JP5501170B2 - Molded and fired refractory material - Google Patents
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- JP5501170B2 JP5501170B2 JP2010202782A JP2010202782A JP5501170B2 JP 5501170 B2 JP5501170 B2 JP 5501170B2 JP 2010202782 A JP2010202782 A JP 2010202782A JP 2010202782 A JP2010202782 A JP 2010202782A JP 5501170 B2 JP5501170 B2 JP 5501170B2
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本発明は、黒鉛を主成分とする耐火材により形成されるとともに、ガラス質層が表面に被膜された耐火材の成形焼成物に関する。 The present invention relates to a molded fired product of a refractory material which is formed of a refractory material mainly composed of graphite and has a glassy layer coated on the surface thereof.
例えば鋳物工場などでは、従来から、アルミニウム、銅、亜鉛などの金属材料を溶融してインゴットなどの地金を鋳造したり、溶融した金属材料を所要の温度で保持したりするための容器として、各種の耐火材を成形して焼成した坩堝が使用されており、坩堝の代表例としては黒鉛質坩堝が広く知られている。この黒鉛質坩堝は、黒鉛、炭化珪素を主成分とするもので、とりわけ黒鉛が多く配合されることによって、耐熱衝撃性、高熱伝導性、および溶融金属に濡れない非反応性などが優れている。 For example, in a foundry , conventionally, as a container for melting a metal material such as aluminum, copper or zinc to cast a metal such as an ingot or holding a molten metal material at a required temperature, A crucible obtained by molding and firing various refractory materials is used, and a graphite crucible is widely known as a typical example of a crucible. This graphite crucible is composed mainly of graphite and silicon carbide, and is particularly excellent in thermal shock resistance, high thermal conductivity, and non-reactivity that does not get wet with molten metal when it contains a large amount of graphite. .
図3は、黒鉛質坩堝3がセットされた坩堝炉の側断面図である。耐火物からなる炉本体1の燃焼室6内に、坩台2を介して黒鉛質坩堝3が配備されている。炉本体1の側壁下部には加熱バーナー4が設置されており、この加熱バーナー4により黒鉛質坩堝3の外周を加熱することにより、内部の金属材料が溶融し、溶融した金属が所要の温度に保持される(例えば、特許文献1参照)。
FIG. 3 is a side sectional view of the crucible furnace in which the graphite crucible 3 is set. In the
ここで、黒鉛質坩堝3を加熱バーナー4で加熱する際には、黒鉛質坩堝3は約600℃〜1300℃の高温に加熱される。このような高温雰囲気下で、黒鉛を多く含む黒鉛質坩堝3を長期間使用すると、坩堝中の黒鉛の酸化(C+O2→CO2)が進行することによる材質の劣化が生じ、これにより、坩堝の耐熱衝撃性の低下を招いて、熱衝撃により坩堝が破損し易くなる結果、坩堝の耐用時間(寿命)が短くなるという問題がある。 Here, when the graphite crucible 3 is heated by the heating burner 4, the graphite crucible 3 is heated to a high temperature of about 600 ° C to 1300 ° C. When the graphite crucible 3 containing a large amount of graphite is used for a long period of time in such a high temperature atmosphere, the material deteriorates due to the progress of oxidation (C + O 2 → CO 2 ) of the graphite in the crucible. As a result, the crucible is easily damaged by thermal shock, resulting in a problem that the service life (life) of the crucible is shortened.
そこで、黒鉛質坩堝3の酸化による劣化を防止するため、黒鉛質坩堝3の表面に、泥しょう状の釉薬(ガラス質の材料を粉砕して水に溶かした液状のもの)を塗布し、これを高温で焼成することにより、黒鉛質坩堝3の表面にガラス質層によるコーティングを行うことが提案されている。 Therefore, in order to prevent deterioration of the graphite crucible 3 due to oxidation, a slurry-like glaze (a liquid material obtained by crushing a glassy material and dissolving in water) is applied to the surface of the graphite crucible 3. It has been proposed to coat the surface of the graphite crucible 3 with a vitreous layer by firing at a high temperature.
しかしながら、黒鉛質坩堝の表面に釉薬を単に塗布しただけでは、黒鉛質坩堝の主成分である黒鉛は釉薬との濡れ性が悪いために、黒鉛質坩堝の表面と形成されるガラス質層との密着性が劣る。また、一般的に、泥しょう状態の釉薬の熱膨張率は黒鉛質坩堝の熱膨張率よりも大きく、この熱膨張率の差により、焼成の過程で釉薬が収縮するときに発生する応力によって、亀裂やピンホール、クラックなどの欠陥が焼成後のガラス質層に生じる。このようにガラス質層に欠陥が生じると、黒鉛質坩堝が外気に露出し、その部分が酸化劣化しやすいなどの問題がある。 However, if the glaze is simply applied to the surface of the graphite crucible, the graphite, which is the main component of the graphite crucible, has poor wettability with the glaze, so the surface of the graphite crucible and the vitreous layer to be formed Adhesion is poor. Further, generally, the thermal expansion coefficient of the glaze in the mud state is larger than the thermal expansion coefficient of the graphite crucible, and due to the difference in the thermal expansion coefficient, due to the stress generated when the glaze contracts during the firing process, Defects such as cracks, pinholes and cracks occur in the vitreous layer after firing. When defects occur in the vitreous layer in this manner, there is a problem that the graphite crucible is exposed to the outside air and the portion is easily oxidized and deteriorated.
本発明は、上記した問題に着目してなされたもので、亀裂などの欠陥発生が抑制されたガラス質層を表面に成膜可能な耐火材の成形焼成物を提供することを目的とする。 The present invention has been made paying attention to the above-described problems, and an object of the present invention is to provide a molded fired product of a refractory material capable of forming a glassy layer on the surface of which generation of defects such as cracks is suppressed.
本発明の前記目的は、黒鉛を主成分とする耐火材により形成されるとともに、釉薬からなるガラス質層が表面に被膜された耐火材の成形焼成物であって、前記釉薬は、融点が少なくとも600℃以上であり、該釉薬の融点よりも高い融点を有する材料からなりかつ粒径が0.5mm〜3mmである骨材粒子を、釉薬100容量部あたり5〜30容量部の比率で含み、前記ガラス質層には、前記骨材粒子が分散されている耐火材の成形焼成物によって達成される。 The object of the present invention is a molded fired product of a refractory material formed of a refractory material mainly composed of graphite and having a glassy layer made of glaze coated on the surface, wherein the glaze has a melting point of at least 600 ° C. or more, the aggregate particles become and the particle size of a material having a melting point higher than the melting point of the glaze is 0.5 mm to 3 mm, seen containing a ratio of glaze 5-30 parts by volume per 100 parts by volume The glassy layer is achieved by a molded fired product of a refractory material in which the aggregate particles are dispersed .
前記釉薬は、前記耐火材と同等の熱膨張特性を有していることを特徴としている。 The glaze has a thermal expansion characteristic equivalent to that of the refractory material.
本発明の好ましい実施態様においては、前記骨材粒子は、SiO2、Al2O3、SiC、Si、またはこれらの複合物からなることを特徴としている。 In a preferred embodiment of the present invention, the aggregate particles is characterized in that it consists of SiO 2, Al 2 O 3, SiC, Si , or a composite thereof.
本発明のさらに好ましい実施態様においては、前記ガラス質層は、厚みが0.1mm〜1mmであることを特徴としている。 In a further preferred embodiment of the present invention, the glassy layer has a thickness of 0.1 mm to 1 mm.
本発明のさらに好ましい実施態様においては、前記耐火材の成形焼成物が黒鉛質坩堝であることを特徴としている。 In a further preferred embodiment of the present invention, the fired fired molded material is a graphite crucible.
本発明によると、耐火材の成形焼成物の表面に、亀裂などの欠陥発生が抑制されたガラス質層を成膜することができる。 According to the present invention, a vitreous layer in which defects such as cracks are suppressed can be formed on the surface of a fired fired molded article.
以下、本発明の実施の形態について説明する。本実施形態の耐火材の成形焼成物は、黒鉛を主成分とする耐火材により形成されるものであり、例えば、鱗状黒鉛および炭化珪素を主成分とし、これに金属珪素粉末、酸化防止材原料および有機質結合材剤を混練して成形したものを焼成することにより得られる黒鉛質坩堝を好適に挙げることができる。 Embodiments of the present invention will be described below. The fired material formed and fired product of the present embodiment is formed of a refractory material mainly composed of graphite, for example, mainly composed of scaly graphite and silicon carbide. In addition, a graphite crucible obtained by firing a material obtained by kneading and molding an organic binder can be preferably used.
黒鉛質坩堝は、有底で上部に開口を有する円筒容器状のものであり、非鉄金属溶解用の坩堝炉の主要部品として多用されている。この黒鉛質坩堝3は、坩堝炉1の加熱バーナー4から噴射する火炎でその外周面を高温(約600℃〜1300℃)で加熱することで、内部に収容した非鉄金属(アルミニウム、銅、および、これらの合金など)などを溶解する(図3参照)。黒鉛質坩堝は、非鉄金属に対して耐食性が高く、不純物の混入が少ないため、高品質の非金属を得ることができるうえ、熱伝導率が高く、かつ、優れた耐酸化性、耐熱性、耐熱衝撃性、および化学的・物理的耐食性を有し、低温から高温までの広い温度範囲で優れた耐久性を発揮する。 A graphite crucible is a cylindrical container having a bottom and an opening at the top, and is frequently used as a main part of a crucible furnace for melting non-ferrous metals. This graphite crucible 3 is a flame injected from the heating burner 4 of the crucible furnace 1 and its outer peripheral surface is heated at a high temperature (about 600 ° C. to 1300 ° C.), so that non-ferrous metals (aluminum, copper, and , These alloys, etc.) are dissolved (see FIG. 3). Graphite crucible has high corrosion resistance with respect to non-ferrous metals and is less contaminated with impurities, so it is possible to obtain high-quality non-metals, high thermal conductivity, and excellent oxidation resistance, heat resistance, It has thermal shock resistance and chemical / physical corrosion resistance, and exhibits excellent durability over a wide temperature range from low to high temperatures.
上記構成の黒鉛質坩堝は、酸化雰囲気では、黒鉛の酸化による酸化劣化が激しくて耐用時間が短いという問題を有している。そのため、黒鉛質坩堝の内表面および外表面には、黒鉛質坩堝の酸化を防止するため、その全体を被覆するように、釉薬からなるガラス質層によるコーティングが施されている。 The graphite crucible having the above-described configuration has a problem that, in an oxidizing atmosphere, oxidative deterioration due to oxidation of graphite is severe and the service life is short. Therefore, in order to prevent oxidation of the graphite crucible, the inner surface and the outer surface of the graphite crucible are coated with a glassy layer made of a glaze so as to cover the entire surface.
この酸化防止用のガラス質層は、泥しょう状の釉薬を黒鉛質坩堝の内表面および外表面に塗布し、所定の温度(約900℃以上)で焼成することで形成される。黒鉛質坩堝の内表面および外表面に塗布される釉薬としては、従来公知の釉薬を広く用いることができるが、黒鉛質坩堝との間で熱膨張率の差が小さいものを用いるのが好ましい。黒鉛質坩堝よりも熱膨張率の大きな釉薬を用いると、焼成時に釉薬が収縮するときに発生する応力によって、焼成後のガラス質層に亀裂やピンホール、クラックが生じたり、または、ガラス質層の剥離が生じたりするからである。そのため、黒鉛質坩堝の熱膨張率にできる限り近い熱膨張率を有する釉薬を用いることにより、ガラス質層に対する亀裂や剥離などの欠陥発生を抑制可能であり、黒鉛質坩堝とガラス質層との密着性を向上できる。 This glass layer for preventing oxidation is formed by applying a slurry-like glaze to the inner and outer surfaces of a graphite crucible and firing it at a predetermined temperature (about 900 ° C. or higher). As the glaze applied to the inner surface and the outer surface of the graphite crucible, conventionally known glazes can be widely used. However, it is preferable to use a glaze having a small difference in thermal expansion coefficient with the graphite crucible. If a glaze with a thermal expansion coefficient larger than that of the graphite crucible is used, cracks, pinholes, cracks may occur in the vitreous layer after firing due to the stress generated when the glaze contracts during firing, or the vitreous layer This is because peeling occurs. Therefore, by using a glaze having a thermal expansion coefficient as close as possible to the thermal expansion coefficient of the graphite crucible, it is possible to suppress the occurrence of defects such as cracks and peeling to the vitreous layer. Adhesion can be improved.
また、釉薬としては、黒鉛質坩堝が、約600℃〜1300℃の高温下で使用されることを考慮すれば、耐熱衝撃性に優れ、かつ、この温度域で完全に液化しない程度の融点(少なくとも600℃以上)を有する高温タイプのものであることが好ましい。上記した構成の釉薬としては、SiO2(シリカ)、B2O3(硼酸ガラス)、Na2O(酸化ナトリウム)など、複数種類の材料を組み合わせて調製したものが好ましく使用される。また、焼成後のガラス質層の厚みは、一般的に、0.01mm〜3.0mmの範囲とすることが可能であるが、通常は0.1〜1.0mmで十分である。 Further, as a glaze, considering that a graphite crucible is used at a high temperature of about 600 ° C. to 1300 ° C., a melting point (excellent in thermal shock resistance and not completely liquefied in this temperature range ( It is preferably a high temperature type having at least 600 ° C.). As the glaze having the above-described constitution, those prepared by combining a plurality of kinds of materials such as SiO 2 (silica), B 2 O 3 (borate glass), Na 2 O (sodium oxide) are preferably used. Moreover, although the thickness of the vitreous layer after baking can generally be made into the range of 0.01 mm-3.0 mm, 0.1-1.0 mm is usually enough.
黒鉛質坩堝の内表面および外表面に成膜されるガラス質層には、一定の硬度を有する多数の骨材粒子が分散されている。多数の骨材粒子を泥しょう状の釉薬の中に添加し、釉薬に骨材粒子が混在したものを黒鉛質坩堝の表面に塗布して、所定の温度で焼き付けることで、多数の骨材粒子がガラス質層に分散される。釉薬は、一般的に、黒鉛質坩堝の熱膨張率よりも大きな熱膨張率を有するものであるが、骨材粒子の配合によって、焼成後のガラス質層に亀裂などの欠陥が発生することが抑制されている。 Numerous aggregate particles having a certain hardness are dispersed in the vitreous layer formed on the inner surface and the outer surface of the graphite crucible. A large number of aggregate particles are added to a mud-shaped glaze, and a mixture of the glaze and the aggregate particles is applied to the surface of the graphite crucible and baked at a predetermined temperature. Is dispersed in the vitreous layer. Glaze generally has a thermal expansion coefficient larger than that of a graphite crucible, but the composition of aggregate particles may cause defects such as cracks in the vitreous layer after firing. It is suppressed.
釉薬への骨材粒子の配合で焼成後のガラス質層の欠陥発生が抑制されることは、本発明者が鋭意に調査・研究したことにより、見い出されたものである。その詳細なメカニズムとしては、焼成時に釉薬が収縮する際に発生する応力が骨材粒子に吸収され、かつ、骨材粒子を介して釉薬全体に分散されて、全体として応力が緩和された結果、焼成後のガラス質層の収縮が抑えられて、ガラス質層と黒鉛質坩堝との間の密着性が向上したものと推察できる。 It has been found by the present inventor's earnest investigation and research that the generation of defects in the vitreous layer after firing is suppressed by adding aggregate particles to the glaze. As the detailed mechanism, the stress generated when the glaze contracts during firing is absorbed into the aggregate particles, and dispersed throughout the glaze through the aggregate particles, resulting in the relaxation of the stress as a whole, It can be inferred that the shrinkage of the vitreous layer after firing was suppressed and the adhesion between the vitreous layer and the graphite crucible was improved.
そのため、この骨材粒子は、まず、釉薬の焼成時に溶融しないこと、すなわち、釉薬が溶融する焼成温度で溶融しない高融点の材料(釉薬の融点よりも高い融点を有する材料)により構成されていることが必要である。また、釉薬の焼成時に変質したり、釉薬と反応して一体化したりすることのない材料により構成されていることが必要である。上記した構成の骨材粒子としては、SiO2(珪石)、Al2O3(アルミナ)、SiC(炭化珪素)、Si(珪素)、またはこれらの複合物を好ましく選択することができる。しかし、これに限らず、釉薬とともに焼成しても、焼成時に溶融せず、かつ、変質したり、釉薬と反応したりすることなく本来の硬度を維持するものであれば、種々のものを適用可能である。 Therefore, this aggregate particle is first composed of a material having a high melting point (a material having a melting point higher than that of the glaze) that does not melt at the firing temperature at which the glaze melts, that is, a material having a melting point higher than that of the glaze. It is necessary. Moreover, it is necessary to be comprised with the material which does not change in quality at the time of baking of a glaze, or react with a glaze and integrate. As the aggregate particles having the above-described configuration, SiO 2 (silica stone), Al 2 O 3 (alumina), SiC (silicon carbide), Si (silicon), or a composite thereof can be preferably selected. However, the present invention is not limited to this, and various materials can be used as long as they do not melt during firing and maintain their original hardness without being altered or reacting with the glaze. Is possible.
釉薬に対する骨材粒子の添加量は、少なくては焼成後のガラス質層における骨材粒子の分散状態が不十分なため、骨材粒子の性質が発揮されずに、ガラス質層に亀裂が発生し易くなる。これに対し、骨材粒子の添加量が多すぎては、ガラス質層が黒鉛質坩堝の表面にきれいに成膜されず、黒鉛質坩堝に対する密着性が低下するおそれがある。よって、骨材粒子の添加量は、釉薬100部に対し容積比で5部〜30部程度が好ましく、10部〜20部がより好ましい。 If the amount of aggregate particles added to the glaze is at least small, the aggregate state of the aggregate particles in the vitreous layer after firing is insufficient, so the properties of the aggregate particles are not exhibited and cracks occur in the vitreous layer It becomes easy to do. On the other hand, if the amount of aggregate particles added is too large, the vitreous layer is not neatly formed on the surface of the graphite crucible, and the adhesion to the graphite crucible may be reduced. Therefore, the addition amount of aggregate particles is preferably about 5 to 30 parts by volume with respect to 100 parts of glaze, and more preferably 10 to 20 parts.
骨材粒子の形状は特に限定されないが、その粒径が大きすぎると、焼成後のガラス質層の厚さとの関係で骨材粒子が焼成後の層から大きくはみ出してしまい、釉薬の焼成時にガラス質層から剥離したり、ガラス質層の表面がゴツゴツしてその外観が悪くなる。また、ガラス質層を黒鉛質坩堝の表面にきれいに成膜しにくいという問題もある。これに対し、骨材粒子の粒径が小さすぎると、骨材粒子の性質が発揮されにくいという問題がある。よって、骨材粒子の粒径は、0.1mm〜3mm程度が好ましく、0.5mm〜1mmがより好ましい。 The shape of the aggregate particles is not particularly limited, but if the particle size is too large, the aggregate particles will largely protrude from the fired layer due to the thickness of the vitreous layer after firing, and the glass will be used during glaze firing. It peels off from the quality layer, or the surface of the glassy layer becomes lumpy and the appearance is deteriorated. Another problem is that it is difficult to form a glassy layer on the surface of the graphite crucible. On the other hand, when the particle size of the aggregate particles is too small, there is a problem that the properties of the aggregate particles are hardly exhibited. Therefore, the particle size of the aggregate particles is preferably about 0.1 mm to 3 mm, and more preferably 0.5 mm to 1 mm.
以下、本発明の耐火材の成形焼成物の実施例を示す。 Hereinafter, examples of the molded fired product of the refractory material of the present invention will be shown.
釉薬の全重量に対し、主成分としてSiO2を40%〜60%、B2O3を5%〜30%、Na2Oを1%〜5%含有する釉薬を作成し、作成した釉薬に粒径が0.1mm〜3mmのSiO2(珪石)を入れて混合し、骨材粒子含有の釉薬を作成した。この骨材粒子含有の釉薬を、黒鉛および炭化珪素を主成分とする耐火材の成形焼成物の表面にスプレーなどで塗布し、約900℃以上の温度で60分焼成することにより、表面に凹凸のある厚み0.2mm〜0.6mm程度のガラス質層を、耐火材の成形焼成物の表面に形成した。図1に、本実施例に係る耐火材の成形焼成物10の表面状態を示す。なお、比較例として、図2に、骨材粒子を含有しない上記構成の釉薬を、実施例と同じ構成の耐火材の成形焼成物の表面にスプレーなどで塗布し、同様に焼成して表面にガラス質層を形成した耐火材の成形焼成物20の表面状態を示す。 A glaze containing 40% to 60% of SiO 2 as a main component, 5% to 30% of B 2 O 3 and 1% to 5% of Na 2 O as a main component with respect to the total weight of the glaze. SiO 2 (silica stone) having a particle size of 0.1 mm to 3 mm was added and mixed to prepare glaze containing aggregate particles. This glaze containing aggregate particles is applied to the surface of a molded fired product of a refractory material mainly composed of graphite and silicon carbide by spraying, and fired at a temperature of about 900 ° C. or more for 60 minutes, thereby forming irregularities on the surface. A vitreous layer having a thickness of about 0.2 mm to 0.6 mm was formed on the surface of a fired fired molded article. In FIG. 1, the surface state of the shaping | molding baking products 10 of the refractory material which concerns on a present Example is shown. As a comparative example, in FIG. 2, the glaze having the above-described configuration that does not contain aggregate particles is applied to the surface of the molded fired product of the refractory material having the same configuration as the example by spraying, and similarly fired to the surface. The surface state of the molded fired product 20 of the refractory material on which the glassy layer is formed is shown.
図1および図2に示されているように、比較例に係る耐火材の成形焼成物20では、基材となる耐火材の成形焼成物20よりも釉薬の方が大きな熱膨張率を有するため、表面のガラス質層に欠陥が発生し、その表面状態が良好でないのに対し、本実施例に係る耐火材の成形焼成物10では、基材となる耐火材の成形焼成物10よりも釉薬の方が大きな熱膨張率を有するものであるにも拘らず、表面のガラス質層には、亀裂やクラック、ピンホール、層の剥離などの欠陥がほとんど発生しておらず、表面状態が良好となっていることが確認された。これにより、本実施例の耐火材の成形焼成物10では、欠陥がほとんどなく、かつ、密着性に優れたガラス質層を形成することが可能であることが確認された。 As shown in FIG. 1 and FIG. 2, in the molded fired product 20 of the refractory material according to the comparative example, the glaze has a larger thermal expansion coefficient than the molded fired product 20 of the refractory material as the base material. On the other hand, a defect occurs in the surface vitreous layer, and the surface state is not good. On the other hand, in the molded fired product 10 of the refractory material according to the present embodiment, the glaze than the molded fired product 10 of the refractory material used as the base material. In spite of having a larger coefficient of thermal expansion, the glassy layer on the surface has almost no defects such as cracks, cracks, pinholes, and layer peeling, and the surface condition is good. It was confirmed that Thereby, it was confirmed that the molded fired product 10 of the refractory material of the present example has almost no defects and can form a vitreous layer having excellent adhesion.
上記したとおり、本発明では、釉薬に骨材粒子を配合し、この骨材粒子含有の釉薬を耐火材の成形焼成物の表面に塗布して焼成することによって、ガラス質層を形成している。形成されたガラス質層は、分散した骨材粒子によって亀裂などの欠陥の発生が抑制され、耐火材の成形焼成物の表面にきれいに成膜することが可能である。 As described above, in the present invention, the vitreous layer is formed by blending the aggregate particles with the glaze, applying the glaze containing the aggregate particles to the surface of the molded fired product of the refractory material, and firing it. . In the formed vitreous layer, the occurrence of defects such as cracks is suppressed by the dispersed aggregate particles, and it is possible to form a clean film on the surface of the fired molded material.
3 黒鉛質坩堝
10,20 耐火材の成形焼成物
3 Graphite crucible 10,20 Molded fired refractory
Claims (5)
前記釉薬は、融点が少なくとも600℃以上であり、該釉薬の融点よりも高い融点を有する材料からなりかつ粒径が0.5mm〜3mmである骨材粒子を、釉薬100容量部あたり5〜30容量部の比率で含み、
前記ガラス質層には、前記骨材粒子が分散されている耐火材の成形焼成物。 It is formed by a refractory material mainly composed of graphite, and is a molded fired product of a refractory material in which a glassy layer made of glaze is coated on the surface,
The glaze is composed of a material having a melting point of at least 600 ° C. and a melting point higher than that of the glaze and having a particle size of 0.5 mm to 3 mm. only contains a ratio of parts by volume,
A molded fired product of a refractory material in which the aggregate particles are dispersed in the glassy layer .
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