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CN107285748A - 一种用于乳化泵柱塞的陶瓷复合材料的制备方法 - Google Patents

一种用于乳化泵柱塞的陶瓷复合材料的制备方法 Download PDF

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CN107285748A
CN107285748A CN201710482374.5A CN201710482374A CN107285748A CN 107285748 A CN107285748 A CN 107285748A CN 201710482374 A CN201710482374 A CN 201710482374A CN 107285748 A CN107285748 A CN 107285748A
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ceramic
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CN107285748B (zh
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王旭东
杨建锋
王子敬
张亚明
王波
李春芳
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Fugu Xulin Electromechanical Technology Co Ltd
Xian Jiaotong University
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Xian Jiaotong University
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Abstract

一种用于乳化泵柱塞的陶瓷复合材料的制备方法，首先将氧化铝、六方氮化硼、氧化镁、氧化钙、透辉石进行充分混合，再与莫来石晶须进行充分混合后造粒，粉料置于模具中等静压成形，再将其烧结成致密的氧化铝陶瓷柱塞毛坯件，最后通过磨削加工成具有精密尺寸和精度的陶瓷柱塞；与现有技术相比，本发明的陶瓷柱塞材料可以有效地提高陶瓷柱塞的韧性，降低柱塞的摩擦系数，改善材料的磨削加工型和成品率，提高陶瓷柱塞的使用寿命。

Description

一种用于乳化泵柱塞的陶瓷复合材料的制备方法
技术领域
本发明涉及陶瓷复合材料制备领域，特别涉及一种用于乳化泵柱塞的陶瓷复合材料的制备方法。
背景技术
乳化液泵站是综采工作面的关键设备之一，其正常运行直接影响高产高效工作面的生产效益。由于乳化液泵的工作周期较长，故对其关键件陶瓷柱塞的质量要求相当严格。
从耐磨性进行比较，氧化锆陶瓷是增韧氧化铝陶瓷的2倍，增韧氧化铝陶瓷是氧化铝陶瓷的4倍以上；从断裂韧性进行比较，氧化锆陶瓷是增韧氧化铝的陶瓷的2-3倍，增韧氧化铝陶瓷是氧化铝陶瓷的2 倍左右。氧化锆陶瓷性能最适合煤矿的使用条件，但从经济角度上考虑,氧化锆陶瓷价格昂贵、性价比低，氧化铝陶瓷价格便宜但耐磨性和韧性不够。因此乳化液泵柱塞材料选择增韧氧化铝陶瓷最为合理，并且柱塞在运动过程中可能产生局部瞬时的热量，增韧氧化铝陶瓷比氧化锆在高温下更加稳定。
晶须是具有一定长径比(直径0.1-1.8um，长35-150um)，且缺陷少的陶瓷单晶。具有很高的强度，是一种非常好的陶瓷基复合材料的增韧增强体；纤维长度较陶瓷晶须长数倍，也是一种很好的陶瓷增韧体，同时两者可复合实用。用SiC、Si3N4等晶须或C、SiC等长纤维对氧化铝陶瓷进行复合增韧。晶须或纤维的加入可以增加断裂表面，即增加了裂纹的扩展通道。当裂纹扩展的剩余能量渗入到纤维(晶须)，发生纤维(晶须)的拔出、脱粘和断裂时，导致断裂能被消耗或裂纹扩展方向发生偏转等，从而使复合材料韧性得到提高。但当晶须、纤维含量较高时，由于其拱桥效应而使致密化变得困难，从而引起密度的下降和性能下降。
对于乳化泵陶瓷柱塞来说，柱塞与密封圈之间的滑动摩擦磨损是影响密封的重要因素，而柱塞与密封圈之间的润滑对于降低摩擦系数是重要的手段。
发明内容
为了克服上述现有技术的缺点，本发明的目的在于提供一种用于乳化泵柱塞的陶瓷复合材料的制备方法，在原料中添加了可以起到增韧作用的莫来石晶须、起到润滑作用的六方氮化硼以及改善烧结致密性的各种烧结助剂，可以有效提高氧化铝陶瓷柱塞的烧结致密性、材料的韧性和润滑性。
为了达到上述目的，本发明采取的技术方案为：
一种用于乳化泵柱塞的陶瓷复合材料的制备方法，包括以下步骤：
步骤一；成形粉料的调制：
将氧化铝粉与六方氮化硼、氧化镁、氧化钙、透辉石充分混合后再与莫来石晶须进行充分混合，得到的粉体进行造粒；所述的造粒粉体包括以下组分及重量份数：氧化铝65-90，六方氮化硼2-6，氧化镁1-3，氧化钙1-5，透辉石1-5，莫来石晶须5-20。
步骤二；等静压成型；
将步骤一中得到的混合物颗粒置于模具中冷等静压成形，成形压力200-500MPa，保压时间1-10min，得到的坯体直接进行粗加工；
步骤三；高温烧结；
将得到的粗加工的坯体进行高温烧结成致密化铝复合材料坯体，高温烧结温度为1500-1600℃。；
步骤四；磨削加工；
将致密氧化铝复合陶瓷柱塞坯体磨削加工成陶瓷柱塞。
所述的步骤二中的模具由耐油橡胶管套、多孔保持架、芯棒和胶塞构成。
本发明的有益效果：
本发明的优点在于，可以有效提高氧化铝陶瓷的致密性和加工效率，改善柱塞的断裂韧性和润滑性，实现制备密度高、韧性好、润滑性优良、尺寸精度高的氧化铝陶瓷柱塞的目的，采用这种致密氧化铝陶瓷柱塞作为柱塞泵的核心部件，具有使用寿命长、耐磨、摩擦系数低的优越性，减少停机维修更换柱塞和密封套的次数，节约工程运行成本，还可以扩展到其他氧化铝部件。
同时由于六方氮化硼的添加，有效改善了材料的可加工性，提高了磨削的生产效率。经磨削加工，直径和圆度尺寸公差范围为 <0.01mm，表面光洁度为0.2。
具体实施方式
下面对本发明进一步说明。
实施例一
本实施例的制备方法，包括以下步骤：
步骤一；成形粉料的调制：
将氧化铝粉与六方氮化硼、氧化镁、氧化钙、透辉石充分混合后再与莫来石晶须进行充分混合，得到的粉体在陶瓷容器中用水做介质充分球磨混合，用喷雾造粒机干燥造粒；按照以下的重量份数配方配制：
步骤二；等静压成型；
将步骤一中得到的混合物颗粒装入由芯棒、耐油橡胶套管、多孔保持架及胶塞构成的专用成型模具，密封后放入冷等静压机的油缸中，在400MPa的压力下保压5分钟成型；脱模后先进行毛坯粗加工；
步骤三；高温烧结；
将得到的粗加工的坯体进行高温烧结成致密化铝复合材料坯体，在1550度的烧结温度下，保温180分钟；
步骤四；磨削加工；
将致密氧化铝复合陶瓷柱塞坯体经粗磨和精磨，制成致密氧化铝陶瓷柱塞；相对密度为99.2％，直径公差0.005-0.01mm，表面粗糙度 0.2。
实施例二
本实施例的制备方法，包括以下步骤：
步骤一；成形粉料的调制：
将氧化铝粉与六方氮化硼、氧化镁、氧化钙、透辉石充分混合后再与莫来石晶须进行充分混合，得到的粉体在陶瓷容器中用水做介质充分球磨混合，用喷雾造粒机干燥造粒；按照以下的重量份数配方配制：
步骤二；等静压成型；
将步骤一中得到的混合物颗粒装入由芯棒、耐油橡胶套管、多孔保持架及胶塞构成的专用成型模具，密封后放入冷等静压机的油缸中，在350MPa的压力下保压10分钟成型；脱模后先进行毛坯粗加工；
步骤三；高温烧结；
将得到的粗加工的坯体进行高温烧结成致密化铝复合材料坯体，在1530度的烧结温度下，保温180分钟；
步骤四；磨削加工；
将致密氧化铝复合陶瓷柱塞坯体经粗磨和精磨，制成致密氧化铝陶瓷柱塞；相对密度为99.5％，直径公差0.005-0.01mm，表面粗糙度0.2。
实施例三
本实施例的制备方法，包括以下步骤：
步骤一；成形粉料的调制：
将氧化铝粉与六方氮化硼、氧化镁、氧化钙、透辉石充分混合后再与莫来石晶须进行充分混合，得到的粉体在陶瓷容器中用水做介质充分球磨混合，用喷雾造粒机干燥造粒；按照以下的重量份数配方配制：
步骤二；等静压成型；
将步骤一中得到的混合物颗粒装入由芯棒、耐油橡胶套管、多孔保持架及胶塞构成的专用成型模具，密封后放入冷等静压机的油缸中，在200MPa的压力下保压3分钟成型；脱模后先进行毛坯粗加工；
步骤三；高温烧结；
将得到的粗加工的坯体进行高温烧结成致密化铝复合材料坯体，在1580度的烧结温度下，保温180分钟；
步骤四；磨削加工；
将致密氧化铝复合陶瓷柱塞坯体经粗磨和精磨，制成致密氧化铝陶瓷柱塞；相对密度为98.5％，直径公差0.005-0.01mm，表面粗糙度 0.2。
实施例四
本实施例的制备方法，包括以下步骤：
步骤一；成形粉料的调制：
将氧化铝粉与六方氮化硼、氧化镁、氧化钙、透辉石充分混合后再与莫来石晶须进行充分混合，得到的粉体在陶瓷容器中用水做介质充分球磨混合，用喷雾造粒机干燥造粒；按照以下的重量份数配方配制：
步骤二；等静压成型；
将步骤一中得到的混合物颗粒装入由芯棒、耐油橡胶套管、多孔保持架及胶塞构成的专用成型模具，密封后放入冷等静压机的油缸中，在300MPa的压力下保压1分钟成型；脱模后先进行毛坯粗加工；
步骤三；高温烧结；
将得到的粗加工的坯体进行高温烧结成致密化铝复合材料坯体，在1500度的烧结温度下，保温180分钟；
步骤四；磨削加工；
将致密氧化铝复合陶瓷柱塞坯体经粗磨和精磨，制成致密氧化铝陶瓷柱塞；相对密度为99.0％，直径公差0.005-0.01mm，表面粗糙度0.2。实施例五
本实施例的制备方法，包括以下步骤：
步骤一；成形粉料的调制：
将氧化铝粉与六方氮化硼、氧化镁、氧化钙、透辉石充分混合后再与莫来石晶须进行充分混合，得到的粉体在陶瓷容器中用水做介质充分球磨混合，用喷雾造粒机干燥造粒；按照以下的重量份数配方配制：
步骤二；等静压成型；
将步骤一中得到的混合物颗粒装入由芯棒、耐油橡胶套管、多孔保持架及胶塞构成的专用成型模具，密封后放入冷等静压机的油缸中，在500MPa的压力下保压8分钟成型；脱模后先进行毛坯粗加工；
步骤三；高温烧结；
将得到的粗加工的坯体进行高温烧结成致密化铝复合材料坯体，在1600度的烧结温度下，保温180分钟；
步骤四；磨削加工；
将致密氧化铝复合陶瓷柱塞坯体经粗磨和精磨，制成致密氧化铝陶瓷柱塞，经粗磨和精磨，制成致密氧化铝陶瓷柱塞；相对密度为 99.3％，直径公差0.005-0.01mm，表面粗糙度0.2。

Claims (1)

1.一种用于乳化泵柱塞的陶瓷复合材料的制备方法，其特征在于，包括以下步骤：
步骤一；成形粉料的调制：
将氧化铝粉与六方氮化硼、氧化镁、氧化钙、透辉石充分混合后再与莫来石晶须进行充分混合，得到的粉体进行造粒；所述的造粒粉体包括以下组分及重量份数：氧化铝65-90，六方氮化硼2-6，氧化镁1-3，氧化钙1-5，透辉石1-5，莫来石晶须5-20；
步骤二；等静压成型；
将步骤一中得到的混合物颗粒置于模具中冷等静压成形，成形压力200-500MPa，保压时间1-10min得坯体；
步骤三；高温烧结；
将得到的坯体进行高温烧结成致密化铝复合材料坯体，高温烧结温度为1500-1600℃；
步骤四；磨削加工；
将致密氧化铝复合陶瓷柱塞坯体磨削加工成陶瓷柱塞。
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