CN110551912A - Method for manufacturing aluminum-based fly ash composite material - Google Patents
Method for manufacturing aluminum-based fly ash composite material Download PDFInfo
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- CN110551912A CN110551912A CN201810558582.3A CN201810558582A CN110551912A CN 110551912 A CN110551912 A CN 110551912A CN 201810558582 A CN201810558582 A CN 201810558582A CN 110551912 A CN110551912 A CN 110551912A
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1005—Pretreatment of the non-metallic additives
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
- C22C1/1047—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
- C22C1/1052—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites by mixing and casting metal matrix composites with reaction
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
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Abstract
aluminum-based fly ash castings produced by the manufacturing methods disclosed in the prior art typically have too many pores or pores resulting in reduced or poor mechanical properties. In view of this, the present invention provides a method for manufacturing an aluminum-based fly ash composite material. The manufacturing method of the invention particularly completes the coarse screening and fine screening treatment of the fly ash in the modes of a floating screen and a magnetic screen, then batch-wise adds the preheated fly ash into the aluminum base material in a molten state, and finally processes the aluminum melt mixed with the fly ash into an aluminum-based fly ash casting by using a die dipping fast solidification method. Furthermore, experimental data show that the proposed method for manufacturing aluminum-based fly ash composite material does help to reduce the porosity and maintain or enhance the mechanical properties of aluminum-based fly ash castings.
Description
Technical Field
The invention relates to the technical field of Aluminum-Fly Ash (ALFA) composite materials, in particular to a manufacturing method of an Aluminum-Fly Ash composite material capable of reducing internal pores and enhancing mechanical properties.
Background
Metal Matrix Composites (MMC) are prepared by solutionizing at least one strengthening phase material into a Matrix phase Metal or alloy thereof. Wherein, the strengthening phase material is mostly inorganic non-metallic material, such as: ceramic (i.e., metal oxide), carbon, silicon, graphite, and boron. In 1993, praadep k. rohatgi produces an aluminum-based Fly Ash composite material (Fly-Ash-Containing aluminum matrix Composites) by causing SiO2 and oxide components such as Fe2O3 contained in Fly Ash of coal-fired waste to chemically react with an aluminum substrate, thereby generating alumina (Al2O3) as a reinforcing phase of the aluminum substrate.
with the continuous progress of the material manufacturing technology, the current process technology of the aluminum-based fly ash composite material mainly comprises a Pressure infiltration method (Pressure infiltration), a Powder metallurgy method (Powder metallurgy) and a composite casting method (compacting). Among them, the composite casting method is currently widely used for manufacturing aluminum-based fly ash composite materials because of its advantage of low process cost. The first document discloses a related technology for manufacturing an aluminum-based fly ash composite material by using a composite casting method. Here, the first literature refers to: zhuangshuangwang et al, "effect of technical Lily Pair (Pair Rehd. et al.) \ 25976 on the uniformity of fly ash in aluminum-based fly ash composites", journal of foundry engineering, vol.39, vol.1 (2013/03/01), P22-P28. We can know from literature that the existing aluminum-based fly ash composite material manufacturing process comprises the following steps:
Selecting F-grade fly ash specified by C618-12a standard specification of American society for testing and materials standards (ASTM), wherein the fly ash comprises 52.73% of SiO 2, 26.87% of Al 2 O 3 and 5.11% of Fe 2 O 3 by X-Ray Diffraction (XRD);
Step (2): sieving the fly ash to screen out fly ash with particle size between 53 μm and 106 μm;
And (3): acid washing the fly ash to remove impurities;
And (4): ADC6 aluminum alloy specified by Japanese Industrial Standards (JIS), wherein the chemical element composition of the ADC6 aluminum alloy includes: 0.45% Si, 3.15% Mg, 0.31% Fe, 0.17% Mn, and 89.39% Al;
And (5): putting the fly ash into a high-temperature furnace and preheating to 800 ℃;
And (6): placing ADC6 aluminum alloy in a high-frequency melting furnace, and heating to 700 ℃ to melt the ADC6 aluminum alloy into aluminum melt;
and (7): stirring the aluminum melt at a rotation speed of 500rpm by using a stirring device, and adding the preheated fly ash into the aluminum melt at a flow rate of 0.2 g/s during stirring;
And (8): the aluminum melt mixed with fly ash is processed into an aluminum-based fly ash casting by using a Mold Immersion Rapid Solidification Process (MIRSP).
based on years of research experience of aluminum-based fly ash composite materials, the inventor of the present invention found that although aluminum-based fly ash castings with hardness as high as 58.13 Briber Hardness (BHN) can be obtained in the steps (1) to (8), the manufacturing process still shows the following practical disadvantages:
(1) The density, shape and particle size of the fly ash particles can influence the dispersibility of the fly ash particles in the aluminum melt, and the fly ash can be clustered in the aluminum melt by adding a large amount of fly ash at one time, so that SiO 2, Al 2 O 3, Fe 2 O 3 and oxides contained in the fly ash are difficult to react with the aluminum melt;
(2) Bearing in point 1 above, the insufficient reaction between the oxide and the molten aluminum eventually leads to the obtained aluminum-based fly ash casting having excessive pores or pores, resulting in the reduction of the mechanical properties of the aluminum-based fly ash casting.
from the above description, it is known that it is a very important issue to design and effectively improve the manufacturing process of aluminum-based fly ash casting with low porosity. In view of the above, the present inventors have made extensive studies and studies, and finally have developed a method for producing an aluminum matrix composite material according to the present invention.
disclosure of Invention
Aluminum-based fly ash castings produced by the manufacturing methods disclosed in the prior art typically have too many pores or pores, resulting in reduced mechanical properties. Therefore, the main object of the present invention is to provide a method for producing an aluminum-based fly ash composite material. The manufacturing method of the invention is characterized in that after the fly ash is roughly screened and finely screened by a floating screen and a magnetic screen, the preheated fly ash is added into an aluminum base material in a molten state in batches, and finally, an aluminum melt mixed with the fly ash is processed into an aluminum-based fly ash casting by a die dipping fast solidification method. Furthermore, experimental data show that the proposed method for manufacturing aluminum-based fly ash composite material does help to reduce the porosity and maintain or enhance the mechanical properties of aluminum-based fly ash castings.
In order to achieve the above-mentioned main objective of the present invention, the present inventors provide an embodiment of the method for manufacturing the aluminum-based fly ash composite material, comprising the following steps:
(1) Preparing fly ash and an aluminum substrate;
(2) subjecting the fly ash to a primary screening process to screen out fly ash having a particle size of 53 μm to 106 μm;
(3) Performing a pretreatment on the fly ash to remove impurities;
(4) carrying out fine screening treatment on the fly ash to screen out the fly ash with higher iron content;
(5) carrying out high-temperature baking treatment on the fly ash to burn off impurities and unburned carbon in the fly ash;
(6) placing the fly ash into a preheating device, and preheating to 600-800 ℃;
(7) Placing the aluminum substrate into a metal melting device, and heating to 700-;
(8) stirring the molten aluminum using a stirring device, and adding the preheated fly ash into the molten aluminum at a flow rate of 0.05-0.15 g/s during stirring; and
(9) the aluminum melt mixed with fly ash is processed into an aluminum-based fly ash casting by using a Mold Immersion Rapid Solidification Process (MIRSP).
For the embodiment of the method for manufacturing the aluminum-based fly ash composite material of the present invention, in the step (7), a magnesium material and the aluminum substrate may be placed into the metal melting device together, and heated to 800 ℃ at 700 ℃. so that the magnesium material and the aluminum substrate are melted into the aluminum melt.
for the embodiment of the method for manufacturing the aluminum-based fly ash composite material of the present invention, in the step (8), the fly ash that has been preheated is added to the aluminum melt on a specific number of batches, and the specific number of batches is at least two times. In the step (8), the fly ash of the previous batch is required to be added to the molten aluminum bath after the reaction between the fly ash of the previous batch and the molten aluminum bath is completed.
drawings
FIGS. 1A and 1B are flow charts showing a method of manufacturing an aluminum-based fly ash composite material according to the present invention;
FIG. 2 is a perspective view showing a prescreening device;
fig. 3 is a detailed flowchart showing the step (S2);
FIGS. 4A and 4B are schematic views showing the steps (S7) to (S8);
FIG. 5 is a graph of data showing fly ash addition versus density;
FIG. 6 is a graph of data showing fly ash addition versus porosity; and
FIG. 7 is a data graph showing fly ash addition versus hardness.
Wherein the reference numerals are:
S1-S9 steps
2 preliminary screening device
20 container
21 first screen mesh
22 second screen mesh
23 drainage port
S21-S23 steps
3 Metal melting device
31 aluminum melting soup
5 stirring device
6 mould
4 fly ash feeding device
Detailed Description
In order to more clearly describe the method for manufacturing the aluminum-based fly ash composite material of the present invention, the following description will be made in detail with reference to the drawings.
referring to fig. 1A and 1B, a flow chart of a method for manufacturing an aluminum-based fly ash composite material according to the present invention is shown. As shown in fig. 1A and 1B, to fabricate the aluminum-based fly ash composite material with low porosity and excellent mechanical properties by the method for fabricating the aluminum-based fly ash composite material, the steps (S1) are first performed: fly ash and an aluminum substrate are prepared. Continuously, the manufacturing method of the present invention then executes step (S2): subjecting the fly ash to a primary screening process to screen out fly ash having a particle size of between 53 μm and 106 μm. Please refer to the perspective view of the prescreening device shown in fig. 2 and the detailed flowchart of the step (S2) shown in fig. 3. Specifically, the present invention is completed by a floating sieve method (S2), which includes the following detailed steps:
step (S21): preparing a primary screening device 2, wherein the primary screening device 2 comprises a container 20, and a first screen 21 and a second screen 22 which are arranged in the container 20; the first screen 21 is disposed higher than the second screen 22, and the mesh size of the first screen 21 is larger than that of the second screen 22;
Step (S22): pouring the fly ash into the container 20, injecting flowing water into the container 20, and flushing the fly ash by using the flowing water; and
step (S23): flowing water is discharged from the vessel 20 through a discharge port 23 of the vessel 20, and fly ash having a particle size of 53 μm to 106 μm is screened out between the first screen 21 and the second screen 22.
it must be emphasized that the prior art typically performs the primary screening process on fly ash with a screening machine, however, the screening machine typically takes some time (e.g., 45 minutes) to screen out fly ash with a particle size between 53 μm and 106 μm from the fly ash material. In contrast, the present invention designs the primary screening device 2 and flushes the fly ash with flowing water, such primary screening process can screen out fly ash with particle size between 53 μm and 106 μm from the fly ash raw material within 5 minutes. In addition, it must be particularly emphasized that the present invention is not particularly limited to the kind of the aluminum substrate, and it may be a Die-cast aluminum alloy (Die-cast aluminum alloy) containing a magnesium component, for example: ADC6 aluminum alloy, ADC10 aluminum alloy, and ADC12 aluminum alloy, which are standardized by Japanese Industrial Standards (JIS). In addition, it is known to material engineers familiar with the design and manufacture of aluminum alloys that ZL-based aluminum alloys are also cast aluminum alloys containing magnesium components, such as: ZL101, ZL103, ZL105, ZL108, ZL109, ZL301, ZL305, and the like. In another aspect, the fly ash used in the present invention is class F fly ash as specified in the American society for testing and materials standards (ASTM) Standard code C618-12a, which is determined to contain a number of ingredients as set forth in Table (1) below:
watch (1)
SiO2 | Al2O3 | Fe2O3 | loss On Ignition (LOI) |
58.9 | 25.5 | 4.93 | 4.1% |
continuously, the flow of the manufacturing method then executes step (S3): the fly ash is pretreated to remove impurities. The fly ash pretreatment refers to that the fly ash is subjected to surface treatment to increase the cleanliness of the fly ash and improve the wettability between fly ash particles and a liquid phase substrate. In the step (S3) of the present invention, the fly ash is washed with an acidic solution, and then the washed fly ash is washed with pure water. After the step (S3) is completed, the step (S4) is then performed: and carrying out fine screening treatment on the fly ash to screen out the fly ash with higher iron content. It is noted that the fly ash is washed with the acidic solution and the pure water in the step (S3), respectively, and thus the fly ash obtained after the step (S3) is in a wet state such as mud, which cannot be directly subjected to the fine screening process. For this reason, before the step (S4) is performed, a low-temperature baking process must be performed on the fly ash to remove moisture therefrom.
In step (S4), the fly ash with high iron content is first removed by magnetic attraction using a high-frequency oscillating screening machine and a screen with 53 μm mesh size, and a powerful magnet. After the step (S4) is completed, the manufacturing method of the present invention then performs the step (S5): and carrying out high-temperature baking treatment on the fly ash to burn off impurities and unburned carbon in the fly ash. After the completion of step (S5), it was determined that the fly ash contained various components as listed in the following table (2):
Watch (2)
Comparing table (1) with table (2), it can be easily found that the fly ash obtained after the preliminary screening treatment, the preliminary treatment, the fine screening treatment, and the high-temperature baking treatment is completed contains much reduced Loss On Ignition (LOI) and iron oxide components, as compared with the fly ash not subjected to any treatment process; in contrast, fly ash contains increased amounts of alumina and silica. After the high temperature baking step is completed, the manufacturing method of the present invention then performs the step (S6) to place the fly ash into a preheating device to be preheated to 600 ℃ to 800 ℃, and then performs the steps (S7) to (S8). Fig. 4A and 4B are schematic views illustrating the processes from step (S7) to step (S8). As shown in FIG. 4A, the aluminum substrate is placed in a metal melting apparatus 3 and heated to 800 ℃ at 700 ℃ to make the aluminum substrate become an aluminum melt 31. Further, as shown in FIG. 4A, a stirring device 5 is used to stir the aluminum melt 31 and add the preheated fly ash to the aluminum melt 31 at a flow rate of 0.05-0.15 g/sec by using the fly ash feeding device 4 during the stirring process. Finally, as shown in fig. 4B, the present invention utilizes a Mold Immersion Rapid Solidification (MIRSP) Process to Process the fly ash mixed aluminum melt 31 into an aluminum-based fly ash casting.
It should be noted that, even though the aluminum alloy containing magnesium component is used as the aluminum substrate, in order to improve the wettability between the fly ash and the aluminum substrate, in the step (S7), a magnesium material is put into the metal melting apparatus 3 together with the aluminum substrate and heated to 700 ℃. + 800 ℃ so that the magnesium material is melted together with the aluminum substrate into the so-called aluminum melt 31. it is particularly emphasized that, based on the experimental experience of many years of the aluminum-based fly ash composite material, the inventors found that, when a large amount of fly ash is added at one time into the aluminum melt 31, the fly ash is aggregated in the aluminum melt 31, causing the SiO 2, Al 2 O 3 and Fe 2 O 3 contained in the fly ash to hardly react with the aluminum melt 31, therefore, in the step (S8), the preheated fly ash is added to the aluminum melt 31 on a specific number of times, and the number of the batches is at least two times, and when a next batch of fly ash is added, a next batch of the aluminum melt 31 is waited for adding the next batch of the fly ash.
It should be added that, in the step (S9), after the molten aluminum 31 mixed with the magnesium material and the fly ash is poured into the mold 6 (as shown in fig. 4B), the aluminum-based fly ash casting surface is cooled by the water sprayer for about 30 seconds; and then taking out the aluminum-based fly ash casting after the aluminum-based fly ash casting is shaped, and immediately completely cooling the aluminum-based fly ash casting for 1 minute by using flowing cooling water.
examples of the experiments
For existing aluminum-based-fly ash composites, it typically contains 1-5 wt% magnesium content, 3-15 wt% fly ash, and 96-83 wt% aluminum substrate. Therefore, in the experimental example of the present invention, the aluminum alloy ADC10 was used as the aluminum substrate, and the addition amounts of the fly ash and the magnesium material were divided into 15 wt% and 2 wt%, and the number of batches of fly ash was set to three. Briefly, the preheated fly ash is added to the molten aluminum in three batches, each of 6 wt%, 6 wt% and 3 wt%.
Fig. 5 is a data graph showing the amount of added fly ash with respect to density, and fig. 6 is a data graph showing the amount of added fly ash with respect to porosity. From the experimental data of fig. 5 and 6, it can be seen that the aluminum-based fly ash castings with two batches of added (6 wt% +6 wt%) fly ash exhibit lower porosity compared to the aluminum-based fly ash castings with 6 wt% fly ash added at once. Continuing with FIG. 7, a graph of fly ash addition versus hardness is shown. From the experimental data of fig. 7, it can be seen that the hardness properties of the aluminum-based fly ash castings with 6 wt% fly ash added at once, the aluminum-based fly ash castings with two batches of fly ash added (6 wt% +6 wt%), and the aluminum-based fly ash castings with three batches of fly ash added (6 wt% +6 wt% +3 wt%), are all higher than 85 Brix Hardness (BHN).
thus, the above has fully and clearly illustrated the steps of the method for manufacturing an aluminum-based fly ash composite material of the present invention; moreover, the present invention has the following advantages as follows:
(1) The aluminum-based fly ash castings produced by the manufacturing method disclosed in the prior art (such as the document I) have excessive pores or air holes, which causes the mechanical properties of the aluminum-based fly ash castings to be reduced. Compared with the existing manufacturing method, the manufacturing method of the aluminum-based fly ash composite material provided by the invention particularly adopts the floating sieve and the magnetic sieve to carry out coarse screening and fine screening on the fly ash, then the preheated fly ash is added into the aluminum base material in a molten state in batches, and finally the aluminum melt mixed with the fly ash is processed into an aluminum-based fly ash casting by using a die-dipping fast solidification method. Moreover, experimental data show that the manufacturing method of the aluminum-based fly ash composite material provided by the invention is beneficial to reducing the porosity of the aluminum-based fly ash casting and maintaining or enhancing the mechanical property of the aluminum-based fly ash casting.
it should be emphasized that the above detailed description is specific to possible embodiments of the invention, but this is not to be taken as limiting the scope of the invention, and all equivalent implementations or modifications that do not depart from the technical spirit of the invention are intended to be included within the scope of the present invention.
Claims (11)
1. the method for manufacturing the aluminum-based fly ash composite material is characterized by comprising the following steps of:
(1) Preparing fly ash and an aluminum substrate;
(2) Carrying out primary screening treatment on the fly ash;
(3) performing a pretreatment on the fly ash to remove impurities;
(4) Carrying out fine screening treatment on the fly ash to screen out the fly ash with higher iron content;
(5) carrying out high-temperature baking treatment on the fly ash to burn off impurities and unburned carbon in the fly ash;
(6) Placing the fly ash into a preheating device, and preheating to 600-800 ℃;
(7) Placing the aluminum substrate into a metal melting device, and heating to 700-;
(8) Stirring the molten aluminum using a stirring device, and adding the preheated fly ash into the molten aluminum at a flow rate of 0.05-0.15 g/s during stirring; and
(9) The aluminum melt mixed with fly ash is processed into an aluminum-based fly ash casting by using a Mold Immersion Rapid Solidification Process (MIRSP).
2. The method of claim 1, wherein the aluminum substrate is a Die-cast aluminum alloy (Die-cast aluminum alloy) containing magnesium.
3. The method of manufacturing an aluminum-based fly ash composite material as claimed in claim 1, wherein the primary screening process is performed to screen out fly ash having a particle size of 53 μm to 106 μm from the fly ash.
4. the method for producing an aluminum-based fly ash composite material according to claim 1, wherein the step (2) comprises the following detailed steps:
(21) preparing a container, and arranging a first screen and a second screen in the container; wherein the first screen is arranged higher than the second screen, and the aperture of the first screen is larger than that of the second screen;
(22) Pouring the fly ash into the container, injecting flowing water into the container, and flushing the fly ash by using the flowing water; and
(23) Flowing water is discharged from the vessel through a discharge port of the vessel, fly ash having a particle size of 53 μm to 106 μm is screened out between the first screen and the second screen.
5. The method for producing an aluminum-based fly ash composite material according to claim 1, wherein the step (3) comprises the following detailed steps:
Washing the fly ash with an acidic solution; and
the fly ash was washed with pure water.
6. the method for producing an aluminum-based fly ash composite material according to claim 1, wherein the step (4) comprises the following detailed steps:
Screening the fly ash by using a high-frequency oscillation type screening machine and a screen with the aperture size of 53 mu m; and
And (3) carrying out magnetic absorption treatment on the fly ash by using a powerful magnet to absorb the fly ash with higher iron content.
7. the method of claim 1, wherein in step (8), the preheated fly ash is added to the molten aluminum bath on a batch basis, and the batch is performed at least twice.
8. the method of claim 6, wherein in step (8), the fly ash of the previous batch is added to the aluminum melt after the reaction between the fly ash of the previous batch and the aluminum melt is completed.
9. The method of claim 1, wherein in the step (7), a magnesium material and the aluminum substrate are placed into the metal melting device and heated to 800 ℃ to melt the magnesium material and the aluminum substrate into the aluminum melt.
10. The method for producing an aluminum-based fly ash composite material according to claim 1, wherein the step (3) and the step (4) further comprise the following steps:
Performing a low temperature baking process on the fly ash to remove moisture therefrom.
11. The method of claim 9, wherein the magnesium metal, the fly ash and the aluminum substrate are present in an amount of 1-5 wt%, 3-15 wt% and 96-83 wt%, respectively, based on the weight of the aluminum-based fly ash casting.
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JPH10152734A (en) * | 1996-11-21 | 1998-06-09 | Aisin Seiki Co Ltd | Wear resistant metal composite |
CN1174895A (en) * | 1997-01-05 | 1998-03-04 | 吉林工业大学 | Aluminium-base electric power plant fly-ash compsite material and preparation method and device |
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Application publication date: 20191210 |