CN107522476B - Manufacturing method of wear-resistant ceramic roller lining plate - Google Patents

Manufacturing method of wear-resistant ceramic roller lining plate Download PDF

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CN107522476B
CN107522476B CN201710849064.2A CN201710849064A CN107522476B CN 107522476 B CN107522476 B CN 107522476B CN 201710849064 A CN201710849064 A CN 201710849064A CN 107522476 B CN107522476 B CN 107522476B
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base material
lining plate
powder
mixing
milling
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CN107522476A (en
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张鑫军
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Pingxiang Xingfeng High Tech Industrial Co ltd
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Pingxiang Xingfeng High Tech Industrial Co ltd
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    • 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
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Abstract

The invention discloses a method for manufacturing a wear-resistant ceramic roller lining plate, which comprises the steps of ball-milling and mixing 30-40wt% of aluminum trioxide, 10-20 wt% of kaolin, 10-25wt% of alumina, 20-35wt% of quartz powder, 5-10wt% of feldspar powder and 1-3wt% of zirconium oxide according to a proportion to obtain a base material, adding 1-3wt% of carboxymethyl cellulose and 2-5 wt% of Guangdong black mud into the base material, carrying out ball-milling and stirring uniformly to obtain clinker, spraying reinforcing materials accounting for 1-3wt% of the base material into the clinker under the air pressure of 0.3-0.5MPa, carrying out ball-milling, mixing and stirring to obtain powdery materials, carrying out extrusion molding on the powdery materials to obtain a lining plate blank, drying, firing, cooling and discharging from a furnace. It improves the elastic modulus and fracture toughness of the base material crystal grains, so that the lining plate not only has high compression strength and bending strength and high acid and alkali corrosion resistance, but also has better fracture toughness and impact resistance.

Description

Manufacturing method of wear-resistant ceramic roller lining plate
Technical Field
The invention relates to a conveyor part, in particular to a manufacturing method of a wear-resistant ceramic lining plate of a conveyor transmission and bend pulley.
Background
As is known, the conveyer is a conveying device which has the advantages of large conveying capacity, high conveying efficiency, low conveying cost, no dust, low noise, no limitation by factors such as topography, climate and environment and the like and can realize long-distance and long-time continuous conveying. The conveying roller and the bend roller of the traditional conveyor mostly adopt cast rubber or viscose glue arranged on the surface of a processed steel pipe as a wear-resistant layer, but the cast rubber or viscose glue conveying and bend roller has low wear resistance in the actual use process, the service life of the roller is short, the roller needs to be frequently exchanged, the maintenance time is increased, the working cost of the conveyor is improved, and the conveying efficiency of the conveyor is reduced. At present, the conveying and bend drums of the conveyor are made of integral ceramic, and although the wear resistance is improved and the service life is prolonged, the integral ceramic drum is heavy in weight, large in transmission resistance, high in electric power consumption and troublesome in processing and installation. At present, people mostly adopt to lay a high-aluminum ceramic lining plate on the surface of a steel roller body, although the mechanical strength and the acid-base corrosion of the roller body are high, the wear resistance is high, and the weight is reduced, firstly, a connecting glue layer between the lining plate and the surface of the roller body is easy to fall off, the lining plate is easy to loosen, the antiskid property of the contact surface between the lining plate and a belt is not high, the belt is easy to slip, and even safety accidents such as derailment of the belt can be caused, thirdly, the mechanical strength of the ceramic lining plate is high, but the content of aluminum trioxide is up to more than 80%, the sintering temperature of the lining plate is up to more than 1650 ℃, the firing time is 30-40 hours, the sintering shrinkage rate is up to 20%, the brittleness of the lining plate is high, the impact resistance is not good.
Disclosure of Invention
Aiming at the problems of the high-aluminum ceramic lining plate in the prior art, the invention provides the manufacturing method of the lining plate, which has the advantages of high mechanical strength, low brittleness, good impact resistance, difficult fracture, small transmission resistance and long service life.
The invention relates to a manufacturing method of a wear-resistant ceramic roller lining plate, which comprises the following steps:
1. firstly, 30-40wt% of alumina, 10-20 wt% of kaolin, 10-25wt% of alumina, 20-35wt% of quartz powder, 5-10wt% of feldspar powder and 1-3wt% of zirconia are ball-milled and mixed according to the proportion to obtain a base material,
2. ball-milling and mixing a nanoscale rare earth powder material accounting for 3-5% of the weight of the base material and a composite accounting for 0.2-0.5% of the weight of the base material and formed by nanoscale magnesium oxide, mullite and aluminum nitride to obtain an intermediate material, adding a proper amount of water and a silane coupling agent into the intermediate material, heating and stirring, spray-drying, heating in a furnace in a nitrogen atmosphere to 700-800 ℃, preserving heat for 2-3 hours, crushing, sieving by a 250-mesh sieve to obtain a reinforcing material formed by mixing magnesium oxide, mullite, aluminum nitride and the rare earth powder material, wherein the weight ratio of the nanoscale magnesium oxide to the mullite to the aluminum nitride is 1-2:0.5-1:1-3,
3. adding carboxymethyl cellulose 1-3wt% of base material and Guangdong black mud 2-5 wt% of base material into base material, ball milling and stirring to obtain clinker, spraying reinforcing material 1-3wt% of base material into the clinker under the air pressure of 0.3-0.5MPa, ball milling, mixing and stirring to obtain powder material,
4. the powdery material is extruded and molded to be made into a lining board blank,
5. microwave drying the lining board blank to make the water content of the lining board blank less than 2% to obtain semi-finished lining board,
6. then the semi-finished lining plate is put into a hot air furnace for drying, so that the water content in the semi-finished lining plate is less than 0.2 percent,
7. and (3) placing the dried semi-finished lining plate into a high-temperature shuttle kiln, heating to 500-1500 ℃, preserving heat for 2-3 hours, heating to 1400-1500 ℃, preserving heat for 4-5 hours, and cooling and discharging.
The main technical indexes of the invention are as follows:
bulk density (g/cm 3): not less than 2.2, water absorption (%): less than or equal to 0.2 percent,
compressive strength (MPa): 270, flexural strength (MPa): the content of the sodium hydroxide is more than or equal to 105,
acid and alkali resistance (%): not less than 99.8, thermal stability (220-20 ℃): three times without cracking and peeling.
The preparation method of the lining plate is realized by two technical process improvements on the basis of the existing high-alumina ceramic lining plate with the alumina content of more than 80 percent: firstly, the content of alumina in the raw materials is reduced to 30-40%, and the aims of reducing the firing temperature of the lining plate, shortening the firing time, reducing the energy consumption and the production cost, reducing the firing shrinkage of the lining plate and reducing the brittleness are achieved; secondly, in order to ensure that the lining plate has high mechanical strength, high acid and alkali corrosion, higher fracture toughness and high impact resistance, the medium aluminum wear-resistant ceramic lining plate with high compression strength and bending strength is prepared by adding a reinforcing material into the raw materials and adopting a spray dispersion toughening method. The lining plate has the advantages of high temperature resistance, high mechanical strength, strong acid and alkali corrosion resistance, good fracture toughness and low brittleness, can meet the technical requirement of the lining plate on mechanical strength, can improve the thermal stability and impact resistance, reduces the material cost and prolongs the service life.
The reinforcing material used in the invention is prepared by mixing and ball-milling a nano-scale (50-100 nm) rare earth powder material and a combination formed by magnesium oxide, mullite and nitridation, heating and dissolving, spray drying, sintering under the protection of nitrogen, crushing and sieving, the phase transition temperature is reduced by adding the reinforcing material, so that reinforcing material particles are filled in gaps among base material crystal grains through phase transition strengthening, a reticular high-toughness framework formed by reinforcing material whiskers can be formed on the interface among the base material crystal grains after sintering, when the base material is stressed or impacted, relatively large elastic displacement can be generated among the crystal grains, thereby improving the elastic modulus and the fracture toughness of the base material crystal grains, leading the lining plate to have high toughness when the content of alumina is reduced to 30-40 percent, not only has high compression strength and bending strength and high acid and alkali corrosion resistance, but also has better fracture toughness and impact resistance.
The content of alumina in the lining plate is 30-40%, and the Rare Earth (RE) powder material is yttrium oxide powder (Y2O 3) or scandium oxide powder (Sc)2O3）。
The alumina content in the alumina raw material is 30-40%, and the addition of alumina can improve the rapid cooling and heating resistance and the high-temperature volume stability, prevent the deformation and the peeling of the material and prolong the service life of the material. The mullite has the characteristics of uniform expansion, excellent thermal shock stability, high loaded softening point, small high-temperature creep value, high hardness, good chemical corrosion resistance and the like.
The Guangdong black mud has the characteristics of high viscosity, high whiteness and easy dispersion, and the carboxymethyl cellulose can form a high-viscosity colloid and has the characteristics of viscosity, thickening and emulsifying dispersion.
The lining plate is in the shape of a tile with the thickness of 80-100 multiplied by 50-60 multiplied by 10-15 mm.
The inner surface or/and the outer surface of the lining plate is/are provided with grooves distributed in a diamond shape or a square shape at intervals.
Detailed Description
Embodiment 1, the manufacturing method of the wear-resistant ceramic roller lining plate of the invention comprises the following steps:
1. firstly, 35wt% of alumina, 15 wt% of kaolin, 10wt% of alumina, 30wt% of quartz powder, 7wt% of feldspar powder and 3wt% of zirconia are ball-milled and mixed according to a proportion to obtain a base material,
2. ball-milling and mixing a nanoscale rare earth powder material accounting for 4 percent of the weight of the base material and a composite which accounts for 0.3 percent of the weight of the base material and is formed by nanoscale magnesium oxide, mullite and aluminum nitride to obtain an intermediate material, adding a proper amount of water and a silane coupling agent into the intermediate material, heating and stirring, spray-drying, then sending into a furnace, heating to 700-800 ℃ in a nitrogen atmosphere, preserving heat for 2-3 hours, crushing, sieving by a 250-mesh sieve to obtain a reinforcing material formed by mixing the composite of the magnesium oxide, the mullite and the aluminum nitride and the rare earth powder material, wherein the weight ratio of the nanoscale magnesium oxide, the mullite and the aluminum nitride is 1:0.5:1,
3. adding carboxymethyl cellulose 2wt% of the base material and Guangdong black mud 3wt% of the base material into the base material, ball milling and stirring uniformly to obtain clinker, spraying reinforcing material 2wt% of the base material into the clinker under the air pressure of 0.3-0.5MPa, ball milling, mixing and stirring to obtain powdery material,
4. the powdery material is extruded and molded to be made into a lining board blank,
5. microwave drying the lining board blank to make the water content of the lining board blank less than 2% to obtain semi-finished lining board,
6. then the semi-finished lining plate is put into a hot air furnace for drying, so that the water content in the semi-finished lining plate is less than 0.2 percent,
7. and (3) placing the dried semi-finished lining plate into a high-temperature shuttle kiln, heating to 500-1500 ℃, preserving heat for 2-3 hours, heating to 1400-1500 ℃, preserving heat for 4-5 hours, and cooling and discharging to obtain the lining plate.
The lining plate of embodiment 1 of the invention has the following main technical indexes:
bulk density (g/cm 3) 2.23, water absorption (%): 0.18,
compressive strength (MPa): 270, flexural strength (MPa): 125,
acid and alkali resistance (%): 99.9, thermal stability (220-20 ℃): the product is not cracked for three times.
Embodiment 2, the manufacturing method of the wear-resistant ceramic roller lining plate of the invention comprises the following steps:
1. firstly, 40wt% of alumina, 15 wt% of kaolin, 21wt% of alumina, 22wt% of quartz powder, 10t% of feldspar powder and 2wt% of zirconia are ball-milled and mixed according to a proportion to obtain a base material,
2. mixing and ball-milling a nanoscale rare earth powder material accounting for 5 percent of the weight of the base material and a composite which accounts for 0.2 percent of the weight of the base material and is formed by nanoscale magnesium oxide, mullite and aluminum nitride to obtain an intermediate material, adding a proper amount of water and a silane coupling agent into the intermediate material, heating and stirring, spray-drying, then sending into a furnace, heating to 700-800 ℃ in a nitrogen atmosphere, preserving heat for 2-3 hours, crushing, sieving by a 250-mesh sieve to obtain a reinforcing material formed by mixing the magnesium oxide, mullite and aluminum nitride composite and the rare earth powder material, wherein the weight ratio of the nanoscale magnesium oxide to the mullite to the aluminum nitride is 1.5:1:2.5,
3. adding carboxymethyl cellulose 2wt% of the base material and Guangdong black mud 3wt% of the base material into the base material, ball milling and stirring uniformly to obtain clinker, spraying reinforcing material 2wt% of the base material into the clinker under the air pressure of 0.3-0.5MPa, ball milling, mixing and stirring to obtain powdery material,
4. the powdery material is extruded and molded to be made into a lining board blank,
5. microwave drying the lining board blank to make the water content of the lining board blank less than 2% to obtain semi-finished lining board,
6. then the semi-finished lining plate is put into a hot air furnace for drying, so that the water content in the semi-finished lining plate is less than 0.2 percent,
7. and (3) placing the dried semi-finished lining plate into a high-temperature shuttle kiln, heating to 500-1500 ℃, preserving heat for 2-3 hours, heating to 1400-1500 ℃, preserving heat for 4-5 hours, and cooling and discharging.
The main technical indexes of embodiment 2 of the invention are as follows:
bulk density (g/cm 3): 2.3, water absorption (%): 0.17,
compressive strength (MPa): 281, flexural strength (MPa): 128,
acid and alkali resistance (%): 99.9, thermal stability (220-20 ℃): the product is not cracked for three times.

Claims (2)

1. A manufacturing method of a wear-resistant ceramic roller lining plate is characterized by comprising the following steps:
a. firstly, 30-40wt% of alumina, 10-20 wt% of kaolin, 10-25wt% of alumina, 20-35wt% of quartz powder, 5-10wt% of feldspar powder and 1-3wt% of zirconia are ball-milled and mixed according to the proportion to obtain a base material,
b. mixing and ball-milling a nano-scale rare earth powder material accounting for 3-5% of the weight of the base material and a composite which accounts for 0.2-0.5% of the weight of the base material and is formed by nano-scale magnesium oxide, mullite and aluminum nitride to obtain an intermediate material, adding a proper amount of water and a silane coupling agent into the intermediate material, heating and stirring, spray-drying, then sending into a furnace, heating to 700-800 ℃ in nitrogen atmosphere, preserving the heat for 2-3 hours, crushing and sieving by a 250-mesh sieve to obtain a reinforcing material formed by mixing the magnesium oxide, mullite and aluminum nitride composite and the rare earth powder material, wherein the weight ratio of the nano-scale magnesium oxide, mullite and aluminum nitride is 1-2:0.5-1:1-3,
c. adding carboxymethyl cellulose 1-3wt% of base material and Guangdong black mud 2-5 wt% of base material into base material, ball milling and stirring to obtain clinker, spraying reinforcing material 1-3wt% of base material into the clinker under the air pressure of 0.3-0.5MPa, ball milling, mixing and stirring to obtain powder material,
d. the powdery material is extruded and molded to be made into a lining board blank,
e. microwave drying the lining board blank to make the water content of the lining board blank less than 2% to obtain semi-finished lining board,
f. then the semi-finished lining plate is put into a hot air furnace for drying, so that the water content in the semi-finished lining plate is less than 0.2 percent,
g. and (3) placing the dried semi-finished lining plate into a high-temperature shuttle kiln, heating to 500-1500 ℃, preserving heat for 2-3 hours, heating to 1400-1500 ℃, preserving heat for 4-5 hours, and cooling and discharging to obtain the lining plate.
2. The method of claim 1 wherein the method further comprises the steps of: the rare earth powder material is yttrium oxide powder or scandium oxide powder.
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