圖。

Claims (4)

  1. 一種氧化鋁質燒結體,其係包含鈦化合物及鐵化合物之氧化鋁質燒結體,其特徵為:鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量與氧化鋁之含有量之合計量為98質量%以上,鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量之合計量為5~13質量%,鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量之質量比(TiO2 :Fe2 O3 )為0.85:1.15~1.15:0.85。
  2. 如請求項1之氧化鋁質燒結體,其中鈦化合物換算成TiO2 之含有量與鐵化合物換算成Fe2 O3 之含有量之合計量為7~10質量%。
  3. 一種研磨粒,其係由如請求項1之氧化鋁質燒結體所構成。
  4. 一種磨具,其係將具有如請求項3之研磨粒之層作為作用面。
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