CN114538944A - Preparation formula and preparation process of carbon fiber kiln furniture - Google Patents
Preparation formula and preparation process of carbon fiber kiln furniture Download PDFInfo
- Publication number
- CN114538944A CN114538944A CN202210294159.3A CN202210294159A CN114538944A CN 114538944 A CN114538944 A CN 114538944A CN 202210294159 A CN202210294159 A CN 202210294159A CN 114538944 A CN114538944 A CN 114538944A
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- parts
- carbon fiber
- kiln furniture
- sintering
- drying
- Prior art date
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- 229920000049 Carbon (fiber) Polymers 0.000 title claims abstract description 82
- 239000004917 carbon fiber Substances 0.000 title claims abstract description 82
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims abstract description 48
- 238000002360 preparation method Methods 0.000 title claims description 17
- 238000009472 formulation Methods 0.000 title claims description 11
- 239000000463 material Substances 0.000 claims abstract description 72
- 238000005245 sintering Methods 0.000 claims abstract description 57
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 20
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 20
- 239000011230 binding agent Substances 0.000 claims abstract description 14
- 238000000034 method Methods 0.000 claims abstract description 13
- 239000002270 dispersing agent Substances 0.000 claims abstract description 11
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 11
- 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 9
- 229910052581 Si3N4 Inorganic materials 0.000 claims abstract description 7
- 229910052878 cordierite Inorganic materials 0.000 claims abstract description 7
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 7
- 239000010431 corundum Substances 0.000 claims abstract description 7
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims abstract description 7
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000003756 stirring Methods 0.000 claims description 26
- 238000001035 drying Methods 0.000 claims description 21
- 239000000047 product Substances 0.000 claims description 16
- 239000000203 mixture Substances 0.000 claims description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 13
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 claims description 10
- 239000002245 particle Substances 0.000 claims description 9
- 230000008569 process Effects 0.000 claims description 9
- BNGXYYYYKUGPPF-UHFFFAOYSA-M (3-methylphenyl)methyl-triphenylphosphanium;chloride Chemical compound [Cl-].CC1=CC=CC(C[P+](C=2C=CC=CC=2)(C=2C=CC=CC=2)C=2C=CC=CC=2)=C1 BNGXYYYYKUGPPF-UHFFFAOYSA-M 0.000 claims description 8
- 229910052782 aluminium Inorganic materials 0.000 claims description 8
- 239000003822 epoxy resin Substances 0.000 claims description 8
- 229920000647 polyepoxide Polymers 0.000 claims description 8
- 239000002994 raw material Substances 0.000 claims description 8
- NGDQQLAVJWUYSF-UHFFFAOYSA-N 4-methyl-2-phenyl-1,3-thiazole-5-sulfonyl chloride Chemical compound S1C(S(Cl)(=O)=O)=C(C)N=C1C1=CC=CC=C1 NGDQQLAVJWUYSF-UHFFFAOYSA-N 0.000 claims description 7
- 239000004327 boric acid Substances 0.000 claims description 7
- 238000002156 mixing Methods 0.000 claims description 7
- -1 aluminum compound Chemical class 0.000 claims description 6
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 6
- 229940105963 yttrium fluoride Drugs 0.000 claims description 6
- RBORBHYCVONNJH-UHFFFAOYSA-K yttrium(iii) fluoride Chemical compound F[Y](F)F RBORBHYCVONNJH-UHFFFAOYSA-K 0.000 claims description 6
- 239000000395 magnesium oxide Substances 0.000 claims description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 5
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 5
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 5
- 238000005303 weighing Methods 0.000 claims description 5
- 239000012752 auxiliary agent Substances 0.000 claims description 4
- 150000002681 magnesium compounds Chemical class 0.000 claims description 4
- YIXJRHPUWRPCBB-UHFFFAOYSA-N magnesium nitrate Chemical compound [Mg+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O YIXJRHPUWRPCBB-UHFFFAOYSA-N 0.000 claims description 4
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 claims description 4
- 150000002910 rare earth metals Chemical class 0.000 claims description 4
- 238000010146 3D printing Methods 0.000 claims description 3
- 229910052582 BN Inorganic materials 0.000 claims description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 3
- 239000006227 byproduct Substances 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims description 3
- 238000004898 kneading Methods 0.000 claims description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 2
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
- 229920001568 phenolic resin Polymers 0.000 claims description 2
- 239000005011 phenolic resin Substances 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims 2
- 229910052799 carbon Inorganic materials 0.000 claims 2
- 229910021538 borax Inorganic materials 0.000 claims 1
- 239000002131 composite material Substances 0.000 claims 1
- 238000000465 moulding Methods 0.000 claims 1
- 238000007639 printing Methods 0.000 claims 1
- 239000004328 sodium tetraborate Substances 0.000 claims 1
- 235000010339 sodium tetraborate Nutrition 0.000 claims 1
- 230000003647 oxidation Effects 0.000 abstract description 6
- 238000007254 oxidation reaction Methods 0.000 abstract description 6
- 230000035939 shock Effects 0.000 abstract description 6
- 239000000919 ceramic Substances 0.000 description 10
- 238000002474 experimental method Methods 0.000 description 9
- 239000013078 crystal Substances 0.000 description 8
- 239000011159 matrix material Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 239000007791 liquid phase Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000012779 reinforcing material Substances 0.000 description 5
- 239000006104 solid solution Substances 0.000 description 5
- 238000012546 transfer Methods 0.000 description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- 239000011261 inert gas Substances 0.000 description 3
- 239000012071 phase Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 230000035882 stress Effects 0.000 description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical group C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000001723 curing Methods 0.000 description 2
- 238000000280 densification Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 229920003063 hydroxymethyl cellulose Polymers 0.000 description 2
- 229940031574 hydroxymethyl cellulose Drugs 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000000016 photochemical curing Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 241001391944 Commicarpus scandens Species 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical group [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 125000005619 boric acid group Chemical group 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052810 boron oxide Inorganic materials 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000009740 moulding (composite fabrication) Methods 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000001272 pressureless sintering Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 description 1
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- C04B35/63—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 using additives specially adapted for forming the products, e.g.. binder binders
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- C04B35/634—Polymers
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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Abstract
The carbon fiber kiln furniture formula comprises 50-80 parts of base material, 0.1-20 parts of carbon fiber, 0.1-8 parts of sintering aid, 0.1-5 parts of carbon fiber aid, 1-10 parts of binder and 0.1-4 parts of dispersing agent by weight; the base material is one or more of mullite, cordierite, corundum, silicon carbide and silicon nitride. The method for preparing the kiln furniture by using the formula is also provided, and the prepared kiln furniture has the advantages of high heat conduction, high strength, thermal deformation resistance, thermal shock resistance, oxidation resistance, wear resistance and long service life.
Description
Technical Field
The invention relates to the technical field of ceramic kiln furniture, in particular to a preparation formula and a preparation process of carbon fiber kiln furniture.
Background
The foamed ceramic is a novel inorganic building material, has the characteristics of light weight, heat preservation, heat insulation, small deformation coefficient, high strength, water resistance, moisture resistance, fire resistance, flame retardance, ageing resistance, stable performance, good ecological environmental protection property, good compatibility with a wall base layer and a finishing layer, good safety and stability and long service life, and the sintering temperature is within 800 plus one hundred thousand DEG C. A plurality of kiln furniture such as decking, bounding wall, square beam and crossbeam need be used to make foamed ceramic, and at present, there are many problems in current foamed ceramic sintering kiln furniture, for example:
1. because the thermal conductivity of the shed plate and the enclosing plate is low, the heat transfer between the contact surfaces of the shed plate and the enclosing plate is too slow when the foamed ceramic is sintered, so that the temperature difference is caused, the structural stability of the sintered foamed ceramic is poor, and the sintering is not uniform;
2. the shed plate and the coaming are in an extremely cold and extremely hot environment; conversion, and meanwhile, the kiln furniture works in a high-temperature environment for a long time, and deformation is caused due to the insufficient thermal expansion, thermal shock resistance and thermal creep resistance of the kiln furniture;
3. as a main weight support and high-temperature airflow diversion structure, the square beam and the cross beam are prepared by the existing materials, the structural strength is not enough, the compactness is not enough, and the square beam and the cross beam are easy to be oxidized, so that the fracture phenomenon is easy to occur;
4. at present, most silicon carbide kiln furniture has a short service life, the use turnover times are basically below 1000 times, and the use times of part of silicon carbide kiln furniture are only about 300-500 times.
Research shows that the service life of the kiln furniture is related to a grain boundary structure formed by the kiln furniture, and the principle is that the disordered grain boundary structure can inhibit the expansion of cracks, so that the strength of the kiln furniture is macroscopically improved. Taking silicon carbide and silicon nitride as examples, although the structural strength is high after the grain boundary is formed, the preparation is difficult; under the condition of not adding an auxiliary agent, the sintering temperature is at least more than 2000 ℃, and meanwhile, a certain hot pressing condition is required to be ensured; and other sintering methods are difficult to realize industrialization. At present, the related kiln furniture is mostly prepared by adopting a pressureless sintering mode in the industry, and the improvement direction is mostly focused on how to reduce the sintering temperature as much as possible. Although the grain boundary formation is simple by adopting materials such as mullite, cordierite, corundum and the like, even if the grain boundary is formed by crosslinking of the base materials after the product is prepared, the properties of the product in all aspects are not enough, such as high-temperature oxidation resistance, high-temperature bending resistance (breaking strength), high-temperature deformation resistance, thermal shock resistance, apparent porosity and the like, and the requirements cannot be met.
The technology adopts a liquid phase sintering method, the sintering mechanism of the liquid phase sintering is that a certain amount of multi-element co-oxide is used as a sintering aid, rare earth elements are added, and the sintering aid forms a eutectic liquid phase at high temperature, so that the mass transfer mode of the system is changed from diffusion mass transfer to viscous flow, and the energy required by densification and the sintering temperature are reduced. And the formation of solid solutions causes lattice defects, forming free enthalpy. Taking the silicon carbide sintering as an example, since the sintering temperature of the silicon carbide is higher, the silicon carbide and the crystal lattices thereof can vibrate more easily at high temperature, so that the free enthalpy is obviously increased along with the rise of the temperature, the internal vacancies of the silicon carbide are greatly increased, and the sintering degree of the silicon carbide is activated. The solid solution can improve the densification rate of the sintered body and reduce the coarsening rate of crystal grains. The liquid phase sintering firstly leads to the change of the material in the structure, the grains are fine and uniform and are in an equiaxed crystal shape, and simultaneously, due to the introduction of a grain boundary liquid phase and the weakening of unique interface combination, the fracture of the material also becomes a complete crystal fracture mode, so that the strength and the toughness of the material are obviously improved. The sintering temperature can be effectively reduced by using the aluminum nitrate and the yttrium nitrate, the aluminum and the magnesium can form a solid solution to prevent the crystal from growing too fast, the density can be effectively improved by adding the aluminum nitrate and the yttrium nitrate, and compared with the prior art, the compactness effect of sintering by adding the silicon carbide micro powder can be achieved when the silicon carbide micro powder is not added when the system sintering aid is adopted. And a proper amount of yttrium fluoride is added, so that not only can the compactness be improved, but also the heat conductivity can be improved, and a plurality of sintering aids can be liquefied to form a second phase to promote sintering. The short carbon fibers are added to play a role in transferring various kiln furniture, and the interface layer needs to have certain strength to transfer load from the matrix to the reinforcing phase carbon fibers. And meanwhile, the interface layer can also be isolated, and the interface layer can inhibit the increase of the bonding strength caused by the atomic diffusion reaction between the matrix and the fiber under the high-temperature or aerobic environment, thereby keeping the excellent toughness of the material. The carbon fiber is graphitized at a higher temperature, so that the damage of the fiber caused by high temperature or chemical reaction in the preparation process is slowed down and avoided. The stress slow release effect is particularly important, when the cracks are transmitted to the interface layer from the matrix, the cracks deflect at the interface or in the interface layer in a diffusion mode, a large number of finer cracks are generated by each matrix crack, the crack transmission path is expanded, the stress release is facilitated, the cracks are prevented from expanding to the inside of the carbon fiber, and the strength and the toughness are improved. However, in order to ensure that the carbon fibers can uniformly exist in the base material and have no negative influence on the structural strength, the chopped carbon fibers within a certain length range need to be used, and the water-based epoxy resin and boric acid are added into the raw materials, so that the homogenization and oxidation resistance of the chopped carbon fiber mixed material can be improved.
Therefore, the preparation formula and the production process of the short carbon fiber kiln furniture for the foamed ceramics aim to solve the problems of insufficient strength, low thermal conductivity and short service life of the existing kiln furniture.
Disclosure of Invention
The invention aims to provide a preparation formula and a preparation process of carbon fiber kiln furniture, kiln furniture products with high strength, high temperature resistance and wear resistance can be produced by adopting the formula and the process, and the production process is simple and low in production cost.
The technical scheme of the invention is as follows: the carbon fiber kiln furniture formula comprises 50-80 parts of base material, 0.1-20 parts of carbon fiber, 0.1-8 parts of sintering aid, 0.1-5 parts of carbon fiber aid, 1-10 parts of binder and 0.1-4 parts of dispersing agent by weight; the base material is one or more of mullite, cordierite, corundum, silicon carbide and silicon nitride. The carbon fiber in the formula is a reinforcing material, and the base material can form a crystal boundary through the interaction of the base material and the reinforcing material, so that the integral structure, high density, high strength and high heat conductivity are maintained.
Furthermore, the particle size of the base material added in the formula is 10-50 mu m, and the thermal conductivity is 10-100W/mK, coefficient of thermal expansion of 1 to 10 x 10-6. Controlling the thermal conductivity of the base material facilitates controlling the thermal conductivity of the final product.
Further, the carbon fiber is a chopped carbon fiber with the length of 1-100 mm, the diameter is within 5-10 mm, the thermal conductivity is 100-700W/mK, the thermal expansion coefficient is (-1) -5 x 10 < -6 >, and the carbon fiber also comprises a carbon fiber byproduct fired by a refractory crucible.
Further, the sintering aid comprises an aluminum compound, a magnesium compound and a rare earth material, wherein the aluminum compound comprises one or more of aluminum oxide and aluminum nitrate; the magnesium compound is one or more of magnesium oxide and magnesium nitrate; the rare earth material is one or more of yttrium nitrate, yttrium oxide, lanthanum oxide and yttrium fluoride.
Further, the carbon fiber auxiliary agent comprises one or more of boric acid, boron nitride and aluminum nitride.
Further, the binder is one or more of water-based epoxy resin and water-based phenolic resin.
According to the formula, one or more materials of mullite, cordierite, corundum, silicon carbide and silicon nitride are used as main base materials, the chopped carbon fibers are used as reinforcing materials, through the interaction of the base materials and the reinforcing materials, the base materials can form a crystal boundary, the integral structure, high density, high strength and high heat conductivity are maintained, the anisotropic combination of the reinforcing materials and the difference of the base materials are interweaved in the structure, the heat conductivity and strength of the chopped carbon fibers are far greater than those of the base materials, and meanwhile, the heat shrinkage performance of the chopped carbon fibers can effectively guarantee the absorption of stress and the high-temperature deformation resistance. The invention adopts normal pressure sintering, the sintering temperature is lower, the compactness is high after sintering, the base material particles are lower in grading, and the nano micro powder is not required to be added, because a quinary or even higher sintering aid system is adopted, the sintering temperature is reduced by aluminum nitrate and yttrium nitrate, aluminum and magnesium can form a solid solution at the same time, yttrium fluoride can also increase the heat conduction, and all the sintering aids can increase the compactness to the maximum extent.
The invention also provides a process for producing kiln furniture by using the formula, which comprises the following steps:
firstly, weighing raw materials with corresponding weights according to the formula, if the base materials are a mixture, mixing the base materials, and storing the mixture and other raw materials in the formula separately for later use;
secondly, adding half of the total amount of the base materials into a stirring tank in sequence, adding all carbon fibers, sintering aids and carbon fiber aids, and stirring at a stirring speed of 30-200 rpm for 1-60 minutes to obtain a mixed material I;
step three, keeping the stirring speed of the previous step, adding all the binder and the dispersing agent, adding 10-20 parts of water, stirring for 1-60 minutes, adding the rest base material for three times, wherein the addition interval is 5 minutes each time, and obtaining a mixed material II;
and fourthly, forming, drying and sintering the mixed material II to obtain a finished kiln furniture product.
Furthermore, in the fourth step, the shaping mode is 3D prints the shaping, can use photocuring pottery 3D printer, through the resin in the laser curing compounding to rapid prototyping avoids the drying process, and direct sintering fires through this mode and can obtain various special dimensions and special-shaped body decking, bounding wall, integration casket box dry billet.
Further, in the drying process of the fourth step, the kneaded and molded kiln furniture blank is dried twice, wherein the first drying is normal temperature drying for 24 hours, the second drying is high temperature drying, the drying temperature is 200-300 ℃, and the drying time is 2 hours.
The invention has the beneficial effects that:
1. advantages of the formula
a) Adding waterborne epoxy resin which is used as a silicon carbide-alumina-silicon dioxide matrix binder at normal temperature to ensure that the viscosity and compactness of the base material are enhanced when the base material is stirred and proportioned, and keeping the shape of the base material fixed when the pressing block is obtained. When the temperature is raised and cured, the water-based epoxy resin can also be used as a bundling agent, the resin phase solubility is exerted, and the hardness of the chopped carbon fibers is enhanced by combining the chopped carbon fibers, so that the carbon fibers are not easy to break during stirring while the matrix strength of the carbon fibers is further enhanced. (the carbon fiber is protected as a solvent during mixing, and is hardened during curing);
b) the length of the chopped carbon fiber is controlled within 3-50mm according to the formula, the stirring strength and the stirring time are controlled during mixing, the chopped carbon fiber is fully dispersed in a base material, the breakage of the chopped carbon fiber is reduced, meanwhile, boric acid is added during stirring to improve the oxidation resistance of the carbon fiber, and when a resin material is carbonized to form pores during sintering, boron oxide obtained by decomposition of the boric acid can form glass-state filled pores, bond the base material and strengthen the compactness;
c) most substances added in the formula can play a role of a sintering aid, carbon fibers have high strength, a carbon boron aluminum system is also a sintering aid, and a small amount of the carbon fibers can play a good effect, boron enhances the oxidation resistance of the carbon fibers and promotes precipitation of crystal boundaries to enhance compactness, aluminum and yttrium reduce the sintering temperature, aluminum and magnesium form solid solution with a base material, and yttrium fluoride enhances the sintering compactness and enhances heat conduction;
d) the silicon nitride in the formula can effectively enhance the wear-resisting property of the kiln furniture, and the nitrates in the aluminum nitrate and the yttrium nitrate can help the silicon nitride to be dispersed more uniformly to achieve better wear-resisting property;
e) the technology can adopt a 3D printing forming process, is quick in forming, free from drying and capable of manufacturing kiln furniture with specified dimensions.
2. The sintered kiln furniture has the advantages that:
a) high heat conduction, high strength, thermal deformation resistance, thermal shock resistance, oxidation resistance, wear resistance and long service life;
b) the prepared kiln furniture has higher normal temperature and high temperature bending strength, can be effectively applied to various sintering scenes and is not limited to foamed ceramics;
c) the heat conductivity coefficient is higher, can effectively utilize the heat, prevents the resource loss.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to examples, but it will be understood by those skilled in the art that the following examples are only illustrative of the present invention and should not be construed as limiting the scope of the present invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially. In this embodiment, the chopped carbon fibers are byproducts in the preparation of the refractory material for the Jinbo crucible
Example 1
The carbon fiber kiln furniture comprises the following components in parts by weight:
70 parts of base material, wherein the weight ratio of cordierite: mullite = 4: 3, wherein the grain diameter of cordierite is 50 μm, and the grain diameter of mullite is 30 μm;
20 parts of short carbon fibers, wherein the length of the short carbon fibers is 5-10 mm, and the diameter of the short carbon fibers is 7 mm;
the total parts of the sintering aid are 6 parts, and the specific parts are as follows: yttrium oxide: lanthanum oxide: magnesium oxide = 3: 0.5: 0.5: 2, the particle size of the sintering aid is 50 μm;
the carbon fiber additive is 2 parts of boric acid;
3 parts of binder, adopting water-based epoxy resin,
1 part of dispersant is sodium hydroxymethyl cellulose.
The preparation process comprises the following steps:
weighing the raw materials according to the proportion, and uniformly mixing the base materials; adding half (35 parts) of the base material, all the carbon fibers, the sintering aid and the carbon fiber aid, stirring at a stirring speed of 100rpm for 10 minutes, adding all the binder and the dispersing agent, adding 10 parts of water, stirring for 10 minutes, adding the rest of the base material for three times, wherein the addition interval is 5 minutes each time, and stirring for 10 minutes after all the materials are added. Kneading by a kneader to obtain a green body of the shed board, drying for 24h at normal temperature, then drying for 2h at 200 ℃, introducing inert gas, raising the temperature to 1450 ℃ at the rate of 4 liters per minute, sintering for 3h, taking out and cooling to obtain the shed board.
To verify the performance of the products produced according to the formulations of this example, a set of control experiments were conducted to maintain the consistency of the materials and process except that no chopped carbon fiber was added to the control experiments, as shown in table 1 below, wherein No. 1 represents the product produced in this example and No. 2 represents the product of the control experiments
As can be seen from table 1, the carbon fiber is added into the cordierite-mullite shed plate, although the density is reduced by 0.1, the breaking strength is obviously improved, wherein the breaking strength at normal temperature is increased by 23MPa, the breaking strength at 1200 ℃ is increased by 22 MPa, the expansion coefficient is reduced to 1.69, and the thermal conductivity is increased to 19.6, so that the high-temperature resistance of the shed plate is better, the sintering heat transfer effect of the foamed ceramic is better, the thermal shock stability is good, and the service life is prolonged.
Example 2
The carbon fiber kiln furniture comprises the following components in parts by weight:
80 parts of a base material, wherein mullite: corundum = 3: 1, wherein corundum is 50 μm, and mullite is 30 μm;
15 parts of short carbon fibers, wherein the length of the short carbon fibers is 5-10 mm, and the diameter of the short carbon fibers is 7 mm;
the total parts of the sintering aid are 6 parts, wherein the parts of aluminum nitrate, yttrium nitrate, lanthanum oxide and magnesium oxide are 2: 1: 1: 2, the particle size of the sintering aid is 50 μm;
2 parts of carbon fiber auxiliary agent, namely boron nitride;
2 parts of binder, adopting water-based epoxy resin,
1 part of dispersant which is sodium hydroxymethyl cellulose.
The preparation process comprises the following steps:
weighing the raw materials according to the proportion, and uniformly mixing the base materials;
adding half (40 parts) of base material, all carbon fibers, sintering aid and carbon fiber aid into a stirrer, stirring at a stirring speed of 100rpm for 10 minutes, adding all binder and dispersant, adding 10 parts of water, stirring for 10 minutes, adding the rest base material for three times, wherein the addition interval is 5 minutes each time, and stirring for 10 minutes after all materials are added.
Kneading by a kneader to obtain a green body of the shed board, drying for 24h at normal temperature, then drying for 2h at 200 ℃, introducing inert gas, raising the temperature to 1550 ℃ at the rate of 4 liters per minute, sintering for 4h, taking out and cooling to obtain the shed board.
To verify the performance of the products produced according to the formulations of this example, a set of control experiments were conducted to maintain the consistency of the materials and process except that no chopped carbon fiber was added to the control experiments, as shown in table 2 below, wherein No. 1 represents the product produced in this example and No. 2 represents the product of the control experiments.
According to the table 2, the addition of the carbon fiber can obviously improve the breaking strength of the corundum-mullite shed plate, and the expansion coefficient is much lower, which shows that the high temperature resistance is greatly increased after the carbon fiber is added, the compactness is further increased, the thermal shock stability is enhanced, and the thermal conductivity is also improved.
Example 3
The carbon fiber kiln furniture comprises the following components in parts by weight:
60 parts of silicon carbide, wherein the particle size of 10 microns is as follows: particle size 20 μm: 50 μm particle size = 3: 1: 2;
10 parts of short carbon fibers, wherein the length of the short carbon fibers is 5-10 mm, and the diameter of the short carbon fibers is 7 mm;
the total parts of the sintering aid are 4 parts, and the parts ratio of aluminum nitrate, yttrium oxide, lanthanum oxide, yttrium fluoride and magnesium oxide is = 1: 0.5: 1: 0.5: 1, and the particle sizes are all 50 mu m;
3 parts of carbon fiber additive, namely boric acid;
8 parts of a binder, namely water-based epoxy resin;
1 part of dispersant is sodium carboxymethyl cellulose
The preparation process comprises the following steps:
weighing the raw materials according to the proportion, and uniformly mixing the base materials;
adding 30 parts of 10-micron-size silicon carbide, all carbon fibers, a sintering aid and a carbon fiber aid, stirring at a stirring speed of 100rpm for 10 minutes, adding all binders and dispersants, adding 10 parts of water, stirring for 10 minutes, adding the rest of the base materials for three times at an interval of 5 minutes each time, and stirring for 10 minutes after all the materials are added.
And manufacturing a green body of the shed plate by using a photocuring ceramic 3D printer, feeding the green body into a sintering kiln, introducing inert gas, raising the temperature to 1750 ℃ at the rate of 5 liters per minute, sintering for 3 hours, taking out and cooling to obtain the shed plate.
To verify the performance of the products produced according to the formulations of this example, a set of control experiments were conducted to maintain the consistency of the materials and process except that no chopped carbon fiber was added to the control experiments, as shown in table 3 below, wherein No. 1 represents the product produced in this example and No. 2 represents the product of the control experiments.
According to table 3, the silicon carbide deck board added with the carbon fibers has the advantages that the volume density is reduced, but the effect of light weight and greatly increased strength is achieved, the carbon fibers and the silicon carbide have good conformity, the material has special tightness, the heat conductivity coefficient is also greatly increased, and the carbon fibers are used as the bonding material of the silicon carbide kiln furniture, so that various high-temperature resistance performances of the silicon carbide kiln furniture can be enlarged.
The present invention is not limited to the above embodiments, and various combinations and modifications of the above technical features may be provided for those skilled in the art, and modifications, variations, equivalents, or uses of the structure or method of the present invention in other fields without departing from the spirit and scope of the present invention are included in the protection scope of the present invention.
Claims (10)
1. The carbon fiber kiln furniture formula is characterized in that: the material comprises, by weight, 50-80 parts of a base material, 0.1-20 parts of carbon fibers, 0.1-8 parts of a sintering aid, 0.1-5 parts of a carbon fiber aid, 1-10 parts of a binder and 0.1-4 parts of a dispersing agent; the base material is one or more of mullite, cordierite, corundum, silicon carbide and silicon nitride.
2. The formulation of claim 1, wherein: the base material has a particle size of 10 to 50 μm, a thermal conductivity of 10 to 100W/mK, and a thermal expansion coefficient of 1 to 10 x 10-6。
3. The formulation of claim 1, wherein: the carbon fiber is a chopped carbon fiber with the length of 1-100 mm and the diameter of 5-22 mm, the heat conductivity is 100-700W/mK, and the thermal expansion coefficient is (-1) -5 multiplied by 10-6。
4. The formulation of claim 1, wherein: the carbon fibers are carbon-based fiber residues separated from byproducts in the processing process of the carbon-based composite material.
5. The formulation of claim 1, wherein: the sintering aid comprises an aluminum compound, a magnesium compound and a rare earth material, wherein the aluminum compound is one or more of aluminum oxide and aluminum nitrate; the magnesium compound is one or more of magnesium oxide and magnesium nitrate; the rare earth material is one or more of yttrium nitrate, yttrium oxide, lanthanum oxide and yttrium fluoride.
6. The formulation of claim 1, wherein: the carbon fiber auxiliary agent is one or more of boric acid, borax, ascharite, boron nitride and aluminum nitride.
7. The formulation of claim 1, wherein: the binder is one or more of waterborne epoxy resin and waterborne phenolic resin.
8. A carbon fiber kiln furniture preparation process is characterized in that the formula of any one of claims 1 to 7 is used, and the preparation process specifically comprises the following steps:
firstly, weighing raw materials with corresponding weights according to the formula, if the base materials are a mixture, mixing the base materials, and storing the mixture and other raw materials in the formula separately for later use;
secondly, adding half of the total amount of the base materials into a stirring tank in sequence, adding all carbon fibers, sintering aids and carbon fiber aids, and stirring at a stirring speed of 30-200 rpm for 1-60 minutes to obtain a mixed material I;
step three, keeping the stirring speed of the previous step, adding all the binder and the dispersing agent, adding 10-20 parts of water, stirring for 1-60 minutes, adding the rest base material for three times, wherein the addition interval is 5 minutes each time, and obtaining a mixed material II;
and fourthly, forming the mixed material II to obtain a kiln furniture blank, drying and sintering to obtain a finished kiln furniture product.
9. The process according to claim 8, characterized in that: and in the fourth step, 3D printing equipment is used for printing and forming, the materials are changed into kiln furniture blanks in corresponding shapes through the 3D printing equipment according to the predesigned shapes, and kiln furniture products in corresponding sizes and shapes are obtained after sintering the kiln furniture blanks.
10. The process according to claim 8, characterized in that: and in the fourth step, kneading and molding are adopted to obtain a kiln furniture blank, and the kiln furniture blank is dried twice, wherein the first drying is normal-temperature drying for 24 hours, the second drying is high-temperature drying, the drying temperature is 200-300 ℃, and the drying time is 2 hours.
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Application publication date: 20220527 |