CN110054497A - 一种致密的纳米增韧碳化硅复相陶瓷的制备方法 - Google Patents

一种致密的纳米增韧碳化硅复相陶瓷的制备方法 Download PDF

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CN110054497A
CN110054497A CN201910441535.5A CN201910441535A CN110054497A CN 110054497 A CN110054497 A CN 110054497A CN 201910441535 A CN201910441535 A CN 201910441535A CN 110054497 A CN110054497 A CN 110054497A
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silicon carbide
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王志江
李冠姝
姜兆华
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Harbin Institute of Technology
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Abstract

本发明公开了一种致密的纳米增韧碳化硅复相陶瓷的制备方法，所述方法包括如下步骤：步骤一、以α‑SiC粒子为原料，纳米β‑SiC粒子为增韧相，添加烧结助剂和粘结剂，配好原料后投入到氧化铝质球磨罐中，加入蒸馏水，投入研磨球进行研磨，获得组分均匀分散的浆料；步骤二、采用喷雾造粒工艺进行造粒；步骤三、将造粒粉干压成型，得到素坯；步骤四、将素坯放置于真空烧结炉中进行常压烧结，得到致密的纳米增韧碳化硅复相陶瓷。本发明解决了陶瓷的脆性问题，提高了强度和韧性，且操作简单，安全可靠，成本低廉，具有良好的推广应用前景。

Description

一种致密的纳米增韧碳化硅复相陶瓷的制备方法
技术领域
本发明属于陶瓷材料制备技术领域，涉及一种制备碳化硅复相陶瓷的方法。
背景技术
SiC陶瓷具有很多优良的性能，例如高硬度、高强度、低热膨胀系数等特点，已经广泛的应用于石油化学工业、汽车制造、半导体材料等诸多领域。其中，SiC陶瓷除了具有密度小、热导率高的特点外，更具有硬度高、耐高温及化学性质稳定的特点。因此，SiC陶瓷的应用也越来越广泛，由SiC陶瓷制成的轴承、发动机部件和耐火材料等在汽车、航空航天、空间技术等多个行业得到了广泛的应用。
SiC陶瓷具有高硬度、高强度、低热膨胀系数等优点，广泛应用于严苛的环境下服役，展现出较高的稳定性和良好的机械性能。但由于陶瓷的脆性，即在外载荷的作用下，陶瓷材料会发生突然的断裂，表现为冲击阻力低、损伤容限低等。为解决SiC陶瓷这一缺陷，可通过将陶瓷材料制备成陶瓷基复合材料来提高性能。纳米技术的出现，在改善陶瓷材料性能的方面显示出极大的优势，加入纳米相可提高材料的韧性。
现阶段，SiC陶瓷制备的原料主要采用α-SiC粉体，与常见的α-SiC相比，β-SiC属于低温晶型，超过1800℃时可转化为α-SiC，在转化过程中体积发生变化，其组织更加致密，从而提高了SiC陶瓷的强度和韧性。
发明内容
为了解决现有技术中存在的制备SiC陶瓷强度和韧性较低的问题，本发明提供了一种成本低廉、操作简单的致密的纳米增韧碳化硅复相陶瓷的制备方法。该方法以α-SiC为主，加入纳米β-SiC作为增韧相，β-SiC粒子在1800℃以上的高温下会发生相变产生长轴状晶体，会产生裂纹偏转及桥连的作用，起到增韧的作用。本发明解决了陶瓷的脆性问题，提高了强度和韧性，且操作简单，安全可靠，成本低廉，具有良好的推广应用前景。
本发明的目的是通过以下技术方案实现的：
一种致密的纳米增韧碳化硅复相陶瓷的制备方法，以α-SiC粒子为原料，纳米β-SiC粒子为增韧相，加入一定的烧结助剂和粘结剂，进行高温烧结，最终形成纳米增韧碳化硅复相陶瓷。具体包括如下步骤：
步骤一、纳米β-SiC粒子的制备：将碳粉、硅粉和二氧化硅粉混合均匀，在高温下烧结，得到纳米β-SiC粒子，其中：碳粉、硅粉和二氧化硅粉的摩尔比为1:3～7:1；混合时间为30～90min；烧结温度为1200～1900℃，烧结时间为2～6h；
步骤二、混料：采用湿混工艺，以α-SiC粒子为原料，纳米β-SiC粒子为增韧相，添加烧结助剂和粘结剂，配好原料后投入到氧化铝质球磨罐中，加入蒸馏水，投入研磨球进行研磨，获得组分均匀分散的浆料，其中：α-SiC粒子与增韧相纳米β-SiC粒子的质量比为1：0.05～1；原料、研磨球与蒸馏水的质量比为3：6～9：1；烧结助剂为B4C，添加量为原料总质量的1～5%；粘结剂为酚醛树脂，添加量为原料总质量的10～15%；研磨的转速为300～390r/min；时间为8～12h；
步骤三、造粒：采用喷雾造粒工艺，首先用蠕动泵通入清水，待整个体系得到润湿后，通入混合均匀的浆料，在喷雾干燥机喷头的一定转速下进行造粒，收集造粒粉，其中：喷雾干燥机的喷头转速为20000～24000r/min；
步骤四、成型：将造粒粉干压成型，得到素坯，其中：成型压力为100～600MPa；
步骤五、烧结：将素坯放置于真空烧结炉中进行常压烧结，得到致密的纳米增韧碳化硅复相陶瓷，其中：烧结气氛为惰性气体，烧结温度为1900～2100℃，时间为0.5～2h。
上述方法在β-SiC粒子生成的过程中体系中会发生如下化学反应：
一、固-气反应：
C(s)+ Si(s) = SiC(s) （1）；
SiO(g) + 2C(s) = SiC(s) + CO(g) （2）；
二、气相反应：
SiO2(s)+ Si(s) = 2SiO(g) （3）；
SiO2(s)+ C(s) = SiO(g) + CO(g) （4）；
C(s)+ CO2(g) = 2CO(g) （5）；
SiO(g)+3CO(g) = SiC(s) + 2CO2(g) （6）。
相比于现有技术，本发明具有如下优点：
1、本发明提供了一种简便、易于放大的制备致密的纳米碳化硅复相陶瓷的方法，该方法改善了陶瓷的脆性，起到了强化和增韧的效果，制备的陶瓷耐高温、力学性能优异。
2、本发明通过改变纳米β-SiC粒子的用量来调节碳化硅复相陶瓷的微观形貌和力学性能。
3、本发明使用纳米β-SiC粒子作为增韧相，纳米粒子周围的局部拉伸应力诱发穿晶断裂，并由于硬粒子对裂纹尖端的反射作用而产生韧化。
4、本发明使用的粘结剂是酚醛树脂，在高温下，酚醛树脂会发生碳化并产生65%的残炭，为烧结提供了少量碳源，有利于烧结致密化的进行。
5、本发明在高温烧结时，通过改变烧结温度和保温时间，可以调节碳化硅复相陶瓷的致密度和机械性能。
附图说明
图1为实施例1制备的纳米增韧碳化硅复相陶瓷的样品图；
图2为实施例1制备的纳米增韧碳化硅复相陶瓷的SEM照片；
图3为实施例1制备的纳米增韧碳化硅复相陶瓷的XRD图；
图4为实施例2制备的纳米增韧碳化硅复相陶瓷的SEM照片；
图5为实施例2制备的纳米增韧碳化硅复相陶瓷的XRD照片；
图6为实施例3制备的纳米增韧碳化硅复相陶瓷的SEM照片；
图7为实施例3制备的纳米增韧碳化硅复相陶瓷的XRD图；
图8为实施例1～5制备的纳米增韧碳化硅复相陶瓷的压缩强度。
具体实施方式
下面结合实施例对本发明的技术方案作进一步的说明，但并不局限于此，凡是对本发明技术方案进行修改或者等同替换，而不脱离本发明技术方案的精神和范围，均应涵盖在本发明的保护范围中。
实施例1：
本实施例提供了一种致密的纳米增韧碳化硅复相陶瓷的制备方法，所述方法是按以下步骤完成的：
一、纳米β-SiC粒子的制备：将碳粉、硅粉和二氧化硅粉以1:4:1的摩尔比在高速混合机中混合60min，在1600℃下烧结；
二、混料：采用湿混工艺，以α-SiC粒子为原料，纳米β-SiC粒子为增韧相，添加B4C和酚醛树脂，其中：α-SiC粒子与增韧相纳米β-SiC粒子的质量比为1:0.05，B4C的添加量为原料总质量的3%；酚醛树脂的添加量为原料总质量的10%，按设计的配方配好原料后，投入到氧化铝质球磨罐中，加入蒸馏水，投入研磨球，其中：原料、研磨球、蒸馏水的质量比为3：8：1，以380r/min的转速研磨9h，获得组分均匀分散的实验浆料；
三、造粒：采用喷雾造粒工艺，首先用蠕动泵通入清水，待整个体系得到润湿后，通入混合均匀的浆料，在喷雾干燥机喷头的19000r/min转速下，造粒完成，然后在喷雾干燥机的下方收集造粒粉；
四、成型：将造粒粉在500MPa的压力下干压成型，得到素坯；
五、烧结：将压制的素坯置于石墨坩埚中，以惰性气体作为保护气，在高温烧结炉中于2000℃下烧结1.5h，冷却至室温，得到致密的纳米增韧碳化硅复相陶瓷。
图1为本实施例制备的复相SiC陶瓷的样品图，由图中可以看到：表面无裂纹，无明显宏观缺陷，并出现了一定程度的体积收缩。
图2为本实施例制备的复相SiC陶瓷的SEM图，由图中可以看到：添加了β-SiC的样品断面，晶界模糊，呈凹凸新装，它的断裂模式为沿晶/穿晶混合断裂模式，在裂纹产生的过程中，晶界对其扩展产生了阻碍，从而提高了材料的强度。
图3为本实施例制备的复相SiC陶瓷的XRD图，由图中可以看到：烧结后的材料的主要晶相为6H-SiC相，添加的β-SiC已经全部转化为α-SiC。
实施例2：
本实施例与实施例1不同点是：α-SiC粒子与增韧相纳米β-SiC粒子的比例为1：0.1。
图4为本实施例制备的复相SiC陶瓷的SEM图，由图中可以看到：β-SiC含量提高以后，制得的材料样品致密度提高。
图5为本实施例制备的复相SiC陶瓷的XRD图，由图中可以看到：烧结后的材料的主要晶相为6H-SiC相，添加的β-SiC已经全部转化为α-SiC。
实施例3：
本实施例与实施例1不同点是：α-SiC粒子与增韧相纳米β-SiC粒子的比例为1：0.2。
图6为本实施例制备的复相SiC陶瓷的SEM图，由图中可以看到：β-SiC含量继续提高，制得的材料样品致密度提高。
图7为本实施例制备的复相SiC陶瓷的XRD图，由图中可以看到：烧结后的材料的主要晶相为6H-SiC相，添加的β-SiC已经全部转化为α-SiC。
实施例4：
本实施例与实施例1不同点是：α-SiC粒子与增韧相纳米β-SiC粒子的比例为1：0.3。
实施例5：
本实施例与实施例1不同点是：α-SiC粒子与增韧相纳米β-SiC粒子的比例为1：0.4。
图8为实施例1～5制备的复相SiC陶瓷的压缩强度，由图中可以看到：当：α-SiC粒子与增韧相纳米β-SiC粒子的比例为1：0.2时，复相SiC陶瓷的压缩强度最大，为411MPa。

Claims (10)

1.一种致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述方法包括如下步骤：
步骤一、混料：以α-SiC粒子为原料，纳米β-SiC粒子为增韧相，添加烧结助剂和粘结剂，配好原料后投入到氧化铝质球磨罐中，加入蒸馏水，投入研磨球进行研磨，获得组分均匀分散的浆料，其中：α-SiC粒子与增韧相纳米β-SiC粒子的质量比为1：0.05～1；烧结助剂的添加量为原料总质量的1～5%；粘结剂为的添加量为原料总质量的10～15%；原料、研磨球与蒸馏水的质量比为3：6～9：1；
步骤二、造粒：采用喷雾造粒工艺进行造粒；
步骤三、成型：将造粒粉干压成型，得到素坯；
步骤四、烧结：将素坯放置于真空烧结炉中进行常压烧结，得到致密的纳米增韧碳化硅复相陶瓷。
2.根据权利要求1所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述纳米β-SiC粒子的制备方法如下：将碳粉、硅粉和二氧化硅粉混合均匀，在高温下烧结，得到纳米β-SiC粒子，其中：碳粉、硅粉和二氧化硅粉的摩尔比为1:3～7:1。
3.根据权利要求2所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述混合时间为30～90min；烧结温度为1200～1900℃，烧结时间为2～6h。
4.根据权利要求1所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述烧结助剂为B4C，粘结剂为酚醛树脂。
5.根据权利要求1所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述研磨的转速为300～390r/min，时间为8～12h。
6.根据权利要求1所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述步骤三的具体步骤如下：首先用蠕动泵通入清水，待整个体系得到润湿后，通入混合均匀的浆料，在喷雾干燥机喷头的一定转速下进行造粒，收集造粒粉。
7.根据权利要求6所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述喷雾干燥机的喷头转速为20000～24000r/min。
8.根据权利要求1所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述成型压力为100～600MPa。
9.根据权利要求1所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述烧结气氛为惰性气体。
10.根据权利要求1所述的致密的纳米增韧碳化硅复相陶瓷的制备方法，其特征在于所述烧结温度为1900～2100℃，时间为0.5～2h。
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