CN114951609B - Foamed aluminum plate with uniform closed pores and preparation method thereof - Google Patents
Foamed aluminum plate with uniform closed pores and preparation method thereof Download PDFInfo
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- CN114951609B CN114951609B CN202210385615.5A CN202210385615A CN114951609B CN 114951609 B CN114951609 B CN 114951609B CN 202210385615 A CN202210385615 A CN 202210385615A CN 114951609 B CN114951609 B CN 114951609B
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 104
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 78
- 239000011148 porous material Substances 0.000 title claims abstract description 23
- 238000002360 preparation method Methods 0.000 title abstract description 25
- 239000000843 powder Substances 0.000 claims abstract description 63
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical group [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims abstract description 39
- 239000000203 mixture Substances 0.000 claims abstract description 39
- 239000004088 foaming agent Substances 0.000 claims abstract description 29
- 229910000019 calcium carbonate Inorganic materials 0.000 claims abstract description 25
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 21
- 239000002245 particle Substances 0.000 claims abstract description 21
- 239000002994 raw material Substances 0.000 claims abstract description 19
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 15
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 15
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical group [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052700 potassium Inorganic materials 0.000 claims abstract description 13
- 239000011591 potassium Substances 0.000 claims abstract description 13
- 239000000919 ceramic Substances 0.000 claims abstract description 11
- 229910001610 cryolite Inorganic materials 0.000 claims abstract description 8
- 239000006260 foam Substances 0.000 claims abstract description 6
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 25
- 230000009970 fire resistant effect Effects 0.000 claims description 24
- 238000010304 firing Methods 0.000 claims description 21
- 238000005245 sintering Methods 0.000 claims description 21
- 238000001816 cooling Methods 0.000 claims description 17
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 17
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 17
- 238000002156 mixing Methods 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 claims description 9
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 6
- 239000011261 inert gas Substances 0.000 claims description 6
- 239000012298 atmosphere Substances 0.000 claims description 3
- 230000008569 process Effects 0.000 description 17
- 238000005187 foaming Methods 0.000 description 15
- 230000000052 comparative effect Effects 0.000 description 13
- 230000006872 improvement Effects 0.000 description 8
- 238000009826 distribution Methods 0.000 description 7
- 239000007789 gas Substances 0.000 description 7
- 230000009467 reduction Effects 0.000 description 7
- 238000009472 formulation Methods 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 239000012300 argon atmosphere Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000012299 nitrogen atmosphere Substances 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- 238000010791 quenching Methods 0.000 description 3
- 230000000171 quenching effect Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000005997 Calcium carbide Substances 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- CLZWAWBPWVRRGI-UHFFFAOYSA-N tert-butyl 2-[2-[2-[2-[bis[2-[(2-methylpropan-2-yl)oxy]-2-oxoethyl]amino]-5-bromophenoxy]ethoxy]-4-methyl-n-[2-[(2-methylpropan-2-yl)oxy]-2-oxoethyl]anilino]acetate Chemical compound CC1=CC=C(N(CC(=O)OC(C)(C)C)CC(=O)OC(C)(C)C)C(OCCOC=2C(=CC=C(Br)C=2)N(CC(=O)OC(C)(C)C)CC(=O)OC(C)(C)C)=C1 CLZWAWBPWVRRGI-UHFFFAOYSA-N 0.000 description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- -1 TiH 2 Chemical class 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000007723 die pressing method Methods 0.000 description 1
- 238000007688 edging Methods 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 229910052987 metal hydride Inorganic materials 0.000 description 1
- 150000004681 metal hydrides Chemical class 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 229910000568 zirconium hydride Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/005—Casting metal foams
-
- 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
- C22C1/08—Alloys with open or closed pores
-
- 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
- C22C1/08—Alloys with open or closed pores
- C22C1/083—Foaming process in molten metal other than by powder metallurgy
- C22C1/086—Gas foaming process
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
The invention discloses a foam aluminum plate with uniform closed pores, which is mainly prepared from the following raw materials in parts by weight: 90-98 parts of base material, 0.5-5 parts of fluxing agent, 0.5-5 parts of high-temperature tackifier and 0.1-1 part of foaming agent. Wherein the base material is aluminum powder, aluminum scraps and/or aluminum alloy powder; the foaming agent is calcium carbonate powder, and the particle size of the foaming agent is 400-800 meshes; the fluxing agent is potassium fluoaluminate and/or cryolite; the high-temperature tackifier is one or a mixture of more of alumina powder, mullite powder and ceramic powder. Correspondingly, the invention also discloses a preparation method for preparing the foamed aluminum plate with uniform closed pores. By implementing the invention, the large-specification closed-cell foamed aluminum plate with uniform pore diameter, high purity and high strength can be obtained.
Description
Technical Field
The invention relates to the field of foam metal materials, in particular to a foam aluminum plate with uniform closed pores and a preparation method thereof.
Background
Foamed aluminum refers to a composite material which is formed by a metal aluminum/aluminum alloy and gas, wherein a large number of bubbles exist in the metal aluminum/aluminum alloy. The foamed aluminum has the advantages of high porosity, low density, high temperature resistance, corrosion resistance, low heat conductivity, strong electromagnetic shielding performance, good sound absorption and shock absorption performance and the like. Foamed aluminum is widely applied to the fields of concert halls, conference centers, road barriers, ventilation equipment and the like as a functional material and a structural material.
The existing closed-cell foamed aluminum preparation process mainly comprises two steps, namely a powder metallurgy foaming method, wherein a foaming agent (usually TiH 2 powder) and metal aluminum powder are mixed, and the mixture is subjected to mould pressing, high-temperature foaming and cooling to obtain foamed aluminum; by adopting the method, the high-temperature foaming temperature is generally controlled between 690 and 800 ℃. The method has narrower process parameter interval, the prepared foamed aluminum has small size, and the foamed aluminum with different shapes needs different dies due to the need of a die pressing procedure, so that the die preparation cost is high, and the die needs to be frequently replaced in the production process, so that the process cost is high. The other is a foaming method of a foaming agent, which mainly comprises the steps of adding the foaming agent into a melt obtained after aluminum is melted, foaming by gas generated by the foaming agent, and cooling to obtain foamed aluminum. The foaming agent used in this process is typically a metal hydride such as TiH 2、ZrH2. The process needs to add a foaming agent into the aluminum melt, the foaming agent is difficult to mix uniformly, and the uniformity of air holes obtained by foaming is poor. And because of the high temperature of the aluminum melt, the addition of the foaming agent is difficult.
Disclosure of Invention
The invention aims to solve the technical problem of providing a foamed aluminum plate with uniform closed pores, which has high pore diameter uniformity of foaming pores, high strength and large specification and can be processed as required.
The invention also solves the technical problem of providing a preparation method of the foamed aluminum plate with uniform closed pores, which has simple process and can prepare a large-size foamed aluminum plate (maximum specification 2400mm is 3000mm is 200 mm).
In order to solve the technical problems, the invention provides a foam aluminum plate with uniform closed pores, which is mainly prepared from the following raw materials in parts by weight:
90-98 parts of base material, 0.5-5 parts of fluxing agent, 0.5-5 parts of high-temperature tackifier and 0.1-1 part of foaming agent;
Wherein the base material is aluminum powder, aluminum scraps and/or aluminum alloy powder, the foaming agent is calcium carbonate powder, and the particle size of the foaming agent is 400-800 meshes; the fluxing agent is potassium fluoroaluminate (K3 AlF 6) and/or cryolite; the high-temperature tackifier is one or a mixture of more of alumina powder, mullite powder and ceramic powder, and the grain size of the high-temperature tackifier is 100-325 meshes.
As an improvement of the technical scheme, the consumption of the foaming agent is 0.1-0.5 part, and the particle size of the foaming agent is 500-600 meshes.
As an improvement of the technical scheme, the grain size of the base material is 10-100 meshes, the grain size of the fluxing agent is 250-1500 meshes, and the grain size of the high-temperature tackifier is 100-325 meshes.
As an improvement of the technical scheme, the high-temperature tackifier is alumina powder with the particle size of 200-300 meshes.
As an improvement of the technical scheme, aluminum powder is selected as the base material, and the particle size of the aluminum powder is 40-80 meshes.
As an improvement of the technical scheme, the foamed aluminum plate is prepared from the following raw materials in parts by weight:
93-96 parts of aluminum powder, 0.1-0.5 part of calcium carbonate powder, 1.5-3 parts of alumina powder and 1.5-3 parts of potassium fluoroaluminate (K3 AlF 6).
Correspondingly, the invention also discloses a preparation method of the foamed aluminum plate with uniform closed pores, which comprises the following steps:
(1) Providing raw materials, and uniformly mixing the raw materials to obtain a mixture;
(2) Distributing the mixture into a fire-resistant kiln car;
(3) The mixture in the fire-resistant kiln car is burned at 700-750 ℃ and cooled to obtain a finished product of the foamed aluminum plate with uniform closed pores;
wherein, during the sintering process, an inert gas atmosphere is maintained.
As an improvement of the technical scheme, in the step (3), the baking is performed according to the following temperature curve:
the temperature is raised from room temperature to 450 ℃ for 20-30 min;
the temperature is raised from 450 ℃ to 600 ℃ for 30 to 45 minutes;
heating from 600 ℃ to firing temperature for 15-20 min;
the temperature is reduced for 10 to 12 minutes from the firing temperature to 450 ℃;
The temperature is reduced from 450 ℃ to room temperature for 60-80 min;
Wherein the firing temperature is 710 to 730 ℃.
As an improvement of the technical scheme, in the step (1), a screw mixing device is adopted to mix raw materials;
In the step (3), the roller kiln is adopted for sintering.
As an improvement of the technical scheme, the refractory kiln car comprises a first square beam, a second square beam, a base plate and a coaming which are sequentially arranged from bottom to top, wherein the first square beam is perpendicular to the second square beam, and the base plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide;
In the step (2), aluminum silicate high-temperature paper is stuck in the accommodating cavity of the fire-resistant kiln car, and then the material is distributed.
The implementation of the invention has the following advantages:
1. the foamed aluminum plate adopts the calcium carbonate powder with the particle size of 400-800 meshes as the foaming agent, and can decompose to generate a large amount of gas at the temperature of 700-750 ℃ so as to achieve the foaming effect.
2. According to the foamed aluminum plate, the high-temperature tackifier is added in the formula, so that the viscosity of an aluminum melt is increased at high temperature, gas generated by decomposing calcium carbide powder does not flow randomly, the addition amount of a foaming agent is reduced, the uniformity of air holes is ensured, and the air holes are prevented from penetrating through to form open air holes.
3. According to the foamed aluminum plate, the fluxing agent is added in the formula, and as a layer of oxide film (aluminum oxide) exists on the surfaces of aluminum powder and aluminum scraps, the melting point of the aluminum oxide is 2050 ℃, and the fluxing agent added in the invention reacts with the aluminum oxide at 400-600 ℃ to damage the oxide film on the surfaces of the aluminum powder or the aluminum scraps, so that the melting temperature of the aluminum powder or the aluminum scraps is greatly reduced, and the energy consumption is greatly reduced.
4. In the preparation method of the foamed aluminum plate, in the process of cooling the sintering temperature to 450 ℃, the cooling time is controlled to be 10-12 min, namely, a quenching process is adopted; the gas generated by the foaming agent can be fixed in the melt by quenching and solidification, so that the uniformity of the air holes is improved. Meanwhile, the use amount of the high-temperature tackifier is reduced to a certain extent.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the following detailed description.
The invention provides a preparation method of a foamed aluminum plate with uniform closed pores, which is mainly prepared from the following raw materials in parts by weight:
90-98 parts of base material, 0.5-5 parts of fluxing agent, 0.5-5 parts of high-temperature tackifier and 0.1-1 part of foaming agent.
Wherein, the base material is aluminum powder or aluminum scraps, the grain diameter of the base material is 10-100 meshes, and the base material with the grain diameter range can be fully mixed with other raw materials to improve the foaming uniformity. The particle size of the base material is exemplified by, but not limited to, 20 to 60 mesh, 40 to 60 mesh, 20 to 80 mesh, or 60 to 100 mesh. Preferably, the particle size of the base material is 40-80 meshes. Specifically, the amount of the base material is 90 to 98 parts, and 90 parts, 92 parts, 94 parts, 96 parts, or 98 parts are exemplified, but not limited thereto. Preferably, the amount of the base material is 93-95 parts. The foamed aluminum plate of the invention has high base material consumption, high purity, excellent corrosion resistance and excellent electromagnetic shielding performance.
Wherein, the foaming agent is calcium carbonate powder with the particle size of 400-800 meshes, and the calcium carbonate powder with the particle size range can be fully dispersed in the mixture to ensure the foaming uniformity. Preferably, the particle size of the calcium carbonate powder is 500 to 600 mesh. The calcium carbonate powder is used in an amount of 0.1 to 1 part, and exemplary is 0.1 part, 0.15 part, 0.2 part, 0.24 part, 0.44 part, 0.5 part, 0.7 part, or 0.9 part, but is not limited thereto. Preferably, the dosage of the calcium carbonate powder is 0.1-0.5 part, and the preparation process and the high-temperature tackifier cooperate to effectively reduce the dosage of the foaming agent while ensuring the foaming effect.
Furthermore, the formula of the invention also comprises 0.5 to 5 parts of high-temperature tackifier, which can raise the viscosity of the aluminum melt at high temperature, so that the gas generated by decomposing the calcium carbonate powder is remained in the melt, the bubbles do not move randomly, and the uniformity of the bubbles is raised while the consumption of the foaming agent is reduced. Specifically, the high-temperature tackifier may be alumina powder, mullite powder, ceramic powder (such as daily ceramic powder, building ceramic powder, bathroom ceramic powder, foaming ceramic powder, etc.), but is not limited thereto. Preferably, the high temperature tackifier is alumina powder.
Specifically, the particle size of the high-temperature tackifier is 100-325 meshes, preferably 200-300 meshes, the high-temperature tackifier with the particle size range can be uniformly mixed with the base material and the foaming agent, and the proper viscosity is given to the aluminum melt at high temperature, so that the foaming uniformity is improved.
Meanwhile, 0.5-5 parts of fluxing agent is added in the formula, and as a layer of oxide film (alumina) exists on the surfaces of the aluminum powder and the aluminum scraps, the melting point of the alumina is 2050 ℃, and the fluxing agent added in the invention reacts with the alumina at 400-600 ℃ to damage the oxide film on the surfaces of the aluminum powder or the aluminum scraps, thereby greatly reducing the melting temperature of the aluminum powder or the aluminum scraps and greatly reducing the energy consumption. In particular, the fluxing agent may be potassium fluoroaluminate and/or cryolite, but is not limited thereto. The particle size of the fluxing agent is 250-1500 meshes.
Correspondingly, the invention also discloses a preparation method for preparing the foamed aluminum plate with uniform closed holes, which comprises the following steps:
(1) Providing raw materials, and uniformly mixing the raw materials to obtain a mixture.
Specifically, a ball mill, a screw mixing device, a paddle mixer, or the like may be used for mixing, but is not limited thereto. Preferably, the screw mixing device is used for mixing materials, so that the uniformity of the mixing materials can be improved, the feeding and mixing materials are realized, and the production efficiency is improved.
(2) Distributing the mixture into a fire-resistant kiln car;
The refractory kiln car can be of an integrated structure, such as an integrated sagger fired by silicon carbide or mullite, or of an assembled structure. Preferably, the fire-resistant kiln car is of an assembled structure, and the fire-resistant kiln car adopting the assembled structure can produce large-specification foamed aluminum plates, and can be cut according to requirements at the later stage, so that the production flexibility is improved. Specifically, in one embodiment of the invention, the refractory kiln car comprises a first square beam, a second square beam, a base plate and a coaming which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the base plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. The refractory kiln car with the structure runs stably and does not vibrate, so that the foamed aluminum plate can be sintered in a roller kiln, and the production efficiency is improved.
Furthermore, before distributing, aluminum silicate high-temperature paper is stuck in the accommodating cavity of the refractory kiln car, so that high-temperature aluminum melt is prevented from flowing out of the gap of the assembled kiln car.
Specifically, the material distribution equipment can be material distribution equipment commonly used in the field of building ceramics (such as ceramic bricks, foamed ceramics and the like).
(3) And (3) sintering the mixture in the refractory kiln car at 700-750 ℃ and cooling to obtain a finished product of the foamed aluminum plate with uniform closed pores.
Wherein, an inert gas atmosphere is maintained in the sintering process, and concretely, the inert gas can be nitrogen or argon, but is not limited to the inert gas; preferably, the inert gas is argon, which does not consume oxygen in the mixture, facilitating control of foaming. The firing process may be performed in a tunnel kiln, a roller kiln (e.g., a roller kiln for sintering the positive electrode of a lithium battery), or an electric furnace, but is not limited thereto. Preferably, the firing process is carried out in a roller kiln to improve the production efficiency.
Further, in one embodiment of the present invention, firing is performed according to the following temperature profile:
the temperature is raised from room temperature to 450 ℃ for 20-30 min;
the temperature is raised from 450 ℃ to 600 ℃ for 30 to 45 minutes;
heating from 600 ℃ to firing temperature for 15-20 min;
the temperature is reduced for 10 to 12 minutes from the firing temperature to 450 ℃;
The temperature is reduced from 450 ℃ to room temperature for 60-80 min;
Wherein the firing temperature is 710-730 ℃. According to the invention, the quenching section is arranged in the section from the sintering temperature to 450 ℃, so that the gas generated by the foaming agent is fixed in the melt, and the uniformity of the air holes is improved. Meanwhile, the use amount of the high-temperature tackifier is reduced to a certain extent.
The foamed aluminum plate prepared by the preparation method has high pore diameter uniformity, high strength and large specification (the maximum specification is 2400mm and 3000mm and 200 mm), and can be processed according to requirements.
Further, the preparation method of the present invention further includes the step of performing the subsequent processing, such as edging, cutting, engraving, etc., on the fired foamed aluminum plate, but is not limited thereto.
The invention is further illustrated by the following examples:
example 1
This example provides a foamed aluminum sheet with uniform closed cells, formulated as follows:
95 parts of industrial aluminum powder, 1 part of calcium carbonate powder, 2.5 parts of alumina powder and 1.5 parts of potassium fluoroaluminate (K 3AlF6);
wherein, the grain diameter of the industrial aluminum powder is 200-300 meshes, the grain diameter of the calcium carbonate powder is 500-600 meshes, the grain diameter of the alumina powder is 200-325 meshes, and the grain diameter of the potassium fluoaluminate (K 3AlF6) is 1000-1200 meshes.
The preparation method comprises the following steps:
(1) Uniformly mixing various raw materials;
(2) Distributing the mixture into a fire-resistant kiln car;
The fire-resistant kiln car comprises a first square beam, a second square beam, a base plate and a coaming which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the base plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered in the accommodating cavity of the fire-resistant kiln car.
(3) The mixture in the refractory kiln car is sintered at 700 ℃, and after cooling, a finished product of the foamed aluminum plate with uniform closed pores is obtained;
Wherein, the sintering is carried out in a roller kiln, and the nitrogen atmosphere is maintained in the sintering process. The firing temperature profile is:
the temperature rise time is 40min (uniform temperature rise) from room temperature to 700 ℃;
The temperature reduction time from the firing temperature to the room temperature is 120min (uniform temperature reduction).
Example 2
90 Parts of industrial aluminum powder, 0.5 part of calcium carbonate powder, 4.5 parts of alumina powder and 5 parts of potassium fluoroaluminate (K3 AlF 6);
Wherein, the grain diameter of the industrial aluminum powder is 200-300 meshes, the grain diameter of the calcium carbonate powder is 500-600 meshes, the grain diameter of the alumina powder is 100-180 meshes, and the grain diameter of the potassium fluoaluminate (K 3 AlF 6) is 300-600 meshes.
The preparation method is the same as in example 1.
Example 3
This example provides a foamed aluminum sheet with uniform closed cells, formulated as follows:
95 parts of industrial aluminum powder, 0.6 part of calcium carbonate powder, 0.4 part of mullite powder and 4 parts of potassium fluoroaluminate (K3 AlF 6);
Wherein, the grain size of the industrial aluminum powder is 200-300 meshes, the grain size of the mullite powder is 200-325 meshes, the grain size of the calcium carbonate powder is 500-600 meshes, and the grain size of the potassium fluoaluminate (K3 AlF 6) is 500-1000 meshes.
The preparation method is the same as in example 1, but an argon atmosphere is maintained during the firing process.
Example 4
This example provides a foamed aluminum sheet with uniform closed cells, formulated as follows:
97 parts of industrial aluminum powder, 0.4 part of calcium carbonate powder, 0.4 part of alumina powder and 2.2 parts of cryolite (Na 3AlF 6);
Wherein, the grain diameter of the industrial aluminum powder is 200-250 meshes, the grain diameter of the alumina powder is 200-250 meshes, the grain diameter of the calcium carbonate powder is 600-700 meshes, and the grain diameter of cryolite (Na 3AlF 6) is 500-1000 meshes.
The preparation method is the same as in example 3.
Example 5
This example provides a foamed aluminum sheet with uniform closed cells, formulated as follows:
92 parts of aluminum scraps, 0.4 part of calcium carbonate powder, 4.6 parts of alumina powder and 3 parts of cryolite (Na 3AlF 6);
Wherein, the grain size of the aluminum scraps is 10 to 40 meshes, the grain size of the alumina powder is 100 to 200 meshes, the grain size of the calcium carbonate powder is 600 to 700 meshes, and the grain size of cryolite (Na 3AlF 6) is 500 to 1000 meshes.
The preparation method comprises the following steps:
(1) Uniformly mixing various raw materials;
(2) Distributing the mixture into a fire-resistant kiln car;
The fire-resistant kiln car comprises a first square beam, a second square beam, a base plate and a coaming which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the base plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered in the accommodating cavity of the fire-resistant kiln car.
(3) The mixture in the fire-resistant kiln car is burned at 720 ℃, and a finished product of the foamed aluminum plate with uniform closed pores is obtained after cooling;
wherein, sintering is carried out in a roller kiln, and argon atmosphere is maintained in the sintering process. The firing temperature profile is:
the temperature rise time is 22min (constant temperature rise) from room temperature to 450 ℃;
heating from 450 ℃ to 600 ℃ for 40min (constant temperature rise);
Heating from 600 ℃ to 720 ℃ for 16min (constant temperature rise);
the cooling time is 12min (constant cooling) from 720 ℃ to 450 ℃;
the cooling time is 60min (constant cooling) from 450 ℃ to room temperature.
Example 6
This example provides a foamed aluminum sheet with uniform closed cells, formulated as follows:
98 parts of industrial aluminum powder, 0.3 part of calcium carbonate powder, 0.2 part of alumina powder and 1.5 parts of potassium fluoroaluminate (K3 AlF 6);
Wherein, the grain diameter of the industrial aluminum powder is 40 to 100 meshes, the grain diameter of the alumina powder is 250 to 325 meshes, the grain diameter of the calcium carbonate powder is 600 to 700 meshes, and the grain diameter of the potassium fluoaluminate (K3 AlF 6) is 500 to 1000 meshes.
The preparation method comprises the following steps:
(1) Uniformly mixing various raw materials;
(2) Distributing the mixture into a fire-resistant kiln car;
The fire-resistant kiln car comprises a first square beam, a second square beam, a base plate and a coaming which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the base plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered in the accommodating cavity of the fire-resistant kiln car.
(3) The mixture in the refractory kiln car is sintered at 750 ℃, and after cooling, a finished product of the foamed aluminum plate with uniform closed pores is obtained;
wherein, sintering is carried out in a roller kiln, and argon atmosphere is maintained in the sintering process. The firing temperature profile is:
the temperature rise time is 25min (uniform temperature rise) from room temperature to 450 ℃;
the temperature rise time is 35min (uniform temperature rise) from 450 ℃ to 600 ℃;
heating from 600 ℃ to 750 ℃ for 18min (constant temperature rise);
the temperature is reduced from 750 ℃ to 450 ℃ for 11min (uniform temperature reduction);
The cooling time is 65min (constant cooling) from 450 ℃ to room temperature.
Comparative example 1
This comparative example provides an aluminum sheet having the same formulation and preparation method as in example 1. The difference is that the grain diameter of the calcium carbonate powder is 100-200 meshes.
Comparative example 2
This comparative example provides a foamed aluminum sheet having the same formulation and preparation method as in example 1. The difference is that the grain diameter of the calcium carbonate powder is 1000-1200 meshes.
Comparative example 3
This comparative example provides an aluminum sheet having the same formulation as example 1. The preparation method comprises the following steps:
(1) Uniformly mixing various raw materials;
(2) Distributing the mixture into a fire-resistant kiln car;
The fire-resistant kiln car comprises a first square beam, a second square beam, a base plate and a coaming which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the base plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered in the accommodating cavity of the fire-resistant kiln car.
(3) The mixture in the refractory kiln car is sintered at 700 ℃, and after cooling, a finished product of the foamed aluminum plate with uniform closed pores is obtained;
Wherein, the sintering is carried out in a roller kiln, and the nitrogen atmosphere is maintained in the sintering process. The firing temperature profile is:
The temperature rise time is 30min (uniform temperature rise) from room temperature to 700 ℃;
The temperature reduction time is 93min (uniform temperature reduction) from the sintering temperature to the room temperature.
Comparative example 4
This comparative example provides an aluminum sheet having the same formulation as example 1. The preparation method comprises the following steps:
(1) Uniformly mixing various raw materials;
(2) Distributing the mixture into a fire-resistant kiln car;
The fire-resistant kiln car comprises a first square beam, a second square beam, a base plate and a coaming which are sequentially arranged from bottom to top, wherein the first square beam is vertical to the second square beam, and the base plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide. Before material distribution, aluminum silicate high-temperature paper is adhered in the accommodating cavity of the fire-resistant kiln car.
(3) The mixture in the refractory kiln car is sintered at 1000 ℃, and after cooling, a finished product of the foamed aluminum plate with uniform closed pores is obtained;
Wherein, the sintering is carried out in a roller kiln, and the nitrogen atmosphere is maintained in the sintering process. The firing temperature profile is:
the temperature rise time is 44.5min (uniform temperature rise) from room temperature to 1000 ℃;
The temperature reduction time from the firing temperature to the room temperature is 134min (uniform temperature reduction).
Specifically, 4 pieces of each of the plates having a specification of 2.4mX3mX0.15 m were prepared according to the formulations and preparation methods of examples 1 to 6 and comparative examples 1 to 4, and then tested. Wherein, each takes 3 plates to test the volume weight, the heat conductivity coefficient, the compressive strength and the porosity.
The test results are shown in the following table:
as can be seen from the table, the compressive strength of the foamed aluminum plate prepared by the invention is more than or equal to 335N/cm 2, the porosity is more than or equal to 94.3%, and the volume weight is less than or equal to 0.36g/cm 3. It is also evident from comparison of comparative examples 1 to 4 with example 1 that the technical effects of the present invention are hardly achieved by changing the particle size of the calcium carbide powder of the present invention or by changing the firing temperature.
In order to determine the foaming uniformity of the sheet material in the present invention, 2 sheet materials of the sheet materials obtained in the examples and comparative examples were respectively cut at the peripheral edges and the center thereof, 10 sheet materials of 0.2m×0.2m×0.15m in specification were obtained in each example/comparative example, and the compressive strength of the sheet materials was respectively tested, and the specific results are shown in the following table, in which the unit of compressive strength is N/cm 2:
as can be seen from the table, the foamed aluminum plate prepared by the invention has small compressive strength variance at each position, which indicates that the uniformity is high. While the uniformity is relatively poor in the comparative example.
While the foregoing is directed to the preferred embodiments of the present invention, it will be appreciated by those skilled in the art that changes and modifications may be made without departing from the principles of the invention, such changes and modifications are also intended to be within the scope of the invention.
Claims (7)
1. A method of making a foamed aluminum panel having uniform closed cells comprising:
(1) Providing raw materials, and uniformly mixing the raw materials to obtain a mixture;
(2) Distributing the mixture into a fire-resistant kiln car;
(3) Firing the mixture in the refractory kiln car in inert gas atmosphere, and cooling to obtain a finished product of the foamed aluminum plate with uniform closed pores;
Wherein, firing is performed according to the following temperature curve:
The temperature is raised from room temperature to 450 ℃ for 20-30 min;
the temperature is increased from 450 ℃ to 650 ℃ for 30-45 min;
heating from 650 ℃ to sintering temperature for 15-20 min;
the temperature is reduced for 10-12 min from the firing temperature to 450 ℃;
the temperature is reduced from 450 ℃ to room temperature for 60-80 min;
the sintering temperature is 710-730 ℃;
the mixture comprises the following raw materials in parts by weight:
93-96 parts of base material, 0.1-0.5 part of foaming agent, 1.5-3 parts of high-temperature tackifier and 1.5-3 parts of fluxing agent;
Wherein, the base material is aluminum powder and/or aluminum alloy powder, and the grain diameter of the base material is 10-100 meshes; the foaming agent is calcium carbonate powder, and the particle size of the foaming agent is 400-800 meshes; the fluxing agent is potassium fluoaluminate and/or cryolite, and the particle size of the fluxing agent is 250-1500 meshes; the high-temperature tackifier is one or a mixture of more of alumina powder, mullite powder and ceramic powder, and the particle size of the high-temperature tackifier is 100-325 meshes.
2. The method for producing a foamed aluminum sheet having uniform closed cells according to claim 1, wherein the particle size of the foaming agent is 500 to 600 mesh.
3. The method for preparing the foamed aluminum plate with uniform closed cells according to claim 1, wherein the high-temperature tackifier is alumina powder with a particle size of 200-300 meshes.
4. The method for preparing the foamed aluminum plate with uniform closed cells according to claim 1, wherein aluminum powder is selected as the base material, and the particle size of the aluminum powder is 40-80 meshes.
5. The method for producing a foamed aluminum sheet having uniform closed cells according to claim 1, wherein in the step (1), the raw materials are mixed by a screw mixer;
In the step (3), the roller kiln is adopted for sintering.
6. The method for preparing a foamed aluminum plate with uniform closed pores according to claim 1, wherein the refractory kiln car comprises a first square beam, a second square beam, a backing plate and a coaming which are sequentially arranged from bottom to top, the first square beam is perpendicular to the second square beam, and the backing plate and the coaming are enclosed to form a containing cavity for containing the mixture; the first square beam and the second square beam are made of silicon carbide, and the backing plate and the coaming are made of mullite or silicon carbide;
in the step (2), aluminum silicate high-temperature paper is stuck in the accommodating cavity of the fire-resistant kiln car, and then the material is distributed.
7. An aluminum foam sheet having uniform closed cells, characterized by being produced by the method for producing an aluminum foam sheet having uniform closed cells according to any one of claims 1 to 6.
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