AU2016415075B2 - ZrO2-Al2O3 Multiphase Ceramic Particle for Wear-Resistance Application, Preparation Method Therefor and Use Thereof - Google Patents

ZrO2-Al2O3 Multiphase Ceramic Particle for Wear-Resistance Application, Preparation Method Therefor and Use Thereof Download PDF

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AU2016415075B2
AU2016415075B2 AU2016415075A AU2016415075A AU2016415075B2 AU 2016415075 B2 AU2016415075 B2 AU 2016415075B2 AU 2016415075 A AU2016415075 A AU 2016415075A AU 2016415075 A AU2016415075 A AU 2016415075A AU 2016415075 B2 AU2016415075 B2 AU 2016415075B2
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Xiaorong DONG
Haiyan Wang
Juan Wang
Xiulian WANG
Kaihong ZHENG
Nan ZHOU
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Institute Of Materials And Processing Guangdong Academy Of Sciences
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped 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
    • C04B35/101—Refractories from grain sized mixtures
    • C04B35/106—Refractories from grain sized mixtures containing zirconium oxide or zircon (ZrSiO4)
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/48—Shaped 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 zirconium or hafnium oxides, zirconates, zircon or hafnates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/04—Making ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/08—Making cast-iron alloys
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
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Abstract

Disclosed are wear-resistant ZrO

Description

ZrO 2 -A12 0 3 Multiphase Ceramic Particle for Wear-Resistance Application, Preparation Method Therefor and Use Thereof
Field of the Invention The present invention relates to the technical field of preparation of ceramic composite, particularly to a ZrO 2 -A1 2 0 3 multiphase ceramic particle for wear-resistance application, a preparation method therefor and a use thereof.
Background of the Invention ZrO2 -A12 0 3 multiphase ceramics have high toughness, comparative hardness, high wear resistance and adjustable thermal expansion coefficient, and thus can be used as reinforcements for high chromium cast iron, alloy steel and spheroidal graphite cast iron. For ceramics which are large piece-shaped and have smooth surface, due to the poor combination of traditional reinforcements and metal matrices, cracks and spalling of the ceramics occur during the preparation and application of the composite materials, affecting the performance of the composite materials. Therefore, it is of great significance to prepare ceramic particles having a rough surface, a certain particle size, and a high wear resistance and use the particles as reinforcements for metal matrix composite materials.
Summary of the Invention At least one aspect of the present invention provides a rough-surfaced and high wear-resistant ZrO 2 -A120 3 multiphase ceramic particle which is used as reinforcement for steel matrix composite materials, a preparation method therefor, and a use thereof. The present invention provides a ZrO 2 -A1 2 0 3 multiphase ceramic particle for wear-resistance application, and its composition by weight percentage is: 10-90% of stabilized ZrO 2 and 10-90% of Al 2 0 3 .
The stabilized ZrO2 comprises a stabilizer including one or a mixture of two or more in any ratio selected from the group consisting of MgO, TiO2, and Y20 3 , a content of the stabilizer being not higher than 5% of a weight of ZrO 2 .
The present invention further provides a method for preparing the ZrO 2-A1 20 3 multiphase ceramic particle for wear-resistance application, comprising the following steps: (1) disposing stabilized ZrO2 and Al203 powders in a ball-milling container proportionally and ball-milling, the contents of stabilized ZrO2 and Al203 powders by weight percentage being 10-90% of stabilized ZrO2 and 10-90% of Al20 3 ; the stabilized ZrO2 powders comprising a stabilizer including one or a mixture of two or more in any ratio selected from the group consisting of MgO, TiO2, and Y20 3 , a content of the stabilizer being not higher than 5% of a weight of ZrO 2 ; (2) disposing the ball-milled mixture in a mould and performing isostatic pressing to obtain a ZrO 2-A1 20 3 multiphase ceramic green body; (3) disposing the multiphase ceramic green body in an electric furnace and sintering with a sintering temperature of 1100-1200°C which is maintained for 2-3 hours;
(4) grinding the sintered multiphase ceramic green body and then sieving to obtain rough-surfaced multiphase ceramic particles of 0.5-7 mm; and (5) disposing the multiphase ceramic particles in an electric furnace, sintering with a heating rate less than 60°C/h and a sintering temperature of 1500-1600°C which is maintained for 2-3 hours, cooling to 500-600°C with a cooling rate less than 100°C/h, and then subjecting the particles to air cooling. Furthermore, as a preferred embodiment, in step (1), a material-to-ball ratio is 3:1, ZrO 2 hard balls are used for the ball-milling, the ball-milling container is made of polyester material, a ball mill rotational speed is 100-200 revolutions per minute, and the ball-milling is performed for 12-36 hours. Furthermore, as a preferred embodiment, in step (2), a moulding pressure is 250-300 MPa and maintained for 0.5-1 hour. Furthermore, as a preferred embodiment, in step (3), the sintering is performed with a heating rate of less than 80°C/h. Furthermore, as a preferred embodiment, in step (3), the grinding is performed with ajaw crusher. The present invention further provides use of the ZrO 2-Al 20 3 multiphase ceramic particle for wear-resistance application in preparing high chromium cast iron matrix wear-resistant composite material reinforced with ZrO 2 -Al2 0 3 multiphase ceramic particles, wherein, as a preferred embodiment, the particles are combined with high chromium cast iron through a gravity casting process and a volume ratio of the ZrO2 -Al 2 0 3 multiphase ceramic particles to high chromium cast iron is less than 1:1. The present invention further provides use of the ZrO 2-Al 20 3 multiphase ceramic particle for wear-resistance application in preparing alloy steel matrix wear-resistant composite material reinforced with ZrO 2 -Al 20 3 multiphase ceramic particles, wherein, as a preferred embodiment, the particles are combined with alloy steel through a gravity casting process and a volume ratio of the ZrO 2-Al 20 3 multiphase ceramic particles to alloy steel is less than 1:1. The present invention further provides use of the ZrO 2-Al 20 3 multiphase ceramic particle for wear-resistance application in preparing spheroidal graphite cast iron matrix wear-resistant composite material reinforced with ZrO 2 -Al2 0 3 multiphase ceramic particles, wherein, as a preferred embodiment, the particles are combined with spheroidal graphite cast iron through a gravity casting process and a volume ratio of the ZrO 2 -Al2 0 3 multiphase ceramic particles to spheroidal graphite cast iron is less than 1:1. Compared with the prior art, the present invention has achieved the following technical effects. In the present invention, ZrO 2 -Al 20 3 composite powders are adopted and subjected to isostatic pressing and initial sintering to obtain a green body having a certain strength which is not too high but suitable for grinding, while the ground ceramic particles are subjected to high temperature sintering to obtain high strength and hardness. Meanwhile, since microcracks formed on the ground ceramic particles will heal during the high temperature sintering process, adjusting the cooling rate after the sintering can enhance the formation of tetragonal phase in the ZrO 2-Al 20 3 multiphase ceramic particles and increase toughness of the ZrO 2-Al 20 3 multiphase ceramic particles. Therefore, through isostatic pressing, initial sintering, grinding, high temperature sintering, and adjusting cooling rate, rough-surfaced ceramic particle with a certain particle size and high wear-resistance is obtained, which is a ZrO2 -Al 2 0 3 multiphase ceramic particle used as reinforcement for steel matrix composite materials. In summary, a ceramic particle prepared by the present invention has the following advantages: 1. The multiphase ceramic particle has a fracture toughness of greater than or equal to 7 J/cm2 , and a hardness of greater than 1300HV. 2. As a reinforcement material, the particle can be well combined with high chromium cast iron, alloy steel and spheroidal graphite cast iron, and composite materials thereof show wear resistances 3-6 times of those of the corresponding matrices. The present invention will be further described with reference to the drawings.
Description of the Drawings Fig 1 is a photograph showing ZrO 2 -Al 20 3 multiphase ceramic particles as prepared according to embodiment 2 of the present invention. Fig 2 is an X-ray diffraction pattern of the ZrO 2 -Al20 3 multiphase ceramic particles as prepared according to embodiment 2 of the present invention. Fig 3 is a micrograph showing a steel matrix composite material reinforced with ZrO2 -Al 2 0 3 multiphase ceramic particles as prepared according to embodiment 2 of the present invention.
Detailed Description of the Embodiments The above-mentioned and other technical features and advantages of the present invention will be described in detail with reference to the following embodiments. Embodiment 1 (1) ZrO 2 -Al 2 0 3 multiphase ceramic green body (a) Disposing by weight percentage 75% of stabilized ZrO 2 (the stabilized ZrO 2 comprises 4% of MgO2 by weight percentage) and 25% of A1 2 0 3 proportionally in a ball-milling container with a material-to-ball ratio of 3:1, and ball-milling for 25 hours with a ball mill rotational speed of 150 revolutions per minute, where ZrO 2 hard balls are used for the ball-milling and the ball-milling container is made of polyester material. (b) Disposing the ball-milled mixture in a mould and performing isostatic pressing with a moulding pressure of 260 MPa which is maintained for 0.6 hour to obtain a ZrO 2 -Al2 0 3 multiphase ceramic green body. (c) Disposing the multiphase ceramic green body in an electric furnace and sintering with a sintering temperature of 1130°C which is maintained for 2.5 hours and a heating rate of 70°C/h. (2) Preparation of ZrO 2 -Al2 0 3 multiphase ceramic particles (d) Grinding the sintered multiphase ceramic green body with a jaw crusher and then sieving to obtain rough-surfaced multiphase ceramic particles of 1 mm. (e) Disposing the multiphase ceramic particles of 1 mm in an electric furnace, sintering with a heating rate of 50°C/h and a sintering temperature of 1550°C which is maintained for 2.5 hours, then cooling the particles to 550°C with a cooling rate of 90°C/h, taking the particles out of the furnace and subjecting the particles to air cooling. The particles show a fracture toughness of 9.1 J/cm 2, and a hardness of 1310HV. (3) Application of the ZrO 2-Al2 0 3 multiphase ceramic particles: Combining the above ZrO 2-Al 20 3 multiphase ceramic particles with high chromium cast iron through a gravity casting process (a volume ratio of the ceramic particles to high chromium cast iron is 1:1) to obtain a high chromium cast iron matrix wear-resistant composite material reinforced with ZrO 2-Al 20 3 multiphase ceramic particles showing good combination, and the composite material shows a wear-resistance 5.8 times of the high chromium cast iron matrix. Embodiment 2 (1) ZrO 2 -Al 2 0 3 multiphase ceramic green body (a) Disposing by weight percentage 45% of stabilized ZrO 2 (the stabilized ZrO 2 comprises 4.5% of TiO2 by weight percentage) and 55% of A12 0 3 proportionally in a ball-milling container with a material-to-ball ratio of 3:1, and ball-milling for 30 hours with a ball mill rotational speed of 160 revolutions per minute, where ZrO 2 hard balls are used for the ball-milling and the ball-milling container is made of polyester material. (b) Disposing the ball-milled mixture in a mould and performing isostatic pressing with a moulding pressure of 270 MPa which is maintained for 0.7 hour to obtain a ZrO 2 -Al2 0 3 multiphase ceramic green body. (c) Disposing the multiphase ceramic green body in an electric furnace and sintering with a sintering temperature of 1150°C which is maintained for 2.5 hours and a heating rate of 65°C/h. (2) Preparation of ZrO 2 -Al2 0 3 multiphase ceramic particles (d) Grinding the sintered multiphase ceramic green body with a jaw crusher and then sieving to obtain rough-surfaced multiphase ceramic particles of 3 mm. (e) Disposing the multiphase ceramic particles of 3 mm in an electric furnace, sintering with a heating rate of 55°C/h and a sintering temperature of 1560°C which is maintained for 2.5 hours, then cooling the particles to 560°C with a cooling rate of 95°C/h, taking the particles out of the furnace and subjecting the particles to air cooling. The particles show a fracture toughness of 8.4 J/cm 2, and a hardness of 1390HV. Fig 1 is a photograph showing ZrO 2 -Al 20 3 multiphase ceramic particles as prepared according to this embodiment 2. Fig 2 is an X-ray diffraction pattern of the ZrO 2 -Al20 3 multiphase ceramic particles as prepared according to this embodiment 2. (3) Application of the ZrO 2-Al2 0 3 multiphase ceramic particles: Combining the above ZrO2 -Al2 0 3 multiphase ceramic particles with high manganese steel through a gravity casting process (a volume ratio of the ceramic particles to high manganese steel is 1:1.1) to obtain a high manganese steel matrix wear-resistant composite material reinforced with ZrO 2-Al 20 3 multiphase ceramic particles showing good combination (as shown in the micrograph of Fig 3), and the composite material shows a wear-resistance 4 times of the high manganese steel matrix. Embodiment 3 (1) ZrO 2 -Al 2 0 3 multiphase ceramic green body (a) Disposing by weight percentage 15% of stabilized ZrO 2 (the stabilized ZrO 2 comprises 5% of Y 2 0 3 by weight percentage) and 85% of A1 2 0 3 proportionally in a ball-milling container with a material-to-ball ratio of 3:1, and ball-milling for 35 hours with a ball mill rotational speed of 180 revolutions per minute, where ZrO 2 hard balls are used for the ball-milling and the ball-milling container is made of polyester material. (b) Disposing the ball-milled mixture in a mould and performing isostatic pressing with a moulding pressure of 280 MPa which is maintained for 0.8 hour to obtain a ZrO 2 -Al2 0 3 multiphase ceramic green body. (c) Disposing the multiphase ceramic green body in an electric furnace and sintering with a sintering temperature of 1170°C which is maintained for 2.5 hours and a heating rate of 55°C/h. (2) Preparation of ZrO 2 -Al2 0 3 multiphase ceramic particles (d) Grinding the sintered multiphase ceramic green body with a jaw crusher and then sieving to obtain rough-surfaced multiphase ceramic particles of 5 mm. (e) Disposing the multiphase ceramic particles of 5 mm in an electric furnace, sintering with a heating rate of 50°C/h and a sintering temperature of 1570°C which is maintained for 2.5 hours, then cooling the particles to 570°C with a cooling rate of 85°C/h, taking the particles out of the furnace and subjecting the particles to air cooling. The particles show a fracture toughness of 7.9 J/cm 2, and a hardness of 1460HV. (3) Application of the ZrO 2-Al2 0 3 multiphase ceramic particles: Combining the above ZrO 2 -Al20 3 multiphase ceramic particles with spheroidal graphite cast iron through a gravity casting process (a volume ratio of the ceramic particles to spheroidal graphite cast iron is 1:1.2) to obtain a spheroidal graphite cast iron matrix wear-resistant composite material reinforced with ZrO 2 -Al2 0 3 multiphase ceramic particles showing good combination, and the composite material shows a wear-resistance 4 times of the spheroidal graphite cast iron matrix. The above embodiments are preferred embodiments but not to limit the present invention. Any amendment and modification that based on the principal of the present invention shall fall within the scope of the present invention.

Claims (9)

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:
1. A method for preparing a ZrO 2-Al203 multiphase ceramic particle for wear-resistance application, the method comprising the following steps: (1) disposing stabilized ZrO 2 and A1203 powders in a ball-milling container proportionally and ball-milling, the contents of stabilized ZrO 2 and A1203 powders by weight percentage being 10-90% of stabilized ZrO 2 and 10-90% of A120 3 ; the stabilized ZrO2 powders comprising a stabilizer including one or a mixture of two or more in any ratio selected from the group consisting of MgO, TiO 2, and Y2 0 3 , a content of the stabilizer being not higher than 5% of a weight of ZrO 2 ; (2) disposing the ball-milled mixture in a mould and performing isostatic pressing to obtain a ZrO 2-Al203 multiphase ceramic green body; (3) disposing the multiphase ceramic green body in an electric furnace and sintering with a sintering temperature of 1100-1200°C which is maintained for 2-3 hours; (4) grinding the sintered multiphase ceramic green body and then sieving to obtain rough-surfaced multiphase ceramic particles of 0.5-7 mm; and (5) disposing the multiphase ceramic particles in an electric furnace, sintering with a heating rate less than 60°C/h and a sintering temperature of 1500-1600°C which is maintained for 2-3 hours, cooling to 500-600°C with a cooling rate less than 100°C/h, and then subjecting the particles to air cooling.
2. The method according to claim 1 for preparing the ZrO 2-Al203 multiphase ceramic particle for wear-resistance application, wherein, in step (1), a material-to-ball ratio is 3:1, ZrO2 hard balls are used for the ball-milling, the ball-milling container is made of polyester material, a ball mill rotational speed is 100-200 revolutions per minute, and the ball-milling is performed for 12-36 hours.
3. The method according to claim 1 for preparing the ZrO 2-Al203 multiphase ceramic particle for wear-resistance application, wherein, in step (2), a moulding pressure is 250-300 MPa and maintained for 0.5-1 hour.
4. The method according to claim 1 for preparing the ZrO 2-Al203 multiphase ceramic particle for wear-resistance application, wherein, in step (3), the sintering is performed with a heating rate of less than 80°C/h.
5. The method according to claim 1 for preparing the ZrO 2-Al203 multiphase ceramic particle for wear-resistance application, wherein, in step (3), the grinding is performed with a jaw crusher.
6. A ZrO 2 -Al203 multiphase ceramic particle for wear-resistance application prepared by the method of any one of claims I to 5.
7. Use of the ZrO 2 -A 2 0 3 multiphase ceramic particle for wear-resistance application according to claim 6 in preparing high chromium cast iron matrix wear-resistant composite material reinforced with ZrO 2 -Al20 3 multiphase ceramic particles, wherein the particles are preferably combined with high chromium cast iron through a gravity casting process and a volume ratio of the ZrO 2-Al 20 3 multiphase ceramic particles to high chromium cast iron is less than 1:1.
8. Use of the ZrO 2 -Al2 0 3 multiphase ceramic particle for wear-resistance application according to claim 6 in preparing alloy steel matrix wear-resistant composite material reinforced with ZrO 2-Al 20 3 multiphase ceramic particles, wherein the particles are preferably combined with alloy steel through a gravity casting process and a volume ratio of the ZrO 2 -Al20 3 multiphase ceramic particles to alloy steel is less than 1:1.
9. Use of the ZrO 2 -Al2 0 3 multiphase ceramic particle for wear-resistance application according to claim 6 in preparing spheroidal graphite cast iron matrix wear-resistant composite material reinforced with ZrO 2 -Al20 3 multiphase ceramic particles, wherein the particles are preferably combined with spheroidal graphite cast iron through a gravity casting process and a volume ratio of the ZrO 2-Al 20 3 multiphase ceramic particles to spheroidal graphite cast iron is less than 1:1.
Fig 1
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1/2
Fig 3
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AU2016415075A 2016-07-14 2016-07-19 ZrO2-Al2O3 Multiphase Ceramic Particle for Wear-Resistance Application, Preparation Method Therefor and Use Thereof Active AU2016415075B9 (en)

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