CN109503133A - 一种磁化高润滑高韧性陶瓷研磨段及其制造方法 - Google Patents
一种磁化高润滑高韧性陶瓷研磨段及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种磁化高润滑高韧性陶瓷研磨段及其制造方法,该陶瓷研磨段的组份由四种功能组份组成,其中第一种功能组份A是低温烧结成的陶瓷基体;第二种功能组份B为高温熔融固化的磁化润滑表层;第三种功能组份C是PVA塑质材料;第四种功能组份D为不锈钢丝卷绕后再盘绕成的增韧圆柱体;四种成份的组成关系为:组份C牢固地与组份A互混结合成内核基体,同时纠缠在组份D的钢丝节点上,组份D位于内核的中心且与渗入组份D的基体牢固固定,组份B为通过超音速火焰喷涂工艺涂喷固化在内核基体表面的改性膜层。本发明的陶瓷研磨段表层润滑、研磨效率高、结合力好、磨损小、抗冲击能力强、韧性好、能耗小、研磨更均匀。
Description
技术领域
本发明涉及水泥研磨技术领域,尤其涉及一种磁化高润滑高韧性陶瓷研磨段及其制造方法。
背景技术
水泥球磨,是水泥生产中的必要工序和关键环节,其能耗和电耗占水泥生产总能耗的30%和总电耗70%以上,当前,国家低碳环保要求越来越高,虽然水泥价格快速上涨、利润率增高,但现有技术中,而随着技术发展,传统的钢质磨球已逐渐被陶瓷磨球代替,而目前采用陶瓷球磨技术的设备都不可避免地存在两个问题:1,由于陶瓷球自重低,在同等搅拌速率下挤压力不足,因而导致的球磨效率低下,即单台球磨机产出效率低下;2,由于现有技术中的陶瓷磨球多采用粗糙烧结技术,结构既不致密、又不均衡,同时脆性还大,易碎裂,因而在球磨过程中损耗相较于原钢质磨球更快。
在国内已申请的相关专利中,专利《一种具有磁性研磨球的高效球磨机》(申请号:201410816874.4,公开日:2016-7-20),公布了一种使用了带磁钢球进行双层研磨的技术,但由于采用的是钢球,硬度低而质量重,因而磨料损耗和电能损耗均较高且研磨效果较差,同时磁化磨球也不具有高自结合力和表面润滑的作用。
综上所述,市面上需要一种表层润滑、研磨效率高、结合力好、磨损小、抗冲击能力强、韧性好、能耗小、研磨更均匀的陶瓷研磨段及其制造方法。
发明内容
为解决现有技术中存在的上述缺陷,本发明旨在提供一种表层润滑、研磨效率高、结合力好、磨损小、抗冲击能力强、韧性好、能耗小、研磨更均匀的磁化高润滑高韧性陶瓷研磨段及其制造方法。
为了实现上述目的,本发明采用以下技术方案:一种磁化高润滑高韧性陶瓷研磨段,该陶瓷研磨段的组份由四种功能组份组成,其中第一种功能组份A是以纳米氧化铝粉末65份-70份、碳化硅粉末6份-8份、二硫化钼粉末2份-2.5份、三氧化二钇粉末3份-5份、二氧化锆粉末5份-8份、二氧化钛粉末8份-10份、二氧化硅粉末3份-5份为原材料低温烧结成的陶瓷基体;第二种功能组份B为四氧化三铁粉末8份-10份、二硫化钼粉末3份-5份、银粉3份-3.5份、铜粉1份-1.2份、钛粉1份-1.2份为原材料高温熔融固化的磁化润滑表层;第三种功能组份C是PVA塑质材料;第四种功能组份D为不锈钢丝卷绕后再盘绕成的增韧圆柱体;四种成份的组成关系为:组份C呈网格状牢固地与组份A完全互混结合成内核基体,同时纠缠在组份D的钢丝节点上,组份D位于内核的中心且与渗入组份D镂空网管球状结构的基体牢固固定,组份B为在氩气保护下通过超音速火焰喷涂工艺涂喷固化在内核基体表面的改性膜层。
一种磁化高润滑高韧性陶瓷研磨段的制造方法,包括以下步骤:
1)生产前准备
①原材料准备:按重量份准备纳米氧化铝粉末65份-70份、碳化硅粉末6份-8份、二硫化钼粉末2份-2.5份、三氧化二钇粉末3份-5份、二氧化锆粉末5份-8份、二氧化钛粉末8份-10份、二氧化硅粉末3份-5份、四氧化三铁粉末8份-10份、二硫化钼粉末3份-5份、银粉3份-3.5份、铜粉1份-1.2份、钛粉1份-1.2份、含质量分数5%-6%PVA溶质的PVA水溶液68份-75份、直径0.1mm-0.2mm的奥氏体不锈钢丝15份-20份;
②辅材准备:准备足量去离子水;
2)表面层改性涂层原料的制备
①将阶段1)步骤①准备的四氧化三铁粉末、二硫化钼粉末、银粉、铜粉、钛粉均匀混合并机械研磨至混合颗粒粒径10μm-20μm,获得待喷涂原料;
3)内韧骨架的制备
①以阶段1)步骤①准备的奥氏体不锈钢丝为原料,以0.8mm-1.0mm为内径,以0.2mm-0.3mm为螺距卷绕成钢丝螺旋卷绳;
②将步骤①获得的钢丝螺旋卷绳按毛线柱盘卷方式盘卷成圆柱体,获得增韧圆柱体;
③将步骤②获得的增韧圆柱体采用柱形加压模具,分三次分别采用12MPa、18MPa、24MPa的物理压强进行等静压循环冲压,使冲压成型后的圆柱体为按照设计尺寸等比例缩小的形状,获得冲压增韧圆柱体;
④将步骤③获得的冲压增韧圆柱体置于烘箱中,采用200℃-220℃处理5h-6h,获得稳定化增韧圆柱体,该稳定化增韧圆柱体即为所需内韧骨架;
4)氧化铝基陶瓷球内核的烧结
①将阶段1)步骤①准备的氧化铝粉末、碳化硅粉末、二硫化钼粉末、三氧化二钇粉末、二氧化锆粉末、二氧化钛粉末、二氧化硅粉末混合并搅拌均匀,获得混合物料;
②将步骤①获得的混合物料与阶段1)步骤①准备的PVA水溶液混合并搅拌均匀,获得陶瓷原浆料;
③准备好柱形陶瓷烧结模具,将阶段3)获得的内韧骨架置于柱形陶瓷烧结模具中间,然后将步骤②获得的陶瓷原浆料填入模具中,压紧,压紧力按目标陶瓷段最终体积Vcm3计为3VN/cm3-5VN/cm3;
④将步骤③获得的填充了混合物料的模具放置于炉内压强为12MPa-15Mpa的氩气保护气氛里,1100℃-1150℃温度下进行烧结,烧结时间2h-3h;
⑤烧结完成后,炉冷至280℃-300℃时再出炉空冷至室温,然后脱出模具,获得陶瓷研磨段粗坯,该陶瓷研磨段粗坯即为所需陶瓷研磨段内核;
5)氧化铝基陶瓷球的成型
①以阶段2)获得的待喷涂原料为原料,以阶段4)步骤⑤获得的陶瓷研磨段内核为靶材,采用超音速火焰喷涂设备,在压强为1bar-1.1bar压强的氩气保护环境内,以1880℃-1950℃为出口温度,以300mm-330mm为喷距进行喷涂处理,保持陶瓷研磨段内核以10°/s-12°/s的角速度沿毛线球纺织轨迹进行球面旋转至原料喷涂完毕,获得表面改性陶瓷球;
②采用金刚石磨料振动去毛刺设备对步骤①获得的表面改性陶瓷球进行振动去毛刺及抛光处理,即获得待处理陶瓷研磨段;
③通过电磁感应对步骤②获提的待处理陶瓷研磨段施加强度为2T-3T的磁场,采用巴克球充磁方式进行充磁,充磁时间10min-12min,充磁完成后即获得所需磁化高润滑高韧性陶瓷研磨段。
与现有技术相比较,本发明具有以下优点:(1)本发明最核心的技术构思就是如何将具有抗震、润滑、缓冲功能的组份与硬质且化学性质极稳定的陶瓷基体有机地结合进来,本发明利用了陶瓷原料以一定比例混合后相互促熔的特性,选配了一种高硬度的、可低温烧结的陶瓷基体配方,低温的烧结温度是本发明实现的基础;然后利用原料都是极细粉末的优势将其与PVA溶液混搅成混浊液,获得了渗透性与浸润性,同时在烧结时通过液化的PVA增加了表面能和内结合力,同时赶走了粉末间固有的空气(陶瓷球内气孔的来源),使本发明更加致密;但由于挤压烧结的陶瓷必然存在粗糙的、凹凸不平的表面,本发明利用这个常规技术中的缺陷增强表层改性膜层的结合力,同时按3:1:1的比例混配在四氧化三铁和二硫化钼中的银、铜、钛在高温无氧环境下会生成(Ag72Cu28)97Ti3,这是一种对氧化铝尤其是粗糙表面的氧化铝浸润性极好的合金,其在950℃-1000℃时的浸润性是最好的,这个温度正好是混合粉末在由固转液的过程中,极大地增强了本发明涂层和陶瓷内核的结合力,同时获得抗菌能力(银),并提供一定的润滑性;同时内核中的PVA、表层未形成合金的银颗粒、二硫化钼均能为本发明提供极好的表面润滑效果。(2)本发明还有个核心技术就是磁球表面的四氧化三铁成份,这种成份在充磁后明显能为本发明的研磨球提供一定的磁性,由于使用的是四氧化三铁而不是强磁体钕铁硼,因而本发明的磁强度不会太高,是稍低于研磨球自身重力的(该性能是通过各组份重量配比及充磁强度和时间实现)这就保证了磨球之间不会粘着,同时由于磁场的干扰,常规技术中本身在机械供力方向循环不变的情况下保持一定规则运动的磨球的运动轨迹也变得多变和不可控(磨球不断在旋转,磁极不断变化,部分磨球相斥部分磨球相吸,破坏了搅拌机带来规则作用力的方向),这就是促使本发明能研磨得更均匀的原因,同时研磨接触的两个磨球也必须是磁性相吸的,额外提供了一定的挤压力,同样使用本发明研磨得更细。(3)利用流质原料的特性,选用了镂空但具有极强弹性和缓冲功能的不锈钢冷压镂空柱作为内骨架和韧性支撑,同时保证流质的原料充分与骨架相结合,最终获得以PVC减摩、钢丝柱网增韧抗冲击的陶瓷段,这在现有技术中是完全不存在的。(4)本发明获得的成品密度3.6g/cm3-3.9g/cm3,仅为钢质材料的一半,因而能够有效节电、节能、减少碳排放;陶瓷硬度高,耐磨性好,使用周期长。因此使本发明最终具有表层润滑、研磨效率高、结合力好、磨损小、抗冲击能力强、韧性好、能耗小、研磨更均匀的特性。
具体实施方式
实施例1:
一种磁化高润滑高韧性陶瓷研磨段,该陶瓷研磨段的组份由四种功能组份组成,其中第一种功能组份A是以纳米氧化铝粉末65g、碳化硅粉末8g、二硫化钼粉末2.5g、三氧化二钇粉末5g、二氧化锆粉末8g、二氧化钛粉末10g、二氧化硅粉末5g为原材料低温烧结成的陶瓷基体;第二种功能组份B为四氧化三铁粉末10g、二硫化钼粉末5g、银粉3.5g、铜粉1.2g、钛粉1.2g为原材料高温熔融固化的磁化润滑表层;第三种功能组份C是PVA塑质材料;第四种功能组份D为不锈钢丝卷绕后再盘绕成的增韧圆柱体;四种成份的组成关系为:组份C呈网格状牢固地与组份A完全互混结合成内核基体,同时纠缠在组份D的钢丝节点上,组份D位于内核的中心且与渗入组份D镂空网管球状结构的基体牢固固定,组份B为在氩气保护下通过超音速火焰喷涂工艺涂喷固化在内核基体表面的改性膜层。
一种磁化高润滑高韧性陶瓷研磨段的制造方法,包括以下步骤:
1)生产前准备
①原材料准备:按重量份准备纳米氧化铝粉末65g、碳化硅粉末8g、二硫化钼粉末2.5g、三氧化二钇粉末5g、二氧化锆粉末8g、二氧化钛粉末10g、二氧化硅粉末5g、四氧化三铁粉末10g、二硫化钼粉末5g、银粉3.5g、铜粉1.2g、钛粉1.2g、含质量分数6%PVA溶质的PVA水溶液75g、直径0.1mm的奥氏体不锈钢丝20g;
②辅材准备:准备足量去离子水;
2)表面层改性涂层原料的制备
①将阶段1)步骤①准备的四氧化三铁粉末、二硫化钼粉末、银粉、铜粉、钛粉均匀混合并机械研磨至混合颗粒粒径10μm-20μm,获得待喷涂原料;
3)内韧骨架的制备
①以阶段1)步骤①准备的奥氏体不锈钢丝为原料,以0.8mm为内径,以0.2mm为螺距卷绕成钢丝螺旋卷绳;
②将步骤①获得的钢丝螺旋卷绳按毛线柱盘卷方式盘卷成圆柱体,获得增韧圆柱体;
③将步骤②获得的增韧圆柱体采用柱形加压模具,分三次分别采用12MPa、18MPa、24MPa的物理压强进行等静压循环冲压,使冲压成型后的圆柱体为按照设计尺寸等比例缩小的形状,获得冲压增韧圆柱体;
④将步骤③获得的冲压增韧圆柱体置于烘箱中,采用220℃处理6h,获得稳定化增韧圆柱体,该稳定化增韧圆柱体即为所需内韧骨架;
4)氧化铝基陶瓷球内核的烧结
①将阶段1)步骤①准备的氧化铝粉末、碳化硅粉末、二硫化钼粉末、三氧化二钇粉末、二氧化锆粉末、二氧化钛粉末、二氧化硅粉末混合并搅拌均匀,获得混合物料;
②将步骤①获得的混合物料与阶段1)步骤①准备的PVA水溶液混合并搅拌均匀,获得陶瓷原浆料;
③准备好柱形陶瓷烧结模具,将阶段3)获得的内韧骨架置于柱形陶瓷烧结模具中间,然后将步骤②获得的陶瓷原浆料填入模具中,压紧,压紧力按目标陶瓷段最终体积Vcm3计为5VN/cm3;
④将步骤③获得的填充了混合物料的模具放置于炉内压强为15Mpa的氩气保护气氛里,1150℃温度下进行烧结,烧结时间3h;
⑤烧结完成后,炉冷至280℃时再出炉空冷至室温,然后脱出模具,获得陶瓷研磨段粗坯,该陶瓷研磨段粗坯即为所需陶瓷研磨段内核;
5)氧化铝基陶瓷球的成型
①以阶段2)获得的待喷涂原料为原料,以阶段4)步骤⑤获得的陶瓷研磨段内核为靶材,采用超音速火焰喷涂设备,在压强为1.1bar压强的氩气保护环境内,以1950℃为出口温度,以300mm为喷距进行喷涂处理,保持陶瓷研磨段内核以10°/s的角速度沿毛线球纺织轨迹进行球面旋转至原料喷涂完毕,获得表面改性陶瓷球;
②采用金刚石磨料振动去毛刺设备对步骤①获得的表面改性陶瓷球进行振动去毛刺及抛光处理,即获得待处理陶瓷研磨段;
③通过电磁感应对步骤②获提的待处理陶瓷研磨段施加强度为3T的磁场,采用巴克球充磁方式进行充磁,充磁时间12min,充磁完成后即获得所需磁化高润滑高韧性陶瓷研磨段。
实施例2:
整体与实施例1一致,差异之处在于:
一种磁化高润滑高韧性陶瓷研磨段,该陶瓷研磨段的组份由四种功能组份组成,其中第一种功能组份A是以纳米氧化铝粉末70g、碳化硅粉末6g、二硫化钼粉末2g、三氧化二钇粉末3g、二氧化锆粉末5g、二氧化钛粉末8g、二氧化硅粉末3g为原材料低温烧结成的陶瓷基体;第二种功能组份B为四氧化三铁粉末8g、二硫化钼粉末3g、银粉3g、铜粉1g、钛粉1g为原材料高温熔融固化的磁化润滑表层;第三种功能组份C是PVA塑质材料;第四种功能组份D为不锈钢丝卷绕后再盘绕成的增韧圆柱体;四种成份的组成关系为:组份C呈网格状牢固地与组份A完全互混结合成内核基体,同时纠缠在组份D的钢丝节点上,组份D位于内核的中心且与渗入组份D镂空网管球状结构的基体牢固固定,组份B为在氩气保护下通过超音速火焰喷涂工艺涂喷固化在内核基体表面的改性膜层;
上述陶瓷研磨段的制造方法,包括以下步骤:
1)生产前准备
①原材料准备:按重量份准备纳米氧化铝粉末70g、碳化硅粉末6g、二硫化钼粉末2g、三氧化二钇粉末3g、二氧化锆粉末5g、二氧化钛粉末8g、二氧化硅粉末3g、四氧化三铁粉末8g、二硫化钼粉末3g、银粉3g、铜粉1g、钛粉1g、含质量分数5%PVA溶质的PVA水溶液68g、直径0.2mm的奥氏体不锈钢丝15g;
3)内韧骨架的制备
①以阶段1)步骤①准备的奥氏体不锈钢丝为原料,以1.0mm为内径,以0.3mm为螺距卷绕成钢丝螺旋卷绳;
④将步骤③获得的冲压增韧圆柱体置于烘箱中,采用200℃处理5h,获得稳定化增韧圆柱体,该稳定化增韧圆柱体即为所需内韧骨架;
4)氧化铝基陶瓷球内核的烧结
③准备好柱形陶瓷烧结模具,将阶段3)获得的内韧骨架置于柱形陶瓷烧结模具中间,然后将步骤②获得的陶瓷原浆料填入模具中,压紧,压紧力按目标陶瓷段最终体积Vcm3计为3VN/cm3;
④将步骤③获得的填充了混合物料的模具放置于炉内压强为12MPa的氩气保护气氛里,1100℃温度下进行烧结,烧结时间2h;
⑤烧结完成后,炉冷至300℃时再出炉空冷至室温,然后脱出模具,获得陶瓷研磨段粗坯,该陶瓷研磨段粗坯即为所需陶瓷研磨段内核;
5)氧化铝基陶瓷球的成型
①以阶段2)获得的待喷涂原料为原料,以阶段4)步骤⑤获得的陶瓷研磨段内核为靶材,采用超音速火焰喷涂设备,在压强为1bar压强的氩气保护环境内,以1880℃为出口温度,以330mm为喷距进行喷涂处理,保持陶瓷研磨段内核以12°/s的角速度沿毛线球纺织轨迹进行球面旋转至原料喷涂完毕,获得表面改性陶瓷球;
③通过电磁感应对步骤②获提的待处理陶瓷研磨段施加强度为2T的磁场,采用巴克球充磁方式进行充磁,充磁时间10min,充磁完成后即获得所需磁化高润滑高韧性陶瓷研磨段。
对所公开的实施例的上述说明,仅为了使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (2)
1.一种磁化高润滑高韧性陶瓷研磨段,其特征在于:该陶瓷研磨段的组份由四种功能组份组成,其中第一种功能组份A是以纳米氧化铝粉末65份-70份、碳化硅粉末6份-8份、二硫化钼粉末2份-2.5份、三氧化二钇粉末3份-5份、二氧化锆粉末5份-8份、二氧化钛粉末8份-10份、二氧化硅粉末3份-5份为原材料低温烧结成的陶瓷基体;第二种功能组份B为四氧化三铁粉末8份-10份、二硫化钼粉末3份-5份、银粉3份-3.5份、铜粉1份-1.2份、钛粉1份-1.2份为原材料高温熔融固化的磁化润滑表层;第三种功能组份C是PVA塑质材料;第四种功能组份D为不锈钢丝卷绕后再盘绕成的增韧圆柱体;四种成份的组成关系为:组份C呈网格状牢固地与组份A完全互混结合成内核基体,同时纠缠在组份D的无数钢丝节点上,组份D位于内核的中心且与渗入组份D镂空网管球状结构的基体牢固固定,组份B为在氩气保护下通过超音速火焰喷涂工艺涂喷固化在内核基体表面的改性膜层。
2.一种磁化高润滑高韧性陶瓷研磨段的制造方法,其特征在于包括以下步骤:
1)生产前准备
①原材料准备:按重量份准备纳米氧化铝粉末65份-70份、碳化硅粉末6份-8份、二硫化钼粉末2份-2.5份、三氧化二钇粉末3份-5份、二氧化锆粉末5份-8份、二氧化钛粉末8份-10份、二氧化硅粉末3份-5份、四氧化三铁粉末8份-10份、二硫化钼粉末3份-5份、银粉3份-3.5份、铜粉1份-1.2份、钛粉1份-1.2份、含质量分数5%-6%PVA溶质的PVA水溶液68份-75份、直径0.1mm-0.2mm的奥氏体不锈钢丝15份-20份;
②辅材准备:准备足量去离子水;
2)表面层改性涂层原料的制备
①将阶段1)步骤①准备的四氧化三铁粉末、二硫化钼粉末、银粉、铜粉、钛粉均匀混合并机械研磨至混合颗粒粒径10μm-20μm,获得待喷涂原料;
3)内韧骨架的制备
①以阶段1)步骤①准备的奥氏体不锈钢丝为原料,以0.8mm-1.0mm为内径,以0.2mm-0.3mm为螺距卷绕成钢丝螺旋卷绳;
②将步骤①获得的钢丝螺旋卷绳按毛线柱盘卷方式盘卷成圆柱体,获得增韧圆柱体;
③将步骤②获得的增韧圆柱体采用柱形加压模具,分三次分别采用12MPa、18MPa、24MPa的物理压强进行等静压循环冲压,使冲压成型后的圆柱体为按照设计尺寸等比例缩小的形状,获得冲压增韧圆柱体;
④将步骤③获得的冲压增韧圆柱体置于烘箱中,采用200℃-220℃处理5h-6h,获得稳定化增韧圆柱体,该稳定化增韧圆柱体即为所需内韧骨架;
4)氧化铝基陶瓷球内核的烧结
①将阶段1)步骤①准备的氧化铝粉末、碳化硅粉末、二硫化钼粉末、三氧化二钇粉末、二氧化锆粉末、二氧化钛粉末、二氧化硅粉末混合并搅拌均匀,获得混合物料;
②将步骤①获得的混合物料与阶段1)步骤①准备的PVA水溶液混合并搅拌均匀,获得陶瓷原浆料;
③准备好柱形陶瓷烧结模具,将阶段3)获得的内韧骨架置于柱形陶瓷烧结模具中间,然后将步骤②获得的陶瓷原浆料填入模具中,压紧,压紧力按目标陶瓷段最终体积Vcm3计为3VN/cm3-5VN/cm3;
④将步骤③获得的填充了混合物料的模具放置于炉内压强为12MPa-15Mpa的氩气保护气氛里,1100℃-1150℃温度下进行烧结,烧结时间2h-3h;
⑤烧结完成后,炉冷至280℃-300℃时再出炉空冷至室温,然后脱出模具,获得陶瓷研磨段粗坯,该陶瓷研磨段粗坯即为所需陶瓷研磨段内核;
5)氧化铝基陶瓷球的成型
①以阶段2)获得的待喷涂原料为原料,以阶段4)步骤⑤获得的陶瓷研磨段内核为靶材,采用超音速火焰喷涂设备,在压强为1bar-1.1bar压强的氩气保护环境内,以1880℃-1950℃为出口温度,以300mm-330mm为喷距进行喷涂处理,保持陶瓷研磨段内核以10°/s-12°/s的角速度沿毛线球纺织轨迹进行球面旋转至原料喷涂完毕,获得表面改性陶瓷球;
②采用金刚石磨料振动去毛刺设备对步骤①获得的表面改性陶瓷球进行振动去毛刺及抛光处理,即获得待处理陶瓷研磨段;
③通过电磁感应对步骤②获提的待处理陶瓷研磨段施加强度为2T-3T的磁场,采用巴克球充磁方式进行充磁,充磁时间10min-12min,充磁完成后即获得所需磁化高润滑高韧性陶瓷研磨段。
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