WO2022165948A1 - 一种氧化锆增韧氧化铝刀具及其制备方法 - Google Patents
一种氧化锆增韧氧化铝刀具及其制备方法 Download PDFInfo
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- WO2022165948A1 WO2022165948A1 PCT/CN2021/083073 CN2021083073W WO2022165948A1 WO 2022165948 A1 WO2022165948 A1 WO 2022165948A1 CN 2021083073 W CN2021083073 W CN 2021083073W WO 2022165948 A1 WO2022165948 A1 WO 2022165948A1
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- zirconia
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 title claims abstract description 160
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Definitions
- the invention belongs to the technical field of ceramic material molding, and in particular relates to a zirconia toughened alumina ceramic cutter and a preparation method thereof.
- High-speed cutting requires tool materials to maintain good mechanical properties, chemical stability and anti-adhesion properties at high temperatures. Advanced ceramic materials can still maintain stable mechanical properties at high temperatures, meeting the requirements of high-speed cutting.
- ZTA ceramic tools It has small flank wear during cutting, and is suitable for applications with wear resistance, corrosion resistance, high temperature stability and excellent mechanical strength, and can maintain good stability under the high temperature generated by cutting.
- ZTA complex-shaped zirconia-toughened alumina
- the chip breaker of the tool not only plays an additional role in the deformation of the chip, but also has an important influence on the shape of the chip and the breaking of the chip. Whether the chipbreaker is reliable or not has a significant impact on normal production and operator safety, as well as tool life and machining quality.
- the limitations of traditional machining preparation methods limit the popularization and application of zirconia toughened alumina (ZTA) ceramic tools.
- the present invention provides a zirconia toughened alumina ceramic tool and a preparation method thereof, which are used to solve the problem that the zirconia toughened alumina ceramic tool prepared by the prior art has low precision, high cost, long cycle, and cannot be used.
- a first aspect of the present application provides a method for preparing a zirconia toughened alumina ceramic cutting tool, comprising the steps of:
- Step 1 ball milling and mixing alumina powder, zirconia, ceramic sintering aid, photosensitive resin, and photoinitiator to obtain a first ceramic slurry;
- Step 2 photocuring the first ceramic slurry to obtain a zirconia toughened alumina ceramic body.
- Step 3 debinding the zirconia toughened alumina ceramic body, and then sintering at high temperature to obtain the zirconia toughened alumina ceramic cutting tool;
- the secondary debinding treatment specifically includes: first vacuum debinding and then air debinding in a low-temperature debinding furnace.
- the zirconia powder is 3Y-TZP powder.
- the step 1 is specifically: ball milling of alumina powder, zirconia powder, ceramic sintering aid, photosensitive resin, and photoinitiator to obtain the first ceramic slurry.
- the vacuum debinding treatment specifically includes: under vacuum conditions, heating the formed blank to 550-750°C at a heating rate of 1-15°C/min, and the holding time is 2-5h; the air
- the degumming treatment specifically includes: in an air environment, the forming body is heated to 550-750°C at a heating rate of 1-15°C/min, and the holding time is 2-5h.
- the high temperature sintering is specifically: after heating to 600-800°C at a first heating rate of 1-15°C/min, and then heating to 1500-1650°C at a second heating rate of 1-20°C/min, Heat preservation for 1.5 to 3 hours.
- the first ceramic slurry includes the following components by weight:
- the ceramic sintering aids include but are not limited to one or more of MgO, Cr2O3, CaO, La2O3, SiO2, Y2O3, TiC, TiN, TiCN, WC, and SiC.
- the photocurable resin is selected from ethoxylated pentaerythritol tetraacrylate, cyclohexane, aliphatic urethane acrylate, ethyl acetate, 1,6-ethylene glycol diacrylate, n-octanol, isopropanol, One or more of polyethylene glycol and methyl acetate.
- the photoinitiator is selected from 2-hydroxy-2-methyl-1-phenyl-1-propanone, phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide, (2 , 4,6-trimethylbenzoyl) diphenylphosphine oxide and one or more of 2-isopropylthioxanthone.
- a second aspect of the present application provides a zirconia toughened alumina ceramic cutting tool.
- the complex shape zirconia toughened alumina ceramic tools prepared by photocuring molding have high precision, low cost and short cycle, and can be prepared by conventional ceramic manufacturing processes.
- the zirconia toughened alumina ceramic body is first debonded by vacuum and then air debonded in a low-temperature debinding furnace, wherein the debinding is performed in a vacuum atmosphere to remove the hydrogen element of the photosensitive resin; the debinding furnace is reduced to After room temperature, air atmosphere debinding is performed to remove the carbon element of the photosensitive resin.
- first vacuum debinding and then air debinding one debinding can be avoided and the hydrocarbon organic matter in the photosensitive resin is removed, resulting in zirconia toughening alumina ceramic blank. Body deformation and cracking.
- Fig. 1 is the zirconia toughened alumina ceramic cutter prepared in Example 1 of the application;
- Figure 2 is a schematic diagram of the dimensions of the zirconia toughened alumina ceramic cutter prepared in Example 1 of the application, in millimeters;
- FIG. 3 is a schematic diagram of a zirconia toughened alumina ceramic cutter prepared in Example 1 of the application;
- FIG. 4 is a zirconia toughened alumina ceramic tool prepared in Example 2 of the application.
- the present application provides a zirconia toughened alumina ceramic tool and a preparation method thereof, which are used to solve the problem that the existing zirconia toughened alumina ceramic tool has low precision, high cost, long cycle, and cannot prepare chip breakers or other complex tools.
- Embodiment 1 of the present application provides a first method for preparing a zirconia toughened alumina ceramic tool, which specifically includes the steps:
- Step 1 Weigh 86 parts of alumina powder and 14 parts of zirconia powder respectively, place them in a ball mill and add anhydrous ethanol to perform mechanical ball milling, wherein the mass ratio of balls to material is 1:1.5, the ball milling time is 2h, and the rotational speed is 250rad /min, the ethanol was removed by rotary evaporation after ball milling to obtain ZTA composite ceramic powder;
- the toughening of alumina by zirconia improves the impact resistance and bending strength of the alumina tool, and reduces the risk of chipping of the alumina tool during cutting;
- Step 2 weigh 78 parts of the above-mentioned ZTA ceramic powder, 22 parts of the photocurable resin and 1 part of the photoinitiator, and place them in a ball mill for ball milling and mixing to obtain the first ceramic slurry;
- Step 3 placing the first ceramic slurry in a photo-curing molding device, and performing curing molding according to a preset model, thereby obtaining a zirconia toughened alumina ceramic tool blank.
- Specific steps include:
- the XY resolution is 20 ⁇ m
- the layer thickness is 50 ⁇ m
- the base layer is 5 layers
- the curing time is 20 s
- the ordinary layer curing time is 5 s.
- Step 4 place the zirconia toughened alumina ceramic tool blank in a low-temperature debinding furnace, raise the temperature to 600 °C at a heating rate of 1 °C/min, and perform debinding in a vacuum atmosphere to remove the hydrogen element of the photosensitive resin and reduce the temperature. After reaching room temperature, the temperature is raised to 600°C at a heating rate of 1°C/min, and debonding is carried out in an air atmosphere to remove the carbon element of the photosensitive resin to obtain a ceramic tool blank after debonding;
- Step 5 place the zirconia toughened alumina ceramic tool blank after debinding in a muffle furnace for high temperature sintering, with a heating rate of 10°C/min to 800°C, and a heating rate of 5°C/min to 1550- 1600 °C, after 2 hours, the temperature is lowered to 800 °C at 5 °C/min, and then cooled with the furnace to obtain zirconia toughened alumina ceramic tools;
- the relative density of the sintered zirconia toughened alumina ceramic tool is 98.81%, the hardness reaches 18.53GPa, and the fracture toughness reaches 5.63MPa ⁇ m1/2;
- the cutting performance test of turning gray cast iron HT200 was carried out on the ceramic tool prepared in Example 1, and it was found that the life of the side with a chip breaker was 30% longer than that of the side without a chip breaker, the surface roughness of the turning workpiece was reduced by 27%, and the chip breaking
- the groove can reduce the cutting force and cutting temperature of the tool during turning, guide and break the chips, reduce the amount of tool wear and improve the surface processing quality of the workpiece; and set a reasonable chip breaker. Width, chipbreaker depth, cutting edge height, and rib width will greatly improve chipbreaker performance.
- the ceramic tool when the width of the chip breaker of the ceramic tool is 2.4 mm, the depth is 0.3 mm, the height of the cutting edge is 0.2 mm, and the width of the rib is 3 mm, the ceramic tool has a long service life and high processing quality.
- the alumina powder is doped with zirconia, which improves the toughness of the alumina, reduces the risk of chipping of the alumina ceramic tool during cutting, and prolongs the service life of the alumina ceramic tool;
- the preparation of zirconia toughened alumina ceramic cutting tools by curing improves the preparation accuracy of complex-shaped zirconia toughened alumina ceramic cutting tools, and reduces the cost and preparation cycle; and the vacuum debinding and then air debinding can avoid the increase of zirconia.
- Embodiment 2 of the present application provides a second preparation method of a zirconia toughened alumina ceramic tool, which specifically includes the steps:
- step 1 97 parts of zirconia and 3 parts of yttrium oxide are weighed and mixed by mass parts to obtain 3Y-TZP powder.
- Step 2 in terms of parts by mass, weighed 84 parts of alumina powder and 16 parts of 3Y-TZP powder, respectively, placed in a ball mill and added dehydrated ethanol for mechanical ball milling, wherein the mass ratio of balls to material was 1:1.5, and the ball milling time was 1:1.5. It is 2h, the rotation speed is 250rad/min, and the ethanol is removed by rotary evaporation after ball milling to obtain ZTA composite ceramic powder; it should be noted that the toughening of alumina by zirconia improves the impact resistance and bending strength of alumina tools, and reduces the Risk of chipping when cutting alumina tools;
- Step 3 weigh 78 parts of the above-mentioned ZTA ceramic powder, 22 parts of the photocurable resin and 1 part of the photoinitiator, and place them in a ball mill for ball milling and mixing to obtain the first ceramic slurry;
- Step 4 placing the first ceramic slurry in a photo-curing molding device, and performing curing molding according to a preset model, thereby obtaining a zirconia toughened alumina ceramic tool blank.
- Specific steps include:
- the XY resolution is 20 ⁇ m
- the layer thickness is 50 ⁇ m
- the base layer is 5 layers
- the curing time is 20 s
- the curing time of the ordinary layer is 5 s.
- Step 5 place the zirconia toughened alumina ceramic tool blank in a low-temperature debinding furnace, heat it up to 600 °C at a heating rate of 1 °C/min, and perform debinding in a vacuum atmosphere to remove the hydrogen element of the photosensitive resin and reduce the temperature. After reaching room temperature, the temperature is raised to 600°C at a heating rate of 1°C/min, and debonding is carried out in an air atmosphere to remove the carbon element of the photosensitive resin to obtain a ceramic tool blank after debonding;
- Step 6 placing the zirconia toughened alumina ceramic tool blank after debinding in a muffle furnace for high temperature sintering, with a heating rate of 10°C/min to 800°C, and a heating rate of 5°C/min to 1550- 1600 °C, after 2 hours, the temperature is lowered to 800 °C at 5 °C/min, and then cooled with the furnace to obtain zirconia toughened alumina ceramic tools;
- the alumina powder is doped with zirconia, which improves the toughness of the alumina, reduces the risk of chipping of the alumina ceramic tool during cutting, and prolongs the service life of the alumina ceramic tool;
- the preparation of zirconia toughened alumina ceramic cutting tools by curing improves the preparation accuracy of complex-shaped zirconia toughened alumina ceramic cutting tools, and reduces the cost and preparation cycle; and the vacuum debinding and then air debinding can avoid the increase of zirconia.
- the risk of deformation and cracking of the tough alumina ceramic tool blank during debonding avoids the reduction of the cutting tool's preparation accuracy; and the zirconia is stabilized by yttrium oxide, which avoids the sharp volume change of the zirconia from high temperature to room temperature. Cracks appear in the embryo body, which further reduces the mechanical properties such as the precision and toughness of the zirconia toughened alumina ceramic tool embryo body. Therefore, the yttria-stabilized zirconia improves the service life of the tool.
- the prepared complex-shaped zirconia toughened alumina ceramic tool has high precision, short cycle, high toughness and long service life, which broadens the application of the zirconia toughened alumina ceramic tool.
- Example 3 of the present application provides a third method for preparing a zirconia toughened alumina ceramic tool.
- the first ceramic slurry in this embodiment includes 2 parts of sintering aid Cr2O3.
- a high-density zirconia toughened alumina ceramic tool can be obtained at a relatively low temperature.
- the present application can efficiently prepare zirconia toughened alumina ceramic tools with high-precision chip breakers or other complex surface patterns through photocuring, and the tool blanks are first vacuum debonded and then debonded. Air debinding and yttria stabilization of zirconia further improve the precision and mechanical properties of zirconia toughened alumina ceramic tools, and high-density zirconia toughened alumina ceramic tools can be obtained by adding sintering aids.
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Abstract
一种氧化锆增韧氧化铝陶瓷刀具及其制备方法。将氧化锆增韧氧化铝复合陶瓷浆料进行光固化成型,得到成型坯体,将成型坯体进行真空排胶后空气排胶处理,然后进行高温烧结,得到氧化锆增韧氧化铝陶瓷刀具。用于解决现有技术制备的氧化锆增韧氧化铝陶瓷刀具精度低,成本高,周期长,且无法制备断屑槽或其它复杂形状的表面花纹的技术问题。
Description
本发明属于陶瓷材料成型技术领域,尤其涉及一种氧化锆增韧氧化铝陶瓷刀具及其制备方法。
高性能刀具材料及技术的需求不断增加,目前切削加工技术的发展趋势是向高速、高精度转变。但是过大的切削力及产生过多的热量阻碍了切削速度的提升,降低了刀具的切削性能,因此对加工刀具的性能要求也就更高。高速切削要求刀具材料在高温时能够依然保持良好的力学性能、化学稳定性以及抗粘接性能。先进陶瓷材料在高温时仍然能保持稳定的力学性能,满足高速切削的要求。
纯Al2O3陶瓷材料抗冲击能力差,抗弯强度较低,在切削时可能会产生微崩刃,而氧化锆增韧氧化铝(ZTA)陶瓷具有高硬度、高耐磨等优异性能,ZTA陶瓷刀具在切削时侧面磨损小,适用于耐磨、耐腐蚀、高温稳定性和优异机械强度的应用场合,在切削产生的高温下可保持良好的稳定性。但是,传统机械加工制备复杂形状的氧化锆增韧氧化铝(ZTA)陶瓷切削刀具时精度低、周期长、成本高,加工复杂形状断屑槽时非常困难或者完全无法制备。刀具的断屑槽不仅对切屑起着附加变形的作用,而且对切屑的形状和切屑的折断有着重要的影响。而断屑槽可靠与否,对正常生产与操作者安全以及刀具寿命、加工质量都有着重大影响。传统机械加工制备方法局限性限制了氧化锆增韧氧化铝(ZTA)陶瓷刀具的推广应用。
发明内容
有鉴于此,本发明提供了一种氧化锆增韧氧化铝陶瓷刀具及其制备方法,用于解决现有技术制备的氧化锆增韧氧化铝陶瓷刀具精度低,成本高,周期长,且无法制备断屑槽或其它复杂形状的表面花纹的技术问题。
本申请第一方面提供了一种氧化锆增韧氧化铝陶瓷刀具的制备方法,包 括步骤:
步骤1,将氧化铝粉体、氧化锆、陶瓷烧结助剂、光敏树脂、光引发剂球磨混合得到第一陶瓷浆料;
步骤2,将第一陶瓷浆料进行光固化成型,得到氧化锆增韧氧化铝陶瓷胚体。
步骤3,将所述氧化锆增韧氧化铝陶瓷坯体进行排胶处理,然后进行高温烧结,得到所述氧化锆增韧氧化铝陶瓷切削刀具;
所述二次排胶处理具体包括:在低温排胶炉中先进行真空排胶后再空气排胶。
优选的,所述氧化锆粉体为3Y-TZP粉体。
优选的,所述步骤1具体为:将氧化铝粉体、氧化锆粉体、陶瓷烧结助剂、光敏树脂、光引发剂球磨混合得到第一陶瓷浆料。
优选的,所述真空排胶处理具体包括:在真空条件下,将所述成型坯体以1-15℃/min的升温速率升温至550-750℃,保温时间为2-5h;所述空气排胶处理具体包括:在空气环境下,将所述成型坯体以1-15℃/min的升温速率升温至550-750℃,保温时间为2-5h。
优选的,所述高温烧结具体为:以1-15℃/min的第一升温速率升温至600~800℃后,再以1-20℃/min的第二升温速率升温至1500~1650℃,保温1.5~3h。
优选的,以重量份计,所述第一陶瓷浆料包括以下重量组份:
氧化铝 80-90份;
氧化锆 10-20份;
烧结助剂 0-5份;
光敏树脂 20-40份;
光引发剂 0.1-6份。
优选的,所述陶瓷烧结助剂包括但不限于MgO、Cr2O3、CaO、La2O3、SiO2、Y2O3、TiC、TiN、TiCN、WC、SiC中的一种或多种。
优选的,所述光固化树脂选自乙氧化季戊四醇四丙烯酸酯、环己烷、脂肪族聚氨酯丙烯酸酯、乙酸乙酯、1,6-乙二醇二丙烯酸酯、正辛醇、异丙醇、聚乙二醇和乙酸甲酯中的一种或多种。
优选的,所述光引发剂选自2-羟基-2-甲基-1-苯基-1-丙酮、苯基双(2,4,6-三甲基苯甲酰基)氧化膦、(2,4,6-三甲基苯甲酰基)二苯基氧化膦和2-异丙基硫杂蒽酮中的一种或多种。
本申请第二方面提供了一种氧化锆增韧氧化铝陶瓷切削刀具。
与现有技术相比,本申请具有以下有益效果。
1、与现有机械加工制备氧化锆增韧氧化铝陶瓷相比,光固化成型制备的复杂形状氧化锆增韧氧化铝陶瓷刀具精度高、成本低、周期短,可以制备常规陶瓷制造工艺无法制备的无法制备断屑槽或其它复杂形状的表面花纹等。
2、本申请在低温排胶炉中将氧化锆增韧氧化铝陶瓷坯体先进行真空排胶后再空气排胶,其中真空气氛进行排胶,除去光敏树脂的氢元素;排胶炉降至室温后,再进行空气气氛排胶,除去光敏树脂的碳元素,通过先进行真空排胶后再空气排胶可避免一次排胶同时除去光敏树脂中碳氢有机物导致氧化锆增韧氧化铝陶瓷胚体变形、开裂。
为了更清楚地说明本申请实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍。
图1为本申请实施例1制备的氧化锆增韧氧化铝陶瓷刀具;
图2为本申请实施例1制备的氧化锆增韧氧化铝陶瓷刀具尺寸示意图,单位为毫米;
图3为本申请实施例1制备的氧化锆增韧氧化铝陶瓷刀具示意图;
图4为本申请实施例2制备的氧化锆增韧氧化铝陶瓷刀具。
本申请提供了一种氧化锆增韧氧化铝陶瓷刀具及其制备方法,用于解决现有氧化锆增韧氧化铝陶瓷刀具精度低,成本高,周期长,且无法制备断屑 槽或其它复杂形状的表面花纹的技术问题。
下面将对本申请实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本申请一部分实施例,而不是全部的实施例。基于本申请中的实施例,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,都属于本申请保护的范围。
实施例1
本申请实施例1提供了第一种氧化锆增韧氧化铝陶瓷刀具的制备方法,具体包括步骤:
步骤1,分别称取86份氧化铝粉体和14份氧化锆粉体,置于球磨机中加无水乙醇进行机械球磨,其中球料质量比为1:1.5,球磨时间为2h,转速为250rad/min,球磨后旋转蒸发去除乙醇得到ZTA复合陶瓷粉体;
需要说明的是,通过氧化锆增韧氧化铝,提高氧化铝刀具的抗冲击能力以及抗弯强度,降低了氧化铝刀具切削加工时崩刃的风险;
步骤2,称取78份上述ZTA陶瓷粉体、22份光固化树脂和1分光引发剂,置于球磨机中球磨混合,得到第一陶瓷浆料;
步骤3,将第一陶瓷浆料置于光固化成型设备中,按照预设模型进行固化成型,进而得到氧化锆增韧氧化铝陶瓷刀具坯体。具体步骤包括:
将刀具模型导入打印软件,设置打印参数为:XY分辨率为20μm,层厚50μm,基层5层,固化时间20s;普通层固化时间5s。逐层固化,层层堆叠实现ZTA陶瓷刀具坯体快速成型;
步骤4,将氧化锆增韧氧化铝陶瓷刀具坯体置于低温排胶炉中,以1℃/min的升温速率升温至600℃,在真空气氛进行排胶,除去光敏树脂的氢元素,降至室温后,再以1℃/min的升温速率升温至600℃,在空气气氛进行排胶,除去光敏树脂的碳元素,获得排胶后的陶瓷刀具坯体;
需要说明的是,相较于一次排胶,先真空排胶再空气排胶可以避免氧化锆增韧氧化铝陶瓷刀具坯体排胶时出现变形、开裂,进而导致制备的氧化锆增韧氧化铝陶瓷刀具精度不高;
步骤5,将排胶后氧化锆增韧氧化铝陶瓷刀具坯体置于马弗炉中进行高温烧结,以10℃/min的升温速度至800℃,以5℃/min的升温速度至1550-1600℃,保2h后以5℃/min降温到800℃,然后随炉降温,得到氧化锆增韧氧化铝陶瓷刀具;
烧结后的氧化锆增韧氧化铝陶瓷刀具的相对密度为98.81%,硬度达到18.53GPa,断裂韧性达到5.63MPa·m1/2;
对实施例1制备的陶瓷刀具进行车削灰铸铁HT200切削性能测试,发现其带断屑槽的一面比不带断屑槽一面的寿命高30%,车削工件表面粗糙度降低了27%,断屑槽能降低车削加工时刀具所受的切削力和切削温度,对切屑起到导向和折断作用,使刀具磨损量减小且提高工件的表面加工质量;且设置合理的断屑槽的断屑槽宽度、断屑槽深度、刃口高度、棱带宽度会大大提高断屑槽的性能。在本实施例中,陶瓷刀具断屑槽宽度为2.4mm,深度为0.3mm,刃口高度为0.2mm,棱带宽度为3mm时,该陶瓷刀具的使用寿命长、加工质量高。
本申请实施例在氧化铝粉体中掺杂氧化锆,提高了氧化铝的韧性,降低了氧化铝陶瓷刀具在切削加工时崩刃的风险,延长了氧化铝陶瓷刀具的使用寿命;同时通过光固化制备氧化锆增韧氧化铝陶瓷刀具,提高了复杂形状氧化锆增韧氧化铝陶瓷切削刀具的制备精度,降低了成本与制备周期;且先真空排胶再空气排胶,可以避免氧化锆增韧氧化铝陶瓷刀具胚体排胶时变形、开裂的风险,避免了切削刀具的制备精度降低,因此,本申请实施例公开的制备方法制备的复杂形状氧化锆增韧氧化铝陶瓷刀具精度高、周期短、韧性高,使用寿命长,拓宽了氧化锆增韧氧化铝陶瓷刀具应用。
实施例2:
本申请实施例2提供了第二种氧化锆增韧氧化铝陶瓷刀具的制备方法,具体包括步骤:
步骤1,按质量份计,称取97份的氧化锆和3份氧化钇球磨混合,得到3Y-TZP粉体。
需要说明的是,通过在氧化锆中掺杂氧化钇,避免了氧化锆从高温冷却至室温,经过相***温度时正方晶转换成单斜晶。
步骤2,按质量份计,分别称取84份氧化铝粉体和16份3Y-TZP粉体,置于球磨机中加无水乙醇进行机械球磨,其中球料质量比为1:1.5,球磨时间为2h,转速为250rad/min,球磨后旋转蒸发去除乙醇得到ZTA复合陶瓷粉体;需要说明的是,通过氧化锆增韧氧化铝,提高氧化铝刀具的抗冲击能力以及抗弯强度,降低了氧化铝刀具切削加工时崩刃的风险;
步骤3,称取78份上述ZTA陶瓷粉体、22份光固化树脂和1分光引发剂,置于球磨机中球磨混合,得到第一陶瓷浆料;
步骤4,将第一陶瓷浆料置于光固化成型设备中,按照预设模型进行固化成型,进而得到氧化锆增韧氧化铝陶瓷刀具坯体。具体步骤包括:
将刀具模型导入打印软件,设置打印参数为:XY分辨率为20μm,层厚50μm,基层5层,固化时间20s;普通层固化时间5s。逐层固化,层层堆叠实现ZTA陶瓷刀具坯体快速成型;
步骤5,将氧化锆增韧氧化铝陶瓷刀具坯体置于低温排胶炉中,以1℃/min的升温速率升温至600℃,在真空气氛进行排胶,除去光敏树脂的氢元素,降至室温后,再以1℃/min的升温速率升温至600℃,在空气气氛进行排胶,除去光敏树脂的碳元素,获得排胶后的陶瓷刀具坯体;
需要说明的是,相较于一次排胶,先真空排胶再空气排胶可以避免氧化锆增韧氧化铝陶瓷刀具坯体排胶时出现变形、开裂,进而导致制备的氧化锆增韧氧化铝陶瓷刀具精度不高;
步骤6,将排胶后氧化锆增韧氧化铝陶瓷刀具坯体置于马弗炉中进行高温烧结,以10℃/min的升温速度至800℃,以5℃/min的升温速度至1550-1600℃,保2h后以5℃/min降温到800℃,然后随炉降温,得到氧化锆增韧氧化铝陶瓷刀具;
本申请实施例在氧化铝粉体中掺杂氧化锆,提高了氧化铝的韧性,降低了氧化铝陶瓷刀具在切削加工时崩刃的风险,延长了氧化铝陶瓷刀具的使用 寿命;同时通过光固化制备氧化锆增韧氧化铝陶瓷刀具,提高了复杂形状氧化锆增韧氧化铝陶瓷切削刀具的制备精度,降低了成本与制备周期;且先真空排胶再空气排胶,可以避免氧化锆增韧氧化铝陶瓷刀具胚体排胶时变形、开裂的风险,避免了切削刀具的制备精度降低;并且通过氧化钇稳定氧化锆,避免了氧化锆由高温降至室温时因剧烈的体积变化导致刀具胚体出现裂缝,进而降低氧化锆增韧氧化铝陶瓷刀具胚体的精度以及韧性等力学性能,因此,通过氧化钇稳定氧化锆提高了刀具使用寿命,综上,本申请实施例公开的制备方法制备的复杂形状氧化锆增韧氧化铝陶瓷刀具精度高、周期短、韧性高,使用寿命长,拓宽了氧化锆增韧氧化铝陶瓷刀具应用。
实施例3:
本申请实施例3提供了第三种氧化锆增韧氧化铝陶瓷刀具的制备方法。与实施例1或2不同的是,按质量份计,本实施例中第一陶瓷浆料包括烧结助剂2份Cr2O3。
需要说明的是,通过在第一陶瓷浆料中添加烧结助剂,在较低的温度下即可获得高致密度的氧化锆增韧氧化铝陶瓷刀具。
从前述实施例可以理解的是,本申请通过光固化可高效制备带有高精度断屑槽或其它复杂形状表面花纹的氧化锆增韧氧化铝陶瓷刀具,且对刀具胚体先真空排胶再空气排胶以及通过氧化钇稳定氧化锆,进一步提高了氧化锆增韧氧化铝陶瓷刀具的精度、力学性能,且通过添加烧结助剂可获得高致密度的氧化锆增韧氧化铝陶瓷刀具。
以上所述仅是本申请的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本申请原理的前提下,还可以做出若干改进,这些改进也应视为本申请的保护范围。
Claims (10)
- 一种氧化锆增韧氧化铝刀具的制备方法,其特征在于,包括以下步骤:步骤1,将氧化铝粉体、氧化锆粉体、陶瓷烧结助剂、光敏树脂、光引发剂球磨混合得到第一陶瓷浆料;步骤2,将第一陶瓷浆料进行光固化成型,得到氧化锆增韧氧化铝陶瓷胚体;步骤3,将所述氧化锆增韧氧化铝陶瓷坯体进行二次排胶处理,然后进行高温烧结,得到所述氧化锆增韧氧化铝陶瓷切削刀具;所述二次排胶处理具体包括:在低温排胶炉中先进行真空排胶后再空气排胶。
- 根据权利要求1所述的制备方法,其特征在于,所述氧化锆粉体为3Y-TZP粉体。
- 根据权利要求1所述的制备方法,其特征在于,所述步骤1具体为:将氧化铝粉体、氧化锆粉体、陶瓷烧结助剂、光敏树脂、光引发剂球磨混合得到第一陶瓷浆料。
- 根据权利要求1所述的制备方法,其特征在于,所述真空排胶处理具体包括:在真空条件下,将所述成型坯体以1-15℃/min的升温速率升温至550-750℃,保温时间为2-5h;所述空气排胶处理具体包括:在空气环境下,将所述成型坯体以1-15℃/min的升温速率升温至550-750℃,保温时间为2-5h。
- 根据权利要求1所述的制备方法,其特征在于,所述高温烧结具体为:以1-15℃/min的第一升温速率升温至600~800℃后,再以 1-20℃/min的第二升温速率升温至1500~1650℃,保温1.5~3h。
- 根据权利要求3所述的制备方法,其特征在于,以重量份计,所述第一陶瓷浆料包括以下重量组份:氧化铝80-90份;氧化锆10-20份;陶瓷烧结助剂0-5份;光敏树脂20-40份;光引发剂0.1-6份。
- 根据权利要求3所述的制备方法,所述陶瓷烧结助剂选自MgO、Cr2O3、CaO、La2O3、SiO2、Y2O3、TiC、TiN、TiCN、WC或SiC中的一种或多种。
- 根据权利要求1所述的制备方法,所述光固化树脂选自乙氧化季戊四醇四丙烯酸酯、环己烷、脂肪族聚氨酯丙烯酸酯、乙酸乙酯、1,6-乙二醇二丙烯酸酯、正辛醇、异丙醇、聚乙二醇和乙酸甲酯中的一种或多种。
- 根据权利要求1所述的制备方法,所述光引发剂选自2-羟基-2-甲基-1-苯基-1-丙酮、苯基双(2,4,6-三甲基苯甲酰基)氧化膦、(2,4,6-三甲基苯甲酰基)二苯基氧化膦和2-异丙基硫杂蒽酮中的一种或多种。
- 一种氧化锆增韧氧化铝刀具,其特征在于,根据权利要求1-9任一项所述的制备方法制备得到。
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