WO2019104809A1 - 电解废弃硬质合金直接制备钨基合金粉末的方法 - Google Patents

电解废弃硬质合金直接制备钨基合金粉末的方法 Download PDF

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WO2019104809A1
WO2019104809A1 PCT/CN2017/119081 CN2017119081W WO2019104809A1 WO 2019104809 A1 WO2019104809 A1 WO 2019104809A1 CN 2017119081 W CN2017119081 W CN 2017119081W WO 2019104809 A1 WO2019104809 A1 WO 2019104809A1
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electrolysis
tungsten
metal oxide
molten salt
alloy powder
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PCT/CN2017/119081
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English (en)
French (fr)
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聂祚仁
李铭
席晓丽
刘庆庆
马立文
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北京工业大学
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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C5/00—Electrolytic production, recovery or refining of metal powders or porous metal masses
    • C25C5/04—Electrolytic production, recovery or refining of metal powders or porous metal masses from melts

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  • the invention belongs to the field of metallurgy, and relates to a method for electrolytically treating waste cemented carbide, and more particularly to a method for directly preparing tungsten-based alloy powder by electrolytic waste cemented carbide.
  • Cemented carbide is generally made of refractory metal tungsten carbide and bonding metal by powder metallurgy. It has high hardness and high flexural strength. It is used in machinery manufacturing, mining, transportation, energy exploration, The field of architectural decoration has been widely used [1].
  • refractory metal tungsten and rare metal cobalt are recognized as extremely important strategic elements in the world and have a very important impact on improving national economic and military competitiveness.
  • more than 50% of the world's tungsten resources are used to manufacture hard alloys, and the tungsten content in waste cemented carbides has reached 74%-91%. China consumes about 27,000 tons of tungsten metal per year, if the recovery rate can reach 40%. % is of great significance for establishing a resource security system and promoting the development of circular economy [2] .
  • Tungsten alloy is a kind of alloy based on tungsten (tungsten content of 85%-98%), adding a small amount of elements such as Ni, Co, Fe, Cu, Mo, Cr, etc., and its density is as high as 16.5-19g/cm 3 , often It is called heavy alloy or high density tungsten alloy [3] .
  • the research of refractory metal tungsten alloy originated in the 1930s. Because of its high density, high strength, high hardness and good ductility, electrical conductivity, thermal conductivity and other comprehensive performance, it is in the defense industry, aerospace, electronics. The information, energy, metallurgical and mechanical processing industries have a very wide range of uses and occupy an important position in the national economy [4] .
  • Tungsten alloy materials have a wide range of applications including two major series: W-Ni-Cu alloy and W-Ni-Fe alloy.
  • W-Ni-Cu alloy has good thermal conductivity and electrical conductivity, and small thermal expansion coefficient, and can be widely used as electrical contact materials, microelectronic packaging materials and heat sink materials.
  • W-Ni-Fe alloy has a wide range of applications in the field of defense because it has better tensile strength and elongation than W-Ni-Cu alloy [5] .
  • other tungsten-based tungsten alloy material systems such as W-Cu, W-Ni-Mo, and W-Ni-Co have led to the rapid development of the application range of tungsten alloy materials.
  • Molten salt electrolysis is a method in which one or more metal salts are used as a dielectric system, and a redox reaction of a substance is realized by mutual conversion of electric energy and chemical energy and control of electrode potential according to different standard electrode potentials of metal elements.
  • the molten salt electrochemical method has the advantage that the aqueous solution can not be compared, so it has been widely studied and paid attention.
  • [7] proposed a new method for recycling waste cemented carbide, that is, directly using waste cemented carbide as anode, titanium plate, stainless steel plate, graphite and carbon plate as cathode, in molten chlorine.
  • the molten salt medium is electrolyzed by constant pressure or constant current, and the electrolysis temperature is 350-1000 ° C.
  • the process is simple in process, no pollutant emission, and environmentally friendly [5] .
  • the purpose of this process is to prepare a single metal tungsten powder and cobalt powder by recycling the waste cemented carbide by molten salt electrolysis, without further improvement of the product.
  • the object of the present invention is to overcome the deficiencies of the prior art and provide a simple, easy-to-operate, high-efficiency method for directly preparing a tungsten-based alloy powder from waste cemented carbide, and realizing one-step regeneration of a tungsten-based alloy from a waste cemented carbide. The process of powder.
  • a method for directly preparing tungsten-based alloy powder by electrolytic waste cemented carbide comprising the steps of:
  • composition of the molten salt electrolyte is (x) A-(y)B and C, where x is the percentage content of A, x is in the range of 5 to 70 mol%, y is the molar percentage of B, and the range of y is 0-60mol%,
  • C accounts for a molar ratio of A and B of 0.1% to 5%; said A is one of CaCl 2 , KF, CaF 2, NaCl, KCl, and B is one of NaF, KF, NaCl, CaF 2 And A and B are not the same salt; C is a metal oxide which is one of CoO, Co 3 O 4 , FeO, Fe 3 O 4 , CuO, NiO, Ni 2 O 5 or Multiple
  • the waste cemented carbide is used as the anode and the nickel plate is used as the cathode with a pole spacing of 10-40 mm;
  • the electrolysis is carried out in a molten metal oxide-containing molten salt electrolyte by means of constant current electrolysis or constant pressure electrolysis, and the electrolysis temperature is from 600 ° C to 1000 ° C.
  • the molar ratio of the metal oxide to the sum of A and B in the step (1) is: CoO accounts for 0.1%-5%, Co 3 O 4 accounts for 0.1-4%, FeO accounts for 0.1%-2%, Fe 3 O 4 accounts for 0.5% to 3%, and CuO accounts for 0.6% to 2%.
  • the waste cemented carbide in the step (2) is a tungsten carbide or a tungsten-cobalt-based cemented carbide, and the tungsten-cobalt-based cemented carbide is one selected from the group consisting of YG3, YG6, YG8, YG10, YG16, and YG20.
  • the refractory material is used to seal the electrode and the lead connection.
  • step (3) In order to sufficiently remove moisture and impurities in the electrolyte, it is preferred to carry out the pretreatment before the electrolysis in step (3): first, the metal oxide is dehydrated in air at 200-300 ° C for 8-15 h, and the A, B electrolyte is dehydrated at 200-350 ° C. 20-30h, then pre-electrolyzed for 1-2h at a cell voltage of 0.1-1.0V.
  • electrolysis is carried out by means of controlling current, and the cathode current density is controlled at 0.02-1.0 A/cm 2 ; or electrolysis is carried out by means of a control voltage, and the cell voltage is controlled at 0.5 V - 2 V.
  • the waste cemented carbide is one of tungsten carbide waste, YG3, YG6, and YG8, and the added metal oxide is CoO, Co 3 O 4 , FeO, Fe 3 O 4 ,
  • One of CuO, NiO, and Ni 2 O 5 is electrolyzed by means of a control voltage.
  • the cell voltage is controlled at 1.0-2.0 V, and gas is used for electrolysis.
  • the volume of oxygen in the gas used for protection is 0-10. %.
  • the product obtained by electrolysis is controlled by controlling the added metal oxide, which is CoO or Co 3 O 4 , and the prepared tungsten-based alloy powder is W-Co; the metal oxide is CuO, and the prepared tungsten is prepared.
  • the base alloy powder is W-Cu, the metal oxide is NiO or Ni 2 O 5 , and the prepared tungsten-based alloy powder is W-Ni.
  • the added metal oxide is one or more of CoO and Co 3 O 4 , and the use control
  • the current is electrolyzed to control the cell voltage to 1.0V-2.0V.
  • Gas is used for electrolysis, and the volume of oxygen in the gas used for protection is 0-10%.
  • the obtained W-Co alloy powder was prepared.
  • the gas for protection may be one or more mixed gases of oxygen, air, nitrogen, and argon.
  • the separation of the molten salt medium from the product powder is carried out by pickling, water washing, centrifugation and vacuum drying. Further, the drying temperature is 30-60 ° C, the drying time is 8-24 hours, the pH of the pickling solution is 5-6.5, and the acid for adjusting the pH is one of sulfuric acid, hydrochloric acid, acetic acid, phosphoric acid or A variety.
  • the metal tungsten and cobalt in the waste cemented carbide are directly dissolved into the molten salt medium in the form of ions, and driven by the electrolytic voltage, and the metal oxide in the molten salt medium.
  • a tungsten-based alloy powder is prepared by co-deposition at the cathode. The method not only realizes the recycling of the cobalt-containing waste cemented carbide, but also realizes the one-step regeneration process from scrap to product, which greatly shortens the existing waste cemented carbide recycling and tungsten-based alloy powder preparation process, and reduces the process flow. Production costs. At the same time, this process is adopted, there is no discharge of solid and liquid waste, and the environment is friendly, and industrial production can be realized.
  • the invention proposes a method for directly preparing a tungsten-based alloy powder by using a waste cemented carbide, and the tungsten-based alloy powder obtained by electrolysis can be a nanometer or micron powder, and the powder particle size ranges from 100 nm to 500 um, and the purity is reached. 99.1%.
  • the electrolysis device is: the electrolyzer is a graphite crucible, and is placed in a closed container, which provides gas protection and electric heating.
  • the cathode and anode extend into the molten salt in the electrolytic cell.
  • W-Cu alloy powder was prepared by molten salt electrolysis using tungsten carbide waste as a consumable anode.
  • the size of the tungsten carbide scrap is 4mm ⁇ 4mm ⁇ 18mm, and the depth of the molten salt interface is 6mm.
  • the electrolytic cell is protected by 99% high-purity argon gas.
  • the composition of the molten salt electrolyte system is NaF-KF (39.7% mol-60.3% mol), and the added metal oxide is CuO, which accounts for 2% of the NaF-KF mole fraction.
  • the CuO powder was dehydrated in air at 250 ° C for 10 h, and the NaF-KF powder was dehydrated at 300 ° C for 24 h, followed by pre-electrolysis at a bath voltage of 0.8 V for 2 h. Then used for electrolysis.
  • the electrolysis temperature was 800 ° C
  • the metal nickel sheet (8 mm ⁇ 40 mm ⁇ 0.3 mm) was used as the cathode, and the pole pitch was 25 mm.
  • the electrode and the lead connection were sealed by a refractory material.
  • Control current electrolysis the electrolysis current is controlled at 100 mA, and the electrolysis time is 4 h.
  • the product obtained by electrolysis was collected by pickling, washing with water, centrifugation, and blast drying.
  • the pickling is a hydrochloric acid solution, the pH is controlled at 5, the blast drying temperature is 40 ° C, and the drying time is 24 h.
  • the W-Cu alloy powder obtained by electrolysis has a purity of 99.1%.
  • the current efficiency is 40%-50%.
  • the W-Co alloy powder was prepared by molten salt electrolysis using tungsten carbide waste as a consumable anode.
  • the size of the tungsten carbide scrap is 4mm ⁇ 4mm ⁇ 18mm, the depth of the molten salt interface is 4mm, and the electrolytic cell is protected by 99% high-purity argon gas.
  • the molten salt system consists of NaCl-KCl (50% mol-50% mol), and the added metal oxide is CoO with a molar mass fraction of 1%.
  • the CoO powder was dehydrated in air at 200 ° C for 10 h, and the NaF-KF powder was dehydrated at 300 ° C for 24 h, then pre-electrolyzed at a cell voltage of 1.0 V for 2 h, and then used for electrolysis.
  • the electrolysis temperature is 750 ° C
  • the metal nickel sheet (8 mm ⁇ 40 mm ⁇ 0.3 mm) is the cathode
  • the pole spacing is 35 mm
  • the current is controlled
  • the electrolysis current is controlled at 100 mA
  • the electrolysis time is 6 h.
  • the product obtained by electrolysis was collected by washing with water, centrifugation, and blast drying.
  • the blast drying temperature was 40 ° C and the drying time was 6 h.
  • the W-Co alloy powder obtained by electrolysis has a purity of 98.4% and a current efficiency of 40%-70%.
  • the waste cemented carbide is used as a consumable anode, and the W-Ni alloy powder is prepared by molten salt electrolysis.
  • the waste cemented carbide is WC-6% Co, the size is 4mm ⁇ 4mm ⁇ 18mm, the depth of the molten salt interface is 10mm, and the electrolytic cell is protected by 10% oxygen + argon gas mixture.
  • the composition of the molten salt system is NaF-KF (39.7% mol-60.3% mol), and the added metal oxide is NiO, and the mole fraction of NaF-KF is 5%.
  • NiO powder was dehydrated in air at 250 ° C for 10 h, and the NaF-KF powder was dehydrated at 300 ° C for 24 h, then pre-electrolyzed at a cell voltage of 1.0 V for 2 h, and then used for electrolysis.
  • the electrolysis temperature is 850 ° C
  • the metal nickel sheet (8 mm ⁇ 40 mm ⁇ 0.3 mm) is the cathode
  • the pole spacing is 40 mm
  • the current is controlled
  • the electrolysis current is controlled at 60 mA
  • the electrolysis time is 4 h.
  • the product obtained by electrolysis was collected by washing with water, centrifugation, and blast drying.
  • the blast drying temperature was 40 ° C and the drying time was 10 h.
  • the W-Ni alloy powder obtained by electrolysis has a purity of 98.9% and a current efficiency of about 50% to 60%.
  • the waste cemented carbide is used as a consumable anode, and the W-Co alloy powder is prepared by molten salt electrolysis.
  • the waste cemented carbide is WC-15% Co and the size is 4 mm ⁇ 4 mm ⁇ 18 mm.
  • the depth of the molten salt interface is 10mm, and the electrolytic cell is protected by 99% high-purity nitrogen gas.
  • the molten salt system consists of NaCl-CaCl 2 (48% mol-52% mol), and the added metal oxide is CoO, which accounts for 1% of the NaF-KF mole fraction.
  • the CoO powder was dehydrated in air at 200 ° C for 10 h, and the NaF-KF powder was dehydrated at 300 ° C for 24 h, then pre-electrolyzed at a cell voltage of 1.0 V for 2 h, and then used for electrolysis.
  • the electrolysis temperature is 700 ° C
  • the metal nickel sheet (8 mm ⁇ 40 mm ⁇ 0.3 mm) is the cathode
  • the pole spacing is 25 mm
  • the control voltage is electrolyzed
  • the electrolysis voltage is controlled at 1.2 V
  • the electrolysis time is 4 h.
  • the product obtained by electrolysis was collected by pickling, washing with water, centrifugation, and blast drying.
  • the pH of the pickling solution was 6, the temperature of the blast drying was 40 ° C, and the drying time was 10 h.
  • the W-Co alloy powder obtained by electrolysis has a purity of 98.6% and a current efficiency of 40% to 50%.
  • the waste cemented carbide is used as a consumable anode, and the W-Co alloy powder is prepared by molten salt electrolysis.
  • the waste cemented carbide is WC-10%Co, the size is 4mm ⁇ 4mm ⁇ 18mm, the depth of the molten salt interface is 6mm, and the electrolytic cell is protected by 10% oxygen + argon gas.
  • the molten salt system has a composition of NaF-CaF 2 (68.8% mol - 31.2% mol), and the added metal oxide is CoO, and the mole fraction of NaF-KF is 1%.
  • the CoO powder was dehydrated in air at 200 ° C for 10 h, and the NaF-KF powder was dehydrated at 300 ° C for 24 h, then pre-electrolyzed at a cell voltage of 1.0 V for 2 h, and then used for electrolysis.
  • the electrolysis temperature was 900 ° C
  • the metal nickel sheet (8 mm ⁇ 40 mm ⁇ 0.3 mm) was used as the cathode
  • the pole spacing was 25 mm
  • the current was controlled
  • the electrolysis current was controlled at 80 mA
  • the electrolysis time was 4 h.
  • the product obtained by electrolysis was collected by pickling, washing with water, centrifugation, and blast drying.
  • the pH of the pickling solution is controlled at 5, the temperature at which the blast is dried is 40 ° C, and the drying time is 24 h.
  • the W-Co alloy obtained by electrolysis has a purity of 97.2% and a current efficiency of 60% to 70%.
  • the invention provides a method for directly preparing a tungsten-based alloy powder by electrolytic waste cemented carbide.
  • the method of the present invention comprises the steps of: (1) proportioning raw material: molten salt electrolyte composition is (x) A-(y)B and C, C is metal oxide, (2) setting electrode: using waste cemented carbide as The anode is made of a nickel plate as a cathode, and (3) electrolysis: electrolysis is carried out in a molten molten salt electrolyte containing a metal oxide, and the electrolysis temperature is 600 ° C - 1000 ° C by means of constant current electrolysis or constant pressure electrolysis.
  • the tungsten and cobalt in the waste cemented carbide are directly dissolved into the molten salt medium in the form of ions, and the tungsten oxide is obtained at the cathode by co-deposition with the metal oxide in the molten salt medium.
  • Alloy powder The method not only realizes the recycling of the cobalt-containing waste cemented carbide, but also realizes the one-step regeneration process from waste to product, which greatly shortens the existing waste cemented carbide recycling and tungsten-based alloy powder preparation process, and reduces the process. Production cost; the obtained tungsten-based alloy powder can be nano- or micro-scale powder, and the powder particle size ranges from 100 nm to 500 um, and the purity reaches 99.1%, which has good economic value and application prospect.

Abstract

本发明提出一种电解废弃硬质合金直接制备钨基合金粉末的方法，包括步骤：(1)配比原材料：熔盐电解质组成为(x)A-(y)B和C，C为金属氧化物，(2)设置电极：以废弃硬质合金为阳极，以镍板为阴极，(3)电解：在熔融的含有金属氧化物的熔盐电解质中电解，采用恒流电解或者恒压电解的方式，电解温度为600℃-1000℃。采用本发明的方案，废硬质合金中的金属钨和钴以离子的形式直接溶出进入到熔盐介质中去，与熔盐介质中的金属氧化物通过共沉积的方式在阴极得到钨基合金粉末。此方法既实现了含钴废弃硬质合金的回收利用，又实现了由废料到产品的一步再生流程，大大缩短了现有的废弃硬质合金回收再生和钨基合金粉末制备工艺流程，并且降低了生产成本。

Description

电解废弃硬质合金直接制备钨基合金粉末的方法 技术领域
本发明属于冶金领域，涉及一种电解处理废弃硬质合金的方法，更具体地，涉及一种电解废弃硬质合金直接制备钨基合金粉末的方法。
背景技术
硬质合金一般是由难熔金属钨的碳化物和粘结金属经过粉末冶金的方法制成的具有高硬度、高抗弯强度的材料，其在机械制造、矿山开采、交通运输、能源勘探、建筑装饰等领域得到了广泛的应用[1]。然而难熔金属钨和稀有金属钴是世界上公认的极为重要的战略元素，对提高国家经济、军事竞争力具有非常重要的影响。目前，全球超过50％的钨资源用于制造硬质合金，而废旧硬质合金中的钨含量就已经达到74％-91％，中国每年消费钨金属约2.7万吨，如果回收率能达到40％，对于建立资源保障体系及促进循环经济发展意义重大 [2]。
钨合金是一种以钨为基(钨含量为85％-98％)，加入少量Ni、Co、Fe、Cu、Mo、Cr等元素组成的合金，其密度高达16.5-19g/cm 3,常被称为重合金或者高密度钨合金 [3]。难熔金属钨合金的研究起源于20世纪30年代，由于它具有高密度、高强度、高硬度和好的延展性、导电性、导热性等综合优异性能，所以在国防工业、航空航天、电子信息、能源、冶金和机械加工工业中具有十分广泛的用途，在国民经济中占有重要的地位 [4]。钨合金材料应用范围较广的主要包括两大系列：W-Ni-Cu合金和W-Ni-Fe合金。W-Ni-Cu合金具有好的热导性和导电性、小的热膨胀系数，可广泛用作电接触材料、微电子封装材料和热沉材料。W-Ni-Fe合金由于具有比W-Ni-Cu合金更好的抗拉强度和延伸性，从而在国防领域有着广泛的应用 [5]。另外还有以W-Cu、W-Ni-Mo、W-Ni-Co等其他以钨为主的钨合金材料体系使得钨合金材料的应用范围迅速发展。
熔盐电解法是以一种或多种金属盐为电介质体系，根据金属元素不同的标准电极电位，通过电能与化学能相互转化以及控制电极电位实现物质 的氧化还原反应的一种方法。在制备难熔金属及其合金化合物的过程中，熔盐电化学法具有水溶液无法比拟的优势，所以得到了广泛的研究和关注。2010年，王旭 [6]等人提出了利用熔盐电解法制备钨合金复合粉末的方法，即在高温熔盐介质中，以惰性电极为阴极和阳极，通过在高温熔盐介质中添加钨酸盐和金属氧化物，采用恒压电解的方式在阴极制备得到钨基合金粉末。该工艺流程简单，没有固、液、气废弃物的排放，环境友好。但是此方法的目的在于利用熔盐电解法制备钨基合金粉末，同时对钨源进行了限定。2014年，聂祚仁等人 [7]提出了一种新的回收废硬质合金的方法，即直接以废硬质合金为阳极，钛板、不锈钢板、石墨以及碳板为阴极，在熔融的氯化物熔盐介质中利用恒压或者恒流方式电解，电解温度为350-1000℃，该工艺同样流程简单，没有污染物排放，环境友好 [5]。但是，此工艺的目的是在于通过熔盐电解法回收废弃硬质合金制备单一的金属钨粉和钴粉，而没有提出对产品进行进一步的改进。
参考文献
[1]Liao Y S,Lin H M.Wang J H,Behaviors of end milling Inconel 718 super alloy by cemented carbide tools[J].J Mater Processing Techn.2008.201:460.
[2]Michael M.全球钨市场供需情况及发展趋势[J].中国钨业,2010,25(2):1.
[3]廖春发,肖志华,王旭,等.熔盐电解法制备钨合金复合粉末技术前景[J].世界有色金属,2011(1):49-51.
[4]刘建民,鲁雄刚,李谦,陈朝祗,程红伟,吕小,周国治.熔盐电解制备难熔金属的现状与展望[J].稀有金属快报,2006(9):1-6.
[5]黄伯云,范景莲.纳米钨合金材料的研究与应用[J].中国钨业,2001(16):38-44.
[6]廖春发,焦云芬,王旭,等.一种熔盐电解制备钨基合金粉末的方法[P].中国专利：CN 101985763A。
[7]聂祚仁，席晓丽，王娜，张力文，司冠豪，马立文.一种回收硬质合金的方法[P].中国专利：CN104018190A。
发明内容
本发明的目的在于克服现有技术的不足，提供一种简单的、易于操作的、高效的直接利用废硬质合金制备钨基合金粉末的方法，实现了从废硬质合金一步再生钨基合金粉末的过程。
实现本发明目的的技术方案如下：
一种电解废弃硬质合金直接制备钨基合金粉末的方法，包括步骤：
(1)配比原材料：
熔盐电解质组成为(x)A-(y)B和C，其中x为A的百分比含量，x的取值范围为5-70mol％，y为B的摩尔百分比含量，y的取值范围为0-60mol％，
C占A，B之和的摩尔比例为0.1％-5％；所述A为CaCl 2、KF、CaF 2、NaCl、KCl中的一种，B为NaF、KF、NaCl、CaF 2中的一种，且A和B不是同样的盐；C为金属氧化物，所述金属氧化物为CoO、Co 3O 4、FeO、Fe 3O 4、CuO、NiO、Ni 2O 5中的一种或多种；
(2)设置电极：
以废弃硬质合金为阳极，以镍板为阴极，极间距10-40mm；
(3)电解：
在熔融的含有金属氧化物的熔盐电解质中电解，采用恒流电解或者恒压电解的方式，电解温度为600℃-1000℃。
其中所述步骤(1)中金属氧化物占A，B之和的摩尔比例分别为：CoO占0.1％-5％，Co 3O 4占0.1-4％，FeO占0.1％-2％，Fe 3O 4占0.5％-3％，CuO占0.6％-2％。
其中，所述步骤(2)中废弃硬质合金是碳化钨或钨钴类硬质合金，所述钨钴类硬质合金选自YG3、YG6、YG8、YG10、YG16、YG20中的一种。
进一步地，所述步骤(2)中采用耐火材料将电极与引线连接处封裹保护。
为充分除去电解质中的水分与杂质，优选地，步骤(3)电解前先进行预处理：首先金属氧化物在空气中200-300℃脱水8-15h，A，B电解质在200-350℃脱水20-30h，之后在0.1-1.0V的槽电压下预电解1-2h。
其中，采用控制电流的方式进行电解，阴极电流密度控制在0.02-1.0A/cm 2；或采用控制电压的方式进行电解，槽电压控制在0.5V-2V。
本发明一种优选技术方案为，所述废弃硬质合金为碳化钨废料、YG3、YG6、YG8中的一种，添加的金属氧化物为CoO、Co 3O 4、FeO、Fe 3O 4、CuO、NiO、Ni 2O 5中的一种，使用控制电压的方式进行电解，槽电压控制在1.0-2.0V，电解时采用气体保护，用于保护的气体中氧气的体积含量为0-10％。
通过控制添加的金属氧化物来控制电解所得产物，所述金属氧化物为CoO或Co 3O 4，制备得到的钨基合金粉末为W-Co；所述金属氧化物为CuO，制备得到的钨基合金粉末为W-Cu，所述金属氧化物为NiO或Ni 2O 5，制备得到的钨基合金粉末为W-Ni。
本发明另一种优选技术方案为，对钴质量分数较高的废硬质合金、YG10、YG16、YG20，添加的金属氧化物为CoO、Co 3O 4中的一种或多种，使用控制电流的方式进行电解使得槽电压控制在1.0V-2.0V。电解时采用气体保护，用于保护的气体中氧气的体积含量为0-10％。制备得到的W-Co合金粉末。
用于保护的气体可以为氧气、空气、氮气、氩气中的一种以上的混合气体。
进一步地，电解后，采用酸洗、水洗、离心及真空干燥进行熔盐介质与产品粉末的分离。进一步地，干燥温度为30-60℃，干燥的时间为8-24小时，酸洗的溶液的pH值为5-6.5，调节pH值的酸为硫酸、盐酸、醋酸、磷酸中的一种或多种。
本发明的有益效果在于：
(1)采用本发明的技术方案，废硬质合金中的金属钨和钴以离子的形式直接溶出进入到熔盐介质中去，在电解电压的驱动下，与熔盐介质中的金属氧化物通过共沉积的方式在阴极制备得到钨基合金粉末。此方法既实现了含钴废弃硬质合金的回收利用，同时又实现了由废料到产品的一步再生流程，大大缩短了现有的废弃硬质合金回收再生和钨基合金粉末制备工艺流程，降低了生产成本。同时采用此工艺，没有固、液废弃物的排放，环境友好，可实现工业化生产。
(2)本发明提出直接利用废硬质合金制备钨基合金粉末的方法，电解所获得的钨基合金粉末可为纳米级或者微米级粉末，其粉末粒径尺寸范围为100nm-500um，纯度达到99.1％。
具体实施方式
以下实施例用于说明本发明，但不用来限制本发明的范围。
实施例1
电解的装置为：电解槽为石墨坩埚，置于一个密闭容器中，该密闭容器提供气体保护和电加热。阴极和阳极伸入电解槽内的熔盐中。
以碳化钨废料为消耗性阳极，采用熔盐电解法制备W-Cu合金粉。碳化钨废料尺寸为4mm×4mm×18mm，插入熔盐界面深度6mm，电解槽采用99％的高纯氩气气体保护。熔盐电解质体系组成为NaF-KF(39.7％mol-60.3％mol)，添加的金属氧化物为CuO，占NaF-KF摩尔分数为2％。将CuO粉末在空气中250℃脱水10h，NaF-KF粉末在300℃脱水24h，之后在0.8V的槽电压下预电解2h。然后用于电解。
电解温度800℃，以金属镍片(8mm×40mm×0.3mm)为阴极，极间距25mm，采用耐火材料将电极与引线连接处封裹保护。
控制电流电解，电解电流控制在100mA，电解时间4h。电解所得的产物用酸洗、水洗、离心、鼓风干燥的方法进行收集。其中酸洗为盐酸溶液，pH值控制在5，鼓风干燥的温度为40℃，干燥时间24h。
电解获得的W-Cu合金粉，其纯度达到99.1％。电流效率为40％-50％。
实施例2
以碳化钨废料为消耗性阳极，采用熔盐电解法制备W-Co合金粉末。碳化钨废料尺寸为4mm×4mm×18mm，插入熔盐界面深度4mm，电解槽采用99％的高纯氩气气体保护。熔盐体系组成为NaCl-KCl(50％mol-50％mol)，添加的金属氧化物为CoO，其摩尔质量分数为1％。将CoO粉末在空气中200℃脱水10h，NaF-KF粉末在300℃脱水24h，之后在1.0V的槽电压下预电解2h，然后用于电解。
电解温度750℃，金属镍片(8mm×40mm×0.3mm)为阴极，极间距35mm，控制电流电解，电解电流控制在100mA，电解时间6h。电解所得的产物用水洗、离心、鼓风干燥的方法进行收集。其中鼓风干燥的温度为40℃，干燥时间6h。
其他设置同实施例1。
电解获得的W-Co合金粉，其纯度达到98.4％，电流效率为40％-70％.
实施例3
以废硬质合金为消耗性阳极，采用熔盐电解法制备W-Ni合金粉末。废硬质合金为WC-6％Co，尺寸为4mm×4mm×18mm，插入熔盐界面深度10mm，电解槽采用10％氧气+氩气混合气体保护。熔盐体系组成为NaF-KF(39.7％mol-60.3％mol)，添加的金属氧化物为NiO，占NaF-KF的摩尔分数为5％。将NiO粉末在空气中250℃脱水10h，NaF-KF粉末在300℃脱水24h，之后在1.0V的槽电压下预电解2h，然后用于电解。
电解温度850℃，金属镍片(8mm×40mm×0.3mm)为阴极，极间距40mm，控制电流电解，电解电流控制在60mA，电解时间4h。电解所得的产物用水洗、离心、鼓风干燥的方法进行收集。其中鼓风干燥的温度为40℃，干燥时间10h。
其他设置同实施例1。
电解获得的W-Ni合金粉，其纯度达到98.9％，电流效率约为 50％-60％。
实施例4
以废硬质合金为消耗性阳极，采用熔盐电解法制备W-Co合金粉末。废硬质合金为WC-15％Co，尺寸为4mm×4mm×18mm。插入熔盐界面深度10mm，电解槽采用99％的高纯氮气气体保护。熔盐体系组成为NaCl-CaCl 2(48％mol-52％mol)，添加的金属氧化物为CoO，占NaF-KF的摩尔分数为1％。将CoO粉末在空气中200℃脱水10h，NaF-KF粉末在300℃脱水24h，之后在1.0V的槽电压下预电解2h，然后用于电解。
电解温度700℃，金属镍片(8mm×40mm×0.3mm)为阴极，极间距25mm，控制电压电解，电解电压控制在1.2V，电解时间4h。电解所得的产物用酸洗、水洗、离心、鼓风干燥的方法进行收集。其中酸洗溶液的pH值为6，鼓风干燥的温度为40℃，干燥时间10h。
其他设置同实施例1。
电解获得的W-Co合金粉，其纯度达到98.6％，电流效率为40％-50％。
实施例5
以废硬质合金为消耗性阳极，采用熔盐电解法制备W-Co合金粉末。废硬质合金为WC-10％Co，尺寸为4mm×4mm×18mm，插入熔盐界面深度6mm，电解槽采用10％氧气+氩气气体保护。熔盐体系组成为NaF-CaF 2(68.8％mol-31.2％mol)，添加的金属氧化物为CoO，占NaF-KF的摩尔分数为1％。将CoO粉末在空气中200℃脱水10h，NaF-KF粉末在300℃脱水24h，之后在1.0V的槽电压下预电解2h，然后用于电解。
电解温度900℃，以金属镍片(8mm×40mm×0.3mm)为阴极，极间距25mm，控制电流电解，电解电流控制在80mA，电解时间4h。电解所得的产物用酸洗、水洗、离心、鼓风干燥的方法进行收集。其中酸洗溶液的PH值控制在5，鼓风干燥的温度为40℃，干燥时间24h。
其他设置同实施例1。
电解获得的W-Co合金，其纯度达到97.2％，电流效率为60％-70％。
以上的实施例仅仅是对本发明的优选实施方式进行描述，并非对本发明的范围进行限定，在不脱离本发明设计精神的前提下，本领域普通工程技术人员对本发明的技术方案作出的各种变型和改进，均应落入本发明的权利要求书确定的保护范围内。
工业实用性
本发明提供一种电解废弃硬质合金直接制备钨基合金粉末的方法。本发明所述方法包括步骤：(1)配比原材料：熔盐电解质组成为(x)A-(y)B和C，C为金属氧化物，(2)设置电极：以废弃硬质合金为阳极，以镍板为阴极，(3)电解：在熔融的含有金属氧化物的熔盐电解质中电解，采用恒流电解或者恒压电解的方式，电解温度为600℃-1000℃。采用本发明提供的方法，废硬质合金中的金属钨和钴以离子的形式直接溶出进入到熔盐介质中去，与熔盐介质中的金属氧化物通过共沉积的方式在阴极得到钨基合金粉末。此方法既实现了含钴废弃硬质合金的回收利用，又实现了由废料到产品的一步再生流程，大大缩短了现有的废弃硬质合金回收再生和钨基合金粉末制备工艺流程，降低了生产成本；所获得的钨基合金粉末可为纳米级或者微米级粉末，其粉末粒径尺寸范围为100nm-500um，纯度达到99.1％，具有较好的经济价值和应用前景。

Claims (10)

  1. 一种电解废弃硬质合金直接制备钨基合金粉末的方法，其特征在于，包括步骤：
    (1)配比原材料：
    熔盐电解质组成为(x)A-(y)B和C，其中x为A的百分比含量，x的取值范围为5-70mol％，y为B的摩尔百分比含量，y的取值范围为0-60mol％，
    C占A，B之和的摩尔比例为0.1％-5％；所述A为CaCl 2、KF、CaF 2、NaCl、KCl中的一种，B为NaF、KF、NaCl、CaF 2中的一种，且A和B不是同样的盐；C为金属氧化物，所述金属氧化物为CoO、Co 3O 4、FeO、Fe 3O 4、CuO、NiO、Ni 2O 5中的一种或多种；
    (2)设置电极：
    以废弃硬质合金为阳极，以镍板为阴极，极间距10-40mm；
    (3)电解：
    在熔融的含有金属氧化物的熔盐电解质中电解，采用恒流电解或者恒压电解的方式，电解温度为600℃-1000℃。
  2. 根据权利要求1所述的方法，其特征在于，所述步骤(1)中金属氧化物占A，B之和的摩尔比例分别为：CoO占0.1％-5％，Co 3O 4占0.1-4％，FeO占0.1％-2％，Fe 3O 4占0.5％-3％，CuO占0.6％-2％。
  3. 根据权利要求1所述的方法，其特征在于，所述步骤(2)中废弃硬质合金是碳化钨或钨钴类硬质合金，所述钨钴类硬质合金选自YG3、YG6、YG8、YG10、YG16、YG20中的一种。
  4. 根据权利要求1所述的方法，其特征在于，所述步骤(2)中采用耐火材料将电极与引线连接处封裹保护。
  5. 根据权利要求1所述的方法，其特征在于，步骤(3)电解前先进行预处理，首先将金属氧化物在空气中200-300℃脱水8-15h，A，B电解质在200-350℃脱水20-30h，之后在0.1-1.0V的槽电压下预电解1-2h。
  6. 根据权利要求1所述的方法，其特征在于，采用控制电流的方式进行电解，阴极电流密度控制在0.02-1.0A/cm 2；或采用控制电压的方式进行电解，槽电压控制在0.5V-2V。
  7. 根据权利要求1-6任一项所述的方法，其特征在于，所述废弃硬质合金为碳化钨废料、YG3、YG6、YG8中的一种，添加的金属氧化物为CoO、Co 3O 4、FeO、Fe 3O 4、CuO、NiO、Ni 2O 5中的一种，使用控制电压的方式进行电解，槽电压控制在1.0-2.0V，电解时采用气体保护，用于保护的气体中氧气的体积含量为0-10％。
  8. 根据权利要求7所述的方法，其特征在于，通过控制添加的金属氧化物来控制电解所得产物，所述金属氧化物为CoO或Co 3O 4，制备得到的钨基合金粉末为W-Co；所述金属氧化物为CuO，制备得到的钨基合金粉末为W-Cu，所述金属氧化物为NiO或Ni 2O 5，制备得到的钨基合金粉末为W-Ni。
  9. 根据权利要求1-6任一项所述的方法，其特征在于，所述废弃硬质合金为YG10、YG16、YG20中的一种，添加的金属氧化物为CoO、Co 3O 4中的一种或多种，使用控制电流的方式进行电解使得槽电压控制在1.0V-2.0V；电解时采用气体保护，用于保护的气体中氧气的体积含量为0-10％，制备得到W-Co合金粉末。
  10. 根据权利要求1-6任一项所述的方法，其特征在于，电解后，采用酸洗、水洗、离心及真空干燥进行熔盐介质与产品粉末的分离，其中干燥温度为30-60℃，干燥的时间为8-24小时，酸洗的溶液的pH值为5-6.5，调节pH值的酸为硫酸、盐酸、醋酸、磷酸中的一种或多种。
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CN108149279A (zh) * 2017-11-30 2018-06-12 北京工业大学 电解废弃硬质合金直接制备钨基合金粉末的方法

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