CN114105644A - 一种高耐磨陶瓷材料及其制备方法和应用 - Google Patents
一种高耐磨陶瓷材料及其制备方法和应用 Download PDFInfo
- Publication number
- CN114105644A CN114105644A CN202111449518.XA CN202111449518A CN114105644A CN 114105644 A CN114105644 A CN 114105644A CN 202111449518 A CN202111449518 A CN 202111449518A CN 114105644 A CN114105644 A CN 114105644A
- Authority
- CN
- China
- Prior art keywords
- ceramic material
- porous ceramic
- wear
- preparation
- fly ash
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/584—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/6261—Milling
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3284—Zinc oxides, zincates, cadmium oxides, cadmiates, mercury oxides, mercurates or oxide forming salts thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5427—Particle size related information expressed by the size of the particles or aggregates thereof millimeter or submillimeter sized, i.e. larger than 0,1 mm
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6562—Heating rate
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6567—Treatment time
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/658—Atmosphere during thermal treatment
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
本发明属于陶瓷材料技术领域,公开了一种高耐磨陶瓷材料及其制备方法和应用,制备方法包括:将粉煤灰经预处理除去其中重金属元素,随后与改性纳米氧化锌经球磨至粒径为20μm以下,加入陶瓷粉末、粘合剂混匀,压制成型后进行热处理,获得多孔陶瓷材料前驱体;将多孔陶瓷材料前驱体浸在醇溶液中,在硅烷偶联剂的作用下,将改性剂接枝在多孔陶瓷材料前驱体表面,获得多孔陶瓷材料;将聚氯乙烯树脂加热至稀软,加入固化剂混匀,获得浸入液;将多孔陶瓷材料浸入于浸入液中,使其浸入多孔陶瓷材料的孔隙中,自然冷却后,获得高耐磨陶瓷材料。本发明制备方法的制备原料易得且成本低、操作容易,且安全性高,制得的陶瓷材料耐磨性能佳。
Description
技术领域
本发明涉及陶瓷材料技术领域,尤其涉及一种高耐磨陶瓷材料及其制备方法和应用。
背景技术
在机械工程中,结构零件如密封件、轴承、刀具、球阀、缸套等都是频繁经受摩擦而易磨损,对机械工作的精准性和安全性造成影响。
现有技术中,为了避免这种情况的发生,提出了一种金属陶瓷复合材料,使陶瓷的高耐磨性、高硬度的特点和金属材料的韧性相结合。然而,目前制备金属陶瓷复合材料时,通过采用复合铸造,将金属高温熔化成液态,然后将金属液浇注于陶瓷中,但是这种方法金属的渗透效果难以控制,容易渗透不均,从而导致金属在陶瓷材料中分布不均,使得整体材料成分不均一,导致无法有效提高材料的耐磨性。
为此,本发明提供一种高耐磨陶瓷材料及其制备方法和应用。
发明内容
为了解决上述现有技术中的不足,本发明提供一种高耐磨陶瓷材料及其制备方法和应用。
本发明的一种高耐磨陶瓷材料及其制备方法和应用是通过以下技术方案实现的:
本发明的第一个目的是提供一种高耐磨陶瓷材料的制备方法,包括以下步骤:
步骤1,制备多孔陶瓷材料:
将粉煤灰经预处理除去其中重金属元素,随后将其与改性纳米氧化锌经球磨至粒径为20μm以下,获得混合粉体;随后向混合粉体中加入陶瓷粉末、粘合剂混匀,压制成型后进行热处理,获得多孔陶瓷材料前驱体;
将多孔陶瓷材料前驱体浸在醇溶液中,随后加入硅烷偶联剂和改性剂,在硅烷偶联剂的作用下,将改性剂接枝在所述多孔陶瓷材料前驱体表面,获得多孔陶瓷材料;
步骤2,制备耐磨陶瓷材料:
将聚氯乙烯树脂加热至稀软,加入固化剂混匀,获得浸入液;将所述多孔陶瓷材料浸入于所述浸入液中,使其浸入所述多孔陶瓷材料的孔隙中,自然冷却后,获得所述高耐磨陶瓷材料。
进一步地,所述热处理包括以下步骤:
将压制成型的胚料在氮气氛围下,以5~10℃/min的速率升温至800~1000℃,保温0.5~2h;随后以1~5℃/min的速率升温至1050~1250℃,保温0.5~2h。
进一步地,所述改性纳米氧化锌是通过以下步骤得到的:
将纳米氧化锌均匀分散于有机酸溶液中,调节pH至3~5,随后于75~85℃下回流反应1~3h,减压抽滤,用去离子水冲洗滤渣至滤液pH为7,将滤渣干燥后,获得所述改性纳米氧化锌。
进一步地,所述有机酸为柠檬酸、乙酸、甲酸、丙二酸中的任意一种。
进一步地,所述有机酸与所述纳米氧化锌的用量比为2~5mL:1g。
进一步地,所述陶瓷粉末为碳化硅和氮化硅中的一种或两种。
进一步地,所述陶瓷粉末的粒径为0.5~10mm。
进一步地,所述粘合剂为硅酸钠、酚醛树脂、聚乙烯醇、羧甲基纤维素、聚丙烯酸酯中的一种或几种。
进一步地,所述硅烷偶联剂为乙烯基三乙氧基硅烷、乙烯基三甲氧基硅烷、乙烯基三(β-甲氧乙氧基)硅烷中的一种或几种。
进一步地,所述改性剂为聚丙烯酰胺。
进一步地,所述固化剂为甲阶酚醛树脂、氨基树脂、双氰胺、聚酰胺树脂中的任意一种。
进一步地,所述预处理过的粉煤灰与所述改性纳米氧化锌的质量比为5~10:1。
进一步地,所述陶瓷粉末与所述混合粉体的质量比为2~5:1。
进一步地,所述粘合剂与所述混合粉体的质量比为0.05~0.1:1。
进一步地,所述树脂与所述多孔陶瓷材料前驱体的质量比为0.5~1.5:1。
进一步地,所述醇溶液与所述多孔陶瓷材料前驱体的用量比为1~3mL:1g;
所述醇溶液为质量浓度为50~70%的乙醇。
进一步地,所述硅烷偶联剂与所述多孔陶瓷材料前驱体的质量比为1:5~10。
进一步地,所述改性剂与所述多孔陶瓷材料前驱体的质量比为0.1~0.5:1。
进一步地,所述固化剂与所述聚氯乙烯树脂的质量比为1:7~9。
进一步地,所述球磨为湿法球磨,溶剂为40~60%的乙醇,球料比为2~4:1;球磨时间为1~4h。
进一步地,所述粉煤灰的预处理如下:
通过磁选除去粉煤灰中存在的铁磁性氧化物,从而去除一部分铁元素;随后加入分散剂搅拌10~20min,使其充分混合均匀之后通过振动打散,使得团聚的粉煤灰变成分散的小颗粒,然后将打散后的粉煤灰加热至120~150℃,并将加热后的粉煤灰输送至静电分离器中,在8000~12000V的高压电场作用下,空气电离形成电晕电场,在电晕电场中,粉煤灰颗粒带电迁移至异性电极,从而被分离出来,收集电极板上粒径20μm以上的粉煤灰,即获得除去重金属元素后的粉煤灰。
进一步地,所述分散剂为三乙醇胺、乙二醇、丙三醇、硬脂酸和硅烷偶联剂中的一种或几种;
所述分散剂与粉煤灰的质量比为0.03%~0.07%:1。
本发明的第二个目的是提供一种上述制备方法制得的高耐磨陶瓷材料。
本发明的第三个目的是提供一种上述高耐磨陶瓷材料在制备机械结构零件中的应用。
本发明与现有技术相比,具有以下有益效果:
本发明通过物理方法去除了粉煤灰中的重金属元素,提高粉煤灰中Al2O3和SiO2的纯度,便于粉煤灰在热处理过程中形成陶瓷骨架,同时防止粉煤灰中重金属造成污染。
本发明通过将纳米氧化锌改性从而提高其在醇溶液中的分散性,避免了纳米氧化锌在醇溶液中发生团聚现象,且改性纳米氧化锌的加入能够降低热处理时的温度,降低了处理难度,同时温度降低也提高了处理的安全性。
本发明通过球磨将改性纳米氧化锌与粉煤灰混合均匀,使得改性纳米氧化锌与粉煤灰中的二氧化硅充分接触,便于在热处理阶段将改性纳米氧化锌被粉煤灰中二氧化硅包裹,使得改性纳米氧化锌与粉煤灰共同形成了陶瓷材料的骨架结构,不仅避免了改性纳米氧化锌在后续使用过程中发生溶出现象,提高了改性纳米氧化锌在陶瓷材料中的稳定性,而且提高了陶瓷材料耐磨性的同时还提高了陶瓷材料中的防霉性能,使得本发明制得的陶瓷材料能够在潮湿环境中正常使用,而不用担心霉菌的腐蚀。
本发明通过将球磨后的粉煤灰和改性纳米氧化锌的混合物于陶瓷粉末与粘合剂混匀后压制成型,在热处理过程中,粉煤灰会释放出气体,进而形成孔隙,同时本发明选择大颗粒的陶瓷粉末加入,大颗粒陶瓷粉末在热处理过程中内部也能够形成多孔通道,使得本发明无需再加其他物质或其他处理进行造孔,通过热处理就能直接获得多孔陶瓷材料前驱体。
本发明通过将获得的多孔陶瓷材料前驱体浸在醇溶液中,使其表面充分润湿,提供其表面的活性,再通过硅烷偶联剂在其表面接枝改性剂,进一步提高多孔陶瓷材料前驱体孔隙表面的活性,使其便于与浇注的稀软树脂进行交联,进一步提高了陶瓷材料的耐磨性能。
本发明制备方法的制备原料易得且成本低、操作容易,且安全性高,制得的陶瓷材料耐磨性能佳。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述。
实施例1
本实施例提供一种高耐磨陶瓷材料,且本实施例的高耐磨陶瓷材料的制备方法如下:
步骤1,制备多孔陶瓷材料:
取一定量的粉煤灰经预处理除去其中重金属元素,备用;
按照1g:3mL的用量比,将纳米氧化锌均匀分散于丙二酸溶液中,调节pH至4,随后于80℃的水浴温度下回流反应2h,减压抽滤,用去离子水冲洗滤渣至滤液pH为7,将滤渣干燥后,获得所述改性纳米氧化锌,备用;
按照7:1的质量比,将预处理过的粉煤灰与改性纳米氧化锌在60%的乙醇溶液中进行球磨处理,设置球料比3:1,球磨2h后平均粒径为20μm,停止球磨,获得混合粉体;将混合粉体取出后于室温下加入粒径为5mm的碳化硅陶瓷粉末和粘合剂羧甲基纤维素混合均匀,静置9h,然后将其置于预先准备好的模具中,采用半干压成型压制成型获得胚料,将胚料在氮气氛围下,以7℃/min的速率升温至900℃,保温1h;随后以3℃/min的速率升温至1150℃,保温1h,冷却至室温,获得多孔陶瓷材料前驱体;
将多孔陶瓷材料前驱体均匀分散于醇溶液中,随后加入硅烷偶联剂乙烯基三乙氧基硅烷和改性剂聚丙烯酰胺,在硅烷偶联剂乙烯基三乙氧基硅烷的作用下,将改性剂聚丙烯酰胺接枝在所述多孔陶瓷材料表面,获得多孔陶瓷材料;
本实施例中,陶瓷粉末与混合粉体的质量比为3.5:1;
粘合剂与混合粉体的质量比为0.07:1;
多孔陶瓷材料前驱体与醇溶液的用量比为1g:2mL;醇溶液为质量浓度为50%的乙醇溶液;
硅烷偶联剂与多孔陶瓷材料前驱体的质量比为1:7;
改性剂与多孔陶瓷材料前驱体的质量比为0.3:1。
步骤2,制备高耐磨陶瓷材料:
将聚氯乙烯树脂加热至稀软,加入固化剂氨基树脂混匀,获得浸入液;然后将步骤1获得的多孔陶瓷材料浸入于上述浸入液中,随后置于真空瓶中并抽真空30min,使浸入液浸入多孔陶瓷材料的孔隙中,随后待其固化后,即获得高耐磨陶瓷材料;
本实施例中,聚氯乙烯树脂与多孔陶瓷材料前驱体的质量比为1:1;
固化剂与聚氯乙烯树脂的质量比为1:8。
实施例2
本实施例提供一种高耐磨陶瓷材料,且本实施例的高耐磨陶瓷材料的制备方法如下:
步骤1,制备多孔陶瓷材料:
取一定量的粉煤灰经预处理除去其中重金属元素,备用;
按照1g:2mL的用量比,将纳米氧化锌均匀分散于柠檬酸溶液中,调节pH至3,随后于75℃的水浴温度下回流反应3h,减压抽滤,用去离子水冲洗滤渣至滤液pH为7,将滤渣干燥后,获得所述改性纳米氧化锌,备用;
按照5:1的质量比,将预处理过的粉煤灰与改性纳米氧化锌在50%的乙醇溶液中进行球磨处理,设置球料比2:1,球磨4h后平均粒径为10μm,停止球磨,获得混合粉体;将混合粉体取出后于室温下加入粒径为0.5mm的氮化硅陶瓷粉末和粘合剂聚乙烯醇混合均匀,静置6h,然后将其置于预先准备好的模具中,采用半干压成型压制成型获得胚料,将胚料在氮气氛围下,以5℃/min的速率升温至800℃,保温2h;随后以1℃/min的速率升温至1050℃,保温2h,冷却至室温,获得多孔陶瓷材料前驱体;
将多孔陶瓷材料前驱体均匀分散于醇溶液中,随后加入硅烷偶联剂乙烯基三甲氧基硅烷和改性剂聚丙烯酰胺,在硅烷偶联剂乙烯基三甲氧基硅烷的作用下,将改性剂聚丙烯酰胺接枝在所述多孔陶瓷材料表面,获得多孔陶瓷材料;
本实施例中,陶瓷粉末与混合粉体的质量比为2:1;
粘合剂与混合粉体的质量比为0.05:1;
多孔陶瓷材料前驱体与醇溶液的用量比为1g:1mL;醇溶液为质量浓度为60%的乙醇溶液;
硅烷偶联剂与多孔陶瓷材料前驱体的质量比为1:5;
改性剂与多孔陶瓷材料前驱体的质量比为0.1:1。
步骤2,制备高耐磨陶瓷材料:
将聚氯乙烯树脂加热至稀软,加入固化剂聚酰胺树脂混匀,获得浸入液;然后将步骤1获得的多孔陶瓷材料浸入于上述浸入液中,随后置于真空瓶中并抽真空20min,使浸入液浸入多孔陶瓷材料的孔隙中,随后待其固化后,即获得高耐磨陶瓷材料;
本实施例中,聚氯乙烯树脂与多孔陶瓷材料前驱体的质量比为0.5:1;
固化剂与聚氯乙烯树脂的质量比为1:7。
实施例3
本实施例提供一种高耐磨陶瓷材料,且本实施例的高耐磨陶瓷材料的制备方法如下:
步骤1,制备多孔陶瓷材料:
取一定量的粉煤灰经预处理除去其中重金属元素,备用;
按照1g:5mL的用量比,将纳米氧化锌均匀分散于乙酸溶液中,调节pH至5,随后于85℃的水浴温度下回流反应1h,减压抽滤,用去离子水冲洗滤渣至滤液pH为7,将滤渣干燥后,获得所述改性纳米氧化锌,备用;
按照10:1的质量比,将预处理过的粉煤灰与改性纳米氧化锌在70%的乙醇溶液中进行球磨处理,设置球料比4:1,球磨1h后平均粒径为15μm,停止球磨,获得混合粉体;将混合粉体取出后于室温下加入粒径为10mm的陶瓷粉末和粘合剂聚丙烯酸酯混合均匀,静置12h,然后将其置于预先准备好的模具中,采用半干压成型压制成型获得胚料,将胚料在氮气氛围下,以10℃/min的速率升温至1000℃,保温0.5h;随后以5℃/min的速率升温至1250℃,保温0.5h,冷却至室温,获得多孔陶瓷材料前驱体;
将多孔陶瓷材料前驱体均匀分散于醇溶液中,随后加入硅烷偶联剂乙烯基三(β-甲氧乙氧基)硅烷和改性剂聚丙烯酰胺,在硅烷偶联剂乙烯基三(β-甲氧乙氧基)硅烷的作用下,将改性剂聚丙烯酰胺接枝在所述多孔陶瓷材料表面,获得多孔陶瓷材料;
本实施例中,陶瓷粉末为碳化硅和氮化硅等质量的混合物;
陶瓷粉末与混合粉体的质量比为5:1;
粘合剂与混合粉体的质量比为0.1:1;
多孔陶瓷材料前驱体与醇溶液的用量比为1g:3mL;醇溶液为质量浓度为70%的乙醇溶液;
硅烷偶联剂与多孔陶瓷材料前驱体的质量比为1:10;
改性剂与多孔陶瓷材料前驱体的质量比为0.3:1。
步骤2,制备高耐磨陶瓷材料:
将聚氯乙烯树脂加热至稀软,加入固化剂甲阶酚醛树脂混匀,获得浸入液;然后将步骤1获得的多孔陶瓷材料浸入于上述浸入液中,随后置于真空瓶中并抽真空60min,使浸入液浸入多孔陶瓷材料的孔隙中,随后待其固化后,即获得高耐磨陶瓷材料;
本实施例中,聚氯乙烯树脂与多孔陶瓷材料前驱体的质量比为1.5:1;
固化剂与聚氯乙烯树脂的质量比为1:9。
需要说明的是,本发明上述实施例中是通过将树脂放在坩埚中,随后将其置于80~90℃的烘箱中,将树脂加热至变得稀软后取出的。
且本发明上述实施例中粉煤灰均是通过以下预处理去除重金属元素的:
通过磁选除去粉煤灰中存在的铁磁性氧化物,从而去除一部分铁元素;随后加入分散剂搅拌10~20min,使其充分混合均匀之后通过振动打散,使得团聚的粉煤灰变成分散的小颗粒,然后将打散后的粉煤灰加热至120~150℃,并将加热后的粉煤灰输送至静电分离器中,在8000~12000V的高压电场作用下,空气电离形成电晕电场,在电晕电场中,粉煤灰颗粒带电迁移至异性电极,从而被分离出来,收集电极板上粒径大于20μm的粉煤灰,即获得除去重金属元素后的粉煤灰。
经静电分离筛分得到粒径在0.1~20μm之间的粉煤灰颗粒,随后将其进行第一次离心分离,在离心力的作用下大颗粒沉降,
进一步地,所述分散剂为三乙醇胺、乙二醇、丙三醇、硬脂酸和硅烷偶联剂中的一种或几种;
所述分散剂与粉煤灰的质量比为0.03%~0.07%:1。
对比例1
本对比例与实施例的区别仅在于:
本对比例未对粉煤灰进行预处理,直接将其与改性纳米氧化锌球磨混合,其他操作与实施例1相同。
对比例2
本对比例与实施例的区别仅在于:
本对比例未对多孔陶瓷材料前驱体进行改性接枝,直接将多孔陶瓷材料前驱体浸入浸入液中,其他操作与实施例1相同。
对比例3
本对比例与实施例的区别仅在于:
本对比例未进行浸入液浸入处理,直接将获得的多孔陶瓷材料作为耐磨陶瓷材料,其他操作与实施例1相同。
试验部分
为了验证本发明制备方法制得的耐磨陶瓷材料的性能,本发明对实施例1-3及对比例1-3制得的耐磨陶瓷材料进行了以下测试。
(一)硬度测试
本发明依据GB/T 16534-2009的标准,采用维氏硬度测试仪对本发明实施例1-3及对比例1-3制得的耐磨陶瓷材料的硬度进行了测试,结果如表1所示。
表1硬度测试结果
实施例1 | 实施例2 | 实施例3 | 对比例1 | 对比例2 | 对比例3 | |
硬度(GPa) | 12.0 | 9.6 | 11.1 | 10.5 | 8.9 | 7.8 |
(二)弯曲强度测试
本发明依据GB/T 6569-2006的标准,采用万能试验机对本发明实施例1-3及对比例1-3制得的耐磨陶瓷材料的弯曲强度进行了测试,结果如表2所示。
表2弯曲强度测试结果
实施例1 | 实施例2 | 实施例3 | 对比例1 | 对比例2 | 对比例3 | |
弯曲强度(MPa) | 712 | 689 | 701 | 703 | 631 | 590 |
(三)摩擦性能测试
本发明依据GB/T 3810.7-2016的标准,采用球盘摩擦磨损试验机对本发明实施例1-3及对比例1-3制得的耐磨陶瓷材料的磨损率进行了测试,结果如表3所示。
表3磨损率测试结果
实施例1 | 实施例2 | 实施例3 | 对比例1 | 对比例2 | 对比例3 | |
磨损率(%) | 2.3×10<sup>-4</sup> | 3.5×10<sup>-4</sup> | 2.7×10<sup>-4</sup> | 2.9×10<sup>-4</sup> | 7.6×10<sup>-4</sup> | 1.1×10<sup>-3</sup> |
显然,上述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
Claims (10)
1.一种高耐磨陶瓷材料的制备方法,其特征在于,包括以下步骤:
步骤1,制备多孔陶瓷材料:
将粉煤灰经预处理除去其中重金属元素,随后将其与改性纳米氧化锌经球磨至粒径为20μm以下,获得混合粉体;随后向混合粉体中加入陶瓷粉末、粘合剂混匀,压制成型后进行热处理,获得多孔陶瓷材料前驱体;
将多孔陶瓷材料前驱体浸在醇溶液中,随后加入硅烷偶联剂和改性剂,在硅烷偶联剂的作用下,将改性剂接枝在所述多孔陶瓷材料前驱体表面,获得多孔陶瓷材料;
步骤2,制备高耐磨陶瓷材料:
将聚氯乙烯树脂加热至稀软,加入固化剂混匀,获得浸入液;将所述多孔陶瓷材料浸入于所述浸入液中,使其浸入所述多孔陶瓷材料的孔隙中,自然冷却后,获得所述高耐磨陶瓷材料。
2.如权利要求1所述的制备方法,其特征在于,所述热处理包括以下步骤:
将压制成型的胚料在氮气氛围下,以5~10℃/min的速率升温至800~1000℃,保温0.5~2h;随后以1~5℃/min的速率升温至1050~1250℃,保温0.5~2h。
3.如权利要求1所述的制备方法,其特征在于,所述改性纳米氧化锌是通过以下步骤得到的:
将纳米氧化锌均匀分散于有机酸溶液中,调节pH至3~5,随后于75~85℃下回流反应1~3h,获得所述改性纳米氧化锌。
4.如权利要求1所述的制备方法,其特征在于,所述陶瓷粉末为碳化硅和氮化硅中的一种或两种;且所述陶瓷粉末的粒径为0.5~10mm;
所述改性剂为聚丙烯酰胺。
5.如权利要求1所述的制备方法,其特征在于,所述预处理过的粉煤灰与所述改性纳米氧化锌的质量比为5~10:1;
所述陶瓷粉末与所述混合粉体的质量比为2~5:1;
所述粘合剂与所述混合粉体的质量比为0.05~0.1:1。
6.如权利要求1所述的制备方法,其特征在于,所述聚氯乙烯树脂与所述多孔陶瓷材料前驱体的质量比为0.5~1.5:1。
7.如权利要求1所述的制备方法,其特征在于,所述醇溶液与所述多孔陶瓷材料前驱体的用量比为1~3mL:1g;
所述硅烷偶联剂与所述多孔陶瓷材料前驱体的质量比为1:5~10;
所述改性剂与所述多孔陶瓷材料前驱体的质量比为0.1~0.5:1。
8.如权利要求1所述的制备方法,其特征在于,所述球磨为湿法球磨,溶剂为40~60%的乙醇,球料比为2~4:1;球磨时间为1~4h。
9.一种权利要求1-8任意一项所述的制备方法制得的高耐磨陶瓷材料。
10.一种权利要求9所述的高耐磨陶瓷材料在制备机械结构零件中的应用。
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202111449518.XA CN114105644A (zh) | 2021-11-30 | 2021-11-30 | 一种高耐磨陶瓷材料及其制备方法和应用 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202111449518.XA CN114105644A (zh) | 2021-11-30 | 2021-11-30 | 一种高耐磨陶瓷材料及其制备方法和应用 |
Publications (1)
Publication Number | Publication Date |
---|---|
CN114105644A true CN114105644A (zh) | 2022-03-01 |
Family
ID=80369518
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN202111449518.XA Pending CN114105644A (zh) | 2021-11-30 | 2021-11-30 | 一种高耐磨陶瓷材料及其制备方法和应用 |
Country Status (1)
Country | Link |
---|---|
CN (1) | CN114105644A (zh) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114736485A (zh) * | 2022-04-14 | 2022-07-12 | 咸阳师范学院 | 一种树脂基陶瓷摩擦材料及其制备方法和应用 |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN85101472A (zh) * | 1984-01-13 | 1987-01-10 | 株式会社日立制作所 | 陶瓷复合材料制品及其生产方法 |
US5217932A (en) * | 1989-09-18 | 1993-06-08 | The Tokyo Electric Power Co., Ltd. | Sintered ceramic composite body and method of manufacturing same |
JP2005146243A (ja) * | 2003-11-17 | 2005-06-09 | Iwao Jiki Kogyo Kk | 樹脂複合多孔質材料 |
CN105036177A (zh) * | 2015-07-20 | 2015-11-11 | 苏州宇希新材料科技有限公司 | 一种纳米氧化锌的制备方法 |
CN108084601A (zh) * | 2017-12-18 | 2018-05-29 | 洛阳名力科技开发有限公司 | 一种树脂基陶瓷摩擦材料的制备方法 |
CN111871605A (zh) * | 2020-07-29 | 2020-11-03 | 杭州石炭纪环保科技有限公司 | 一种去除粉煤灰中重金属的方法 |
CN112620117A (zh) * | 2019-09-24 | 2021-04-09 | 中国科学院过程工程研究所 | 一种粉煤灰中重金属元素的分离方法 |
-
2021
- 2021-11-30 CN CN202111449518.XA patent/CN114105644A/zh active Pending
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN85101472A (zh) * | 1984-01-13 | 1987-01-10 | 株式会社日立制作所 | 陶瓷复合材料制品及其生产方法 |
US5217932A (en) * | 1989-09-18 | 1993-06-08 | The Tokyo Electric Power Co., Ltd. | Sintered ceramic composite body and method of manufacturing same |
JP2005146243A (ja) * | 2003-11-17 | 2005-06-09 | Iwao Jiki Kogyo Kk | 樹脂複合多孔質材料 |
CN105036177A (zh) * | 2015-07-20 | 2015-11-11 | 苏州宇希新材料科技有限公司 | 一种纳米氧化锌的制备方法 |
CN108084601A (zh) * | 2017-12-18 | 2018-05-29 | 洛阳名力科技开发有限公司 | 一种树脂基陶瓷摩擦材料的制备方法 |
CN112620117A (zh) * | 2019-09-24 | 2021-04-09 | 中国科学院过程工程研究所 | 一种粉煤灰中重金属元素的分离方法 |
CN111871605A (zh) * | 2020-07-29 | 2020-11-03 | 杭州石炭纪环保科技有限公司 | 一种去除粉煤灰中重金属的方法 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114736485A (zh) * | 2022-04-14 | 2022-07-12 | 咸阳师范学院 | 一种树脂基陶瓷摩擦材料及其制备方法和应用 |
CN114736485B (zh) * | 2022-04-14 | 2023-09-19 | 咸阳师范学院 | 一种树脂基陶瓷摩擦材料及其制备方法和应用 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CN110078515A (zh) | 一种氧化石墨烯改性碳纤维增强碳化硅陶瓷基复合材料的制备方法 | |
CN108097866B (zh) | 一种提高无机粘结剂砂强度的方法 | |
CN114105644A (zh) | 一种高耐磨陶瓷材料及其制备方法和应用 | |
CN112409008A (zh) | 一种抗磨损碳/陶刹车材料的制备方法 | |
CN111883328A (zh) | 一种改性粘结剂及利用其制备软磁复合材料的方法 | |
CN107326205A (zh) | 一种以粘结化工艺制备粉末冶金铜基摩擦材料的方法 | |
CN109293363A (zh) | 一种铝碳化硼复合材料的制备方法 | |
CN110938281A (zh) | 一种改性碳纤维增强酚醛树脂基复合材料及其制备 | |
CN113270242A (zh) | 一种全无机耐高温复合磁粉芯及其制备方法 | |
CN113667348B (zh) | 一种防氧化防脱碳隔离粘结剂及其制备方法 | |
CN114833733A (zh) | 一种金刚石树脂砂轮及其制备方法 | |
CN113443901A (zh) | 高强度氧化铝泡沫陶瓷及其制备方法 | |
CN105039830A (zh) | 交变磁场中金属/陶瓷梯度材料的流延成型制备方法 | |
CN112160169A (zh) | 环保纤维浸胶液、制备方法及应用 | |
CN116496069A (zh) | 一种纤维多孔陶瓷的制备方法及纤维多孔陶瓷 | |
CN110453101A (zh) | 夹金属铜鳞片石墨增强铜基复合材料及其制备方法和应用 | |
CN114807833B (zh) | 一种金属模具表面处理工艺 | |
CN111779782B (zh) | 一种高稳定性耐摩擦的刹车片及生产工艺 | |
CN114082942A (zh) | 一种金属磁粉芯的制备方法 | |
CN108239741B (zh) | 一种提高铝压铸和精锻模具的加工方法 | |
CN109024055B (zh) | 一种高耐磨性纸基摩擦材料的制备方法 | |
CN112960985A (zh) | 一种液体解胶增强剂及其制备方法 | |
CN109369064B (zh) | 一种超低气孔率高致密化研磨子生产工艺 | |
CN112094683A (zh) | 一种脱模剂及其制备方法与应用 | |
CN108285772B (zh) | 一种基于合金硅-玄武岩纤维复合材料的耐磨制动摩擦材料及其制备方法 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PB01 | Publication | ||
PB01 | Publication | ||
SE01 | Entry into force of request for substantive examination | ||
SE01 | Entry into force of request for substantive examination |