CN109400162B - 一种电火花加工用石墨及其制备方法 - Google Patents
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Abstract
本发明公开了一种电火花加工用石墨,主要由以下质量含量的原料制备而成:45%~55%的生石油焦,15%~25%的石墨粉和25%~35%的改质沥青。本发明还公开了该电火花加工用石墨的制备方法。本发明首次将生石油焦用于电火花加工用石墨的原料,所用的生石油焦的原料成本是煅后焦的三分之一,是中间相碳微球的八分之一,并且用生石油焦和人造石墨参配做成的制品,只要经过一次焙烧,一次浸渍,一次石墨化就可以满足电火花加工用石墨材料的性能要求,大大缩短了生产周期,提高了企业的产能和利润。
Description
技术领域
本发明属于石墨材料制备领域,尤其涉及一种电火花加工用石墨及其制备方法。
背景技术
电火花加工过程中,工具电极是非常重要的部位,目前电火花加工领域多选用铜电极和石墨电极作为工具电极。石墨的熔点极高,达到3650℃,而铜的熔点为1083℃,从而使得石墨电极能承受更大的电流设定条件,当放电面积与电极尺寸缩放量越大时,石墨材料高效率粗加工的优越性越显著。石墨的导热系数是铜的三分之一,其放电过程中产生的热能可更有效的去除金属材料,因此在中粗加工中,其加工效率也比铜电极要高,且根据加工经验在正确的使用条件下,石墨电极的放电加工速度要比铜电极整体快1.5—2倍;因此,石墨电极在电火花加工中被广泛使用。
目前,国内厂家生产电火花加工用石墨材料所用的原料大多为煅后焦(煅后石油焦、煅后沥青焦或这两种混合焦),也有使用中间相碳微球,但中间相碳微球成本太高,不适合用作大批量生产,对企业来说也是生产成本高。而用煅后焦做的制品需要经过二次浸渍和三次焙烧,一次石墨化处理后性能才能达到电火花加工用石墨材料的性能要求,这种配方和工艺生产周期长,加工成本大。
发明内容
本发明所要解决的技术问题是,克服以上背景技术中提到的不足和缺陷,提供一种电火花加工用石墨及其制备方法。
为解决上述技术问题,本发明提出的技术方案为:
一种电火花加工用石墨,主要由以下质量含量的原料制备而成:45%~55%的生石油焦,15%~25%的石墨粉和25%~35%的改质沥青。
上述的电火花加工用石墨,优选的,所述生石油焦的粒径D50为10μm~12μm;所述石墨粉粒径D50为11μm~13μm。
上述的电火花加工用石墨,优选的,所述生石油焦的烘后水分≤0.17%,灰分≤0.22%,挥发分≤11%,含硫量≤0.39%;所述石墨粉的水分≤0.11%,灰分≤0.12%;所述改质沥青的软化点温度为118℃,甲苯不容物(TI)≤29%。进一步优选,石墨粉是选自本公司的石墨破碎后得到的石墨粉。
本发明首次将生石油焦用作电火花加工用石墨的原料,生石油焦具有很高的挥发分,在焙烧时有***结收缩性能,对制品的体积密度和强度有很大的提升;但由于生石油焦的挥发分高,在焙烧时收缩大,制品的各个部位会产生不同的内应力极易导致制品开裂,因此,本发明通过引入石墨粉来,并将其和生石油焦按照一定配比混合制备来保证电火花加工用石墨的成品率。
作为一个总的发明构思,本发明还提供一种上述的电火花加工用石墨的制备方法,包括以下步骤:
(1)将生石油焦进行烘干,再将烘后生石油焦和石墨粉通过气流磨机磨粉后,按照配比进行干混,然后加入改质沥青进行湿混、糊料出锅后进行轧片;
(2)将步骤(1)所得的片料进行二次磨粉;
(3)将步骤(2)后所得的粉料依次进行等静压成型、焙烧、浸渍、石墨化,即得到电火花加工用石墨。
上述的制备方法,优选的,所述步骤(1)中,干混的时间为55-70min,干混后的粉体温度不低于150℃;糊料出锅的温度不低于180℃。
上述的制备方法,优选的,所述步骤(2)中,二次磨粉后的物料过200目筛网的含量超过85%。
上述的制备方法,优选的,所述步骤(3)中,等静压成型的压力为100MPa~120MPa。等静压成型后得到的生坯体积密度为1.31g/cm3~1.40g/cm3;生坯的体积密度不宜过高,因为生石油焦有***结性,在焙烧时制品的体积会产生很大的收缩,易导致制品开裂。
上述的制备方法,优选的,所述步骤(3)中,所述焙烧过程包括升温阶段、保温阶段和冷却阶段。
上述的制备方法,优选的,所述步骤(3)中,浸渍过程包括先对焙烧品进行预热处理,预热温度为220℃~250℃之间,预热时间为6h~8h,再将预热好的制品放入浸渍罐中进行抽真空,真空度为0.098MPa~0.1MPa,抽真空保持时间为80min~100min,再加入浸渍剂沥青进行高压浸渍,压力为1.5MPa~1.8MPa,保压时间为6.5h~8.5h。
上述的制备方法,优选的,所述步骤(3)中,石墨化的过程是指将浸渍后的产品直接通过艾奇逊炉加热至2800℃~3000℃,然后停电冷却。
与现有技术相比,本发明的优点在于:
(1)本发明首次将生石油焦用于电火花加工用石墨的原料,所用的生石油焦的原料成本是煅后焦的三分之一,是中间相碳微球的八分之一,并且用生石油焦和人造石墨参配做成的制品,只要经过一次焙烧,一次浸渍,一次石墨化就可以满足电火花加工用石墨材料的性能要求,大大缩短了生产周期,提高了企业的产能和利润。
(2)本发明选择生石油焦为原料,生石油焦具有***结特性,热处理过程中能始终保持均匀收缩的特性,而石墨粉能够起到一个“骨架”作用,性能稳定,其与生石油焦粉混合制备石墨能保持结构稳定使得产品在热处理过程中不易开裂,提高了制品的成品率能达到85%以上。
(3)本发明制备出的石墨材料的性能达到了电火花加工用石墨电极的要求,并且与常规工艺相比,在达到同样的性能时,本发明的工艺至少减少了一次浸渍和两次焙烧,缩短了产品的生产周期,为公司节省了生产成本,提高了经济效益。
附图说明
图1是本发明实施例1制备电火花加工用石墨的工艺流程图。
具体实施方式
为了便于理解本发明,下文将结合说明书附图和较佳的实施例对本文发明做更全面、细致地描述,但本发明的保护范围并不限于以下具体实施例。
除非另有定义,下文中所使用的所有专业术语与本领域技术人员通常理解含义相同。本文中所使用的专业术语只是为了描述具体实施例的目的,并不是旨在限制本发明的保护范围。
除非另有特别说明,本发明中用到的各种原材料、试剂、仪器和设备等均可通过市场购买得到或者可通过现有方法制备得到。
实施例1:
一种本发明的电火花加工用石墨,主要由以下质量含量的原料制备而成:50%的大港生石油焦、20%的石墨粉和30%的改质沥青。
本实施例的电火花加工用石墨的制备方法,工艺流程图如图1所示,步骤如下:
(1)将生石油焦烘干,气流粉碎成粒径D50为10μm~12μm的生石油焦粉,生石油焦粉中水分0.17%、灰分0.22%、挥发分11%、含硫量0.39%;
将本公司的石墨碎加工料气流成石墨粉,石墨粉的水分0.11%,灰分≤0.12%;
(2)将生石油焦粉和石墨粉放入双搅刀混捏锅中进行干混(搅刀的形状为Z形搅刀),干混60min,干混后混料的温度不低于150℃;再加入粘结剂改质沥青(软化点温度为118℃,甲苯不容物29%)湿混,湿混70min(,湿混后糊料的出锅温度在170℃~190℃之间;
(3)将出锅后的糊料进行双辊轧片处理,片料的厚度要求:一次片料厚度在2mm~3mm,二次片料厚度≤2mm,片料大小(长和宽)≤30mm*30mm;
(4)将片料进行二次磨粉,使磨粉后的物料过200目筛网的含量超过85%;
(5)将步骤(4)后的物料进行等静压成型(压力为110MPa)成生坯,生坯的重量为115kg,尺寸为:623mm*562mm*244mm,生坯体积密度为:1.35g/cm3;
(6)将生坯按照表1的焙烧曲线进行焙烧,经过焙烧后制品的重量为:100.9kg,实际尺寸:555*502*220,测整块的体积密度为:1.65g/cm3,与生坯相比,焙烧后制品的体积收缩率为39.4%,体积密度提高了22.2%,体现了生石油焦制品在焙烧时的***结收缩性能;
附表1 焙烧曲线
本段时间 | 设定温度(℃) | ℃/h |
0 | 30 | - |
34 | 200 | 5 |
20 | 250 | 2.5 |
50 | 300 | 1 |
80 | 350 | 0.625 |
300 | 500 | 0.5 |
80 | 550 | 0.625 |
60 | 600 | 0.833333 |
100 | 700 | 1 |
66 | 800 | 1.51515 |
50 | 900 | 2 |
48 | 900 | 0 |
24 | 900 | 0 |
50 | 800 | -2 |
50 | 700 | -2 |
50 | 600 | -2 |
50 | 500 | -2 |
50 | 400 | -2 |
50 | 300 | -2 |
50 | 200 | -2 |
50 | 100 | -2 |
200 | 50 | -0.25 |
(7)将焙烧后的产品进行预热处理,预热温度为235℃,预热7h,再把预热好的制品放入浸渍罐中进行抽真空,真空度在0.098MPa~0.1MPa之间,抽真空时间90min,再通入浸渍剂沥青进行高压浸渍,压力为1.7MPa,保压7h,经过高压浸渍后,测得制品的浸渍增重率为12.9%;
(8)将浸渍后产品送入艾奇逊石墨化炉中,进行加热,加热至2800℃,最后随炉冷却,得到电火花加工用石墨;该石墨成品率达到90%。
经过石墨化后制品的重量为:100.7kg,实际尺寸:538*490*210,测整块的体积密度为:1.82g/cm3,与一焙制品相比,石墨化后制品的体积收缩率为9.7%,体积密度提高了10.3%,体现了生石油焦制品在石墨化时也有很大的***结收缩性能。
将上述制备得到的石墨化产品机加工制成样品(5组),分别按照行业相关标准(GB/T24528-2009、GB/T1431-2009、GB/T3074.1-2008、JB/T8133.4-1999、GB/T24525-2009、GB/T3074.4-2003、GB/T24529-2009进行检测,得到石墨化制品的基本理化指标(平均值)如下:体积密度:1.81g/cm3,抗压强度:112MPa,抗折强度:58MPa,肖氏硬度:57,电阻率:13.5μΩ·m,热膨胀系数(室温~600℃):5.1×10-6/℃,气孔率:13.8%。
Claims (9)
1.一种电火花加工用石墨的制备方法,其特征在于,所述电火花加工用石墨主要由以下质量含量的原料制备而成:45%~55%的生石油焦,15%~25%的石墨粉和25%~35%的改质沥青,其制备方法包括以下步骤:
(1)将生石油焦进行烘干,再将烘后生石油焦和石墨粉通过气流磨机磨粉后,按照配比进行干混,然后加入改质沥青进行湿混、糊料出锅后进行轧片;
(2)将步骤(1)所得的片料进行二次磨粉;
(3)将步骤(2)后所得的粉料依次进行等静压成型、一次焙烧、一次浸渍、一次石墨化,即得到电火花加工用石墨。
2.如权利要求1所述的制备方法,其特征在于,所述步骤(1)中,干混的时间为55-70min,干混后的粉体温度不低于150℃;糊料出锅的温度不低于180℃。
3.如权利要求1所述的制备方法,其特征在于,所述步骤(2)中,二次磨粉后的物料过200目筛网的含量超过85%。
4.如权利要求1所述的制备方法,其特征在于,所述步骤(3)中,等静压成型的压力为100MPa~120MPa。
5.如权利要求1所述的制备方法,其特征在于,所述步骤(3)中,所述焙烧过程包括升温阶段、保温阶段和冷却阶段。
6.如权利要求1所述的制备方法,其特征在于,所述步骤(3)中,浸渍过程包括先对焙烧品进行预热处理,预热温度为220℃~250℃之间,预热时间为6h~8h,再将预热好的制品放入浸渍罐中进行抽真空,真空度为0.098MPa~0.1MPa,抽真空保持时间为80min~100min,再加入浸渍剂沥青进行高压浸渍,压力为1.5MPa~1.8MPa,保压时间为6.5h~8.5h。
7.如权利要求1所述的制备方法,其特征在于,所述步骤(3)中,石墨化的过程是指将浸渍后的产品直接通过艾奇逊炉加热至2800℃~3000℃,然后停电冷却。
8.如权利要求1所述的制备方法,其特征在于,所述生石油焦的粒径D50为10μm~12μm;所述石墨粉粒径D50为11μm~13μm。
9.如权利要求1所述的制备方法,其特征在于,所述生石油焦的烘后水分≤0.17%,灰分≤0.22%,挥发分≤11%,含硫量≤0.39%;所述石墨粉的水分≤0.11%,灰分≤0.12%;所述改质沥青的软化点温度为118℃,甲苯不容物(TI)≤29%。
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