阅读说明：本技术 一种陶瓷预制体及其制备方法、陶瓷耐磨结构及耐磨件 (Ceramic preform and preparation method thereof, ceramic wear-resistant structure and wear-resistant part ) 是由 李伶 屈忠宝 陈学江 王再义 王营营 刘时浩 吕佳琪 徐丹丹 巩晓霖 于 2019-08-14 设计创作，主要内容包括：本发明涉及一种陶瓷预制体及其制备方法、陶瓷耐磨结构及耐磨件。通过将基于光固化3D打印工艺制备的陶瓷素坯烧结、镀镍处理制得陶瓷预制体,所得陶瓷预制体为泡沫结构的半球体或球体,该半球形或球形结构的设置,使陶瓷预制体在受到外力作用时,基体能够给予外表面最大的支撑作用,且由于经镀镍处理,所以预制体对浇铸金属熔液具有较好的浸润性,便于浇铸过程中金属熔液渗入陶瓷预制体的空腔内部与预制体复合成为一体起到支撑作用,提高整体的耐磨韧性,且结合牢固,不易破损、剥落。根据耐磨件不同部位受到磨损的程度和强度不同,配置陶瓷预制体或陶瓷耐磨结构,满足耐磨件特殊部位的耐磨需求,提高整体的耐磨韧性,延长寿命,降低其维护周期。(The invention relates to a ceramic preform, a preparation method thereof, a ceramic wear-resistant structure and a wear-resistant part. The ceramic biscuit prepared based on the photocuring 3D printing process is sintered and is subjected to nickel plating treatment to prepare a ceramic prefabricated body, the obtained ceramic prefabricated body is a hemisphere or a sphere of a foam structure, the hemisphere or the sphere is arranged, so that when the ceramic prefabricated body is subjected to external force, the base body can provide the largest supporting effect for the outer surface, and the ceramic prefabricated body has better wettability to cast molten metal due to the nickel plating treatment, the molten metal is convenient to permeate into the cavity of the ceramic prefabricated body in the casting process and is compounded with the prefabricated body into a whole to play a supporting role, the whole wear-resisting toughness is improved, and the ceramic prefabricated body is firm in combination, and is not easy to damage and peel off. According to different degrees and different strengths of abrasion on different parts of the abrasion-resistant part, a ceramic prefabricated body or a ceramic abrasion-resistant structure is configured, the abrasion-resistant requirement on the special part of the abrasion-resistant part is met, the integral abrasion-resistant toughness is improved, the service life is prolonged, and the maintenance period is shortened.)

1. A method of preparing a ceramic preform for use as a wear reinforcement for wear resistant equipment, the method comprising the steps of:

preparing a ceramic biscuit by using the photo-curable 3D printing ceramic slurry based on a photo-curable 3D printing process, wherein the ceramic biscuit is a hemisphere or a sphere with a foam structure;

and sintering and nickel plating the ceramic biscuit to obtain the ceramic preform.

2. The method for preparing a ceramic preform according to claim 1, wherein the photocurable 3D printing ceramic slurry comprises, in parts by weight:

25-45 parts of first ceramic powder, 6-10 parts of second ceramic powder, 35-55 parts of a light-cured resin system, 1-10 parts of a dispersing agent and 0.1-1 part of an auxiliary agent, wherein the first ceramic powder provides hardness for the ceramic preform, and the second ceramic powder provides toughness for the ceramic preform.

3. The method of claim 2, wherein the first ceramic powder comprises Al₂O₃Powder, the second ceramic powder comprises ZrO₂The powder and the light-cured resin system comprise acrylic resin and a photoinitiator, wherein the weight ratio of the acrylic resin to the photoinitiator is 70-95: 0.2-5.

4. The method of preparing a ceramic preform according to claim 3, wherein the acrylic resin comprises one of dipropylene glycol acrylate, tripropylene glycol diacrylate, bisphenol A epoxy acrylate, and hydroxyethyl methacrylate;

the photoinitiator comprises one or more of TPO photoinitiator, 1173 photoinitiator, 819 photoinitiator and 659 photoinitiator;

the dispersing agent comprises one or more of ammonium polyacrylate, triethyl phosphate, castor oil, a silane coupling agent KH550 and a silane coupling agent KH 560;

the auxiliary agent comprises at least one of a leveling agent, a defoaming agent and a diluting agent.

5. The method of producing a ceramic preform according to claim 4, wherein at least one of the following is satisfied,

uniformly mixing a photoinitiator with photosensitive resin, then mixing with a dispersant, an auxiliary agent, second ceramic powder and first ceramic powder, uniformly mixing in a stirring mill or a ball mill to obtain the photocurable 3D printing ceramic slurry, and forming a ceramic biscuit by a photocuring 3D printer;

and drying and removing the adhesive from the ceramic biscuit, and sintering to obtain the ceramic preform.

6. The method for preparing a ceramic preform as claimed in any one of claims 1 to 5, wherein the ceramic green body is dried, de-glued at 900 ℃ and sintered at 1680 ℃ and 1500 ℃.

7. A ceramic preform obtained by the method according to any one of claims 1 to 6, wherein the ceramic preform is a hemisphere or sphere of a foam structure produced on the basis of a photocuring 3D printing process, and the ceramic preform is used as a wear reinforcement of a wear-resistant material.

8. A ceramic wear-resistant structure, comprising a ceramic preform obtained by the method according to claim 6 and a first metal substrate, wherein the ceramic preform and the first metal substrate are combined together by casting a first metal melt to form a three-dimensional two-phase interconnected integrated structure.

9. A wear-resistant part, which is characterized by comprising the ceramic prefabricated body of claim 7 or the ceramic wear-resistant structure of claim 8 distributed in the wear-resistant part, wherein the distribution positions and the arrangement modes of the ceramic prefabricated body or the ceramic wear-resistant structure in the wear-resistant part are configured according to the strength and the quantity of friction actions performed by each part of the wear-resistant part, and the ceramic prefabricated body or the ceramic wear-resistant structure and the wear-resistant part are compounded together in a mode of casting second molten metal to form a three-dimensional two-phase intercommunicated integrated structure.

10. A wear part in accordance with claim 9, characterized by being a wear part for use in a cement vertical mill.

Technical Field

The invention belongs to the field of composite wear-resistant materials, and particularly relates to a ceramic preform and a preparation method thereof, a ceramic wear-resistant structure and a wear-resistant part.

Background

The metal ceramic composite material is a composite material prepared by combining high hardness and high wear resistance of ceramic and high toughness of metal, and has a great application prospect in the wear-resistant fields of cement, coal electricity or ore and the like. In the traditional process, a ceramic preform is prepared by a dry pressing method, and is placed in a sand mold for casting after being subjected to surface nickel plating treatment, so that the metal ceramic composite wear-resistant part is obtained, and the wear resistance of the metal ceramic composite wear-resistant part is superior to that of a single metal wear-resistant material.

However, in the practical application process of industrial wear-resistant equipment, the wear degrees and strengths of different parts of the wear-resistant part are different, and the single pressing die cannot meet the wear-resistant requirements of the special parts. The ceramic wear-resistant structure can be added at a specific position in a mode of optimizing the structure, and the working efficiency of the whole wear-resistant part is improved.

Disclosure of Invention

In order to solve the technical problems, the invention aims to provide a ceramic preform and a preparation method thereof, a ceramic wear-resistant structure and a wear-resistant part.

According to an aspect of the present invention, there is provided a method of preparing a ceramic preform for a wear-resistant reinforcement of a wear-resistant device, the method comprising the steps of:

preparing a ceramic biscuit by using the photo-curable 3D printing ceramic slurry based on a photo-curable 3D printing process, wherein the ceramic biscuit is a hemisphere or a sphere with a foam structure;

and sintering and nickel plating the ceramic biscuit to obtain the ceramic preform.

The sintered compact ceramic structure of the ceramic biscuit is coarsened, sensitized and activated, then placed in a plating solution, and reacted for 1-2h under the condition of water bath at 80-90 ℃ to carry out nickel plating treatment, so as to obtain a final alloyed ceramic preform, referring to the nickel plating method introduced in patent CN 101748348A.

Wherein, the plating solution comprises the following components: 30g/L of nickel sulfate, 20g/L of sodium hypophosphite, 10mL/L of 40% hydrofluoric acid, 10g/L of ammonium bifluoride and 30mL/L of ammonia water; the pH value of the plating solution is controlled to be about 6.5 by the complexing agent.

The coarsening agent is hydrofluoric acidOne of an acid or concentrated hydrochloric acid; the sensitizer is stannous chloride (SnCl)₂) And hydrochloric acid, wherein the component of the sensitizing agent is 25g/L SnCl₂10ml/L HCl; the activator is palladium chloride (PdCl)₂) And hydrochloric acid, the activator component is PdCl of 0.25g/ml₂10ml/L HCl.

Further, the raw materials of the photocurable 3D printing ceramic slurry comprise, by weight:

25-45 parts of first ceramic powder, 6-10 parts of second ceramic powder, 35-55 parts of a light-cured resin system, 1-10 parts of a dispersing agent and 0.1-1 part of an auxiliary agent, wherein the first ceramic powder provides hardness for the ceramic preform, and the second ceramic powder provides toughness for the ceramic preform.

Further, the first ceramic powder includes Al₂O₃Powder, the second ceramic powder comprises ZrO₂The powder and the light-cured resin system comprise acrylic resin and a photoinitiator, wherein the weight ratio of the acrylic resin to the photoinitiator is 70-95: 0.2-5. The first ceramic powder is made of Al₂O₃The powder is characterized in that the alumina ceramic has high hardness and excellent wear resistance, which is equal to 260 times of manganese steel, and is particularly suitable for preparing metal ceramic composite wear-resistant materials. The aluminum oxide ceramic is selected for use in the patent, the cost is low, and the wear resistance of the metal matrix can be greatly improved by preparing the composite material. The ZrO is introduced into the alumina ceramic system₂Powder, specifically 3mol Y₂O₃-ZrO₂The (YSZ) powder is prepared by improving the toughness of the ceramic prefabricated structural part by using zirconium oxide, and is beneficial to prolonging the service life of the wear-resistant part. When the wear-resistant part is subjected to high-strength friction and wear, the wear-resistant part not only needs to be made of a material with high strength and high hardness, but also needs to have certain friction toughness, so that the service life is prolonged, and the maintenance period of equipment is shortened. In the photocuring forming process, a small amount of zirconia ceramics is introduced, an alumina-zirconia ceramic biscuit is prepared by integral photocuring forming, and a ceramic preform for casting a wear-resistant part can be obtained by sintering and nickel plating.

Further, the acrylic resin comprises one of dipropylene glycol acrylate, tripropylene glycol diacrylate, bisphenol A epoxy acrylate and hydroxyethyl methacrylate;

the photoinitiator comprises one or more of TPO photoinitiator (2,4, 6-trimethylbenzoyl-diphenyl phosphorus oxide), 1173 photoinitiator (2-hydroxy-2-methyl-1-phenyl-1-acetone), 819 photoinitiator [ bis (2,4, 6-trimethylbenzoyl) phenyl phosphorus oxide ] and 659 photoinitiator { 2-hydroxy-2-methyl-1- [4- (2-hydroxyethoxy) phenyl ] -1-acetone };

the dispersing agent comprises one or more of ammonium polyacrylate, triethyl phosphate, castor oil, a silane coupling agent KH550 and a silane coupling agent KH 560;

the auxiliary agent comprises at least one of a leveling agent, a defoaming agent and a diluting agent.

Further, the method for preparing a ceramic preform satisfies at least one of the following conditions,

uniformly mixing a photoinitiator with photosensitive resin, then mixing with a dispersant, an auxiliary agent, second ceramic powder and first ceramic powder, uniformly mixing in a stirring mill or a ball mill to obtain the photocurable 3D printing ceramic slurry, and forming a ceramic biscuit by a photocuring 3D printer;

and drying and removing the adhesive from the ceramic biscuit, and sintering to obtain the ceramic preform. The ceramic biscuit is dried in an oven at 60-80 ℃, the glue is discharged at the temperature of 900 ℃ under the temperature of 300-.

According to another aspect of the present invention, there is provided a ceramic preform obtained by any one of the above methods, wherein the ceramic preform is a hemisphere or sphere of a foam structure prepared based on a photocuring 3D printing process, and the ceramic preform is used as a wear-resistant reinforcement of a wear-resistant material.

According to another aspect of the invention, a ceramic wear-resistant structure is provided, which comprises the ceramic preform obtained by the method and a first metal base body, wherein the ceramic preform and the first metal base body are compounded together by casting a first metal melt to form a three-dimensional two-phase intercommunicated integrated structure.

According to another aspect of the invention, a wear-resistant part is provided, which comprises the ceramic prefabricated body or the ceramic wear-resistant structure distributed in the wear-resistant part, the distribution positions and the arrangement modes of the ceramic prefabricated body or the ceramic wear-resistant structure in the wear-resistant part are configured according to the strength and the quantity of friction actions performed by each part of the wear-resistant part, and the ceramic prefabricated body or the ceramic wear-resistant structure and the wear-resistant part are compounded together in a mode of casting a second molten metal to form a three-dimensional two-phase interconnected integrated structure.

Furthermore, the wear-resistant part is a wear-resistant part applied to a cement vertical mill, and particularly is a grinding disc or a grinding roller part of the cement vertical mill.

Compared with the prior art, the invention has the following beneficial effects:

1. according to the preparation method of the ceramic preform, the ceramic biscuit prepared based on the photocuring 3D printing process is sintered and subjected to nickel plating treatment to prepare the ceramic preform, the ceramic biscuit is a hemisphere or a sphere with a foam structure, the obtained ceramic preform is also a hemisphere or a sphere with a corresponding foam structure, the hemisphere or the sphere structure is arranged, when the ceramic preform is subjected to external force, the base body can provide the largest supporting effect on the outer surface, and the preform has better wettability on casting molten metal due to the nickel plating treatment, so that the molten metal is easy to permeate into the cavity of the ceramic preform in the casting process to be compounded with the preform to form a whole to play a supporting role, the integral wear resistance and toughness are improved, the bonding is firm, and the ceramic preform is not easy to damage or peel.

2. According to the ceramic preform disclosed by the invention, the ceramic preform is a hemisphere or a sphere of a foam structure prepared based on a photocuring 3D printing process, and the ceramic preform is used as a wear-resistant reinforcement of a wear-resistant material, so that the ceramic preform can provide the maximum supporting effect for the outer surface when an external force is applied, and the wear-resistant strength of the wear-resistant material is improved.

3. According to the ceramic wear-resistant structure disclosed by the invention, the ceramic prefabricated body is a hemisphere or a sphere of a foam structure, and the ceramic prefabricated body and the first metal base body are compounded together in a mode of casting the first metal melt to form a three-dimensional two-phase intercommunicated integrated structure, so that the wear resistance is high.

4. The ceramic prefabricated body or the ceramic wear-resistant structure is distributed in the wear-resistant part, the ceramic prefabricated body or the ceramic wear-resistant structure is a hemisphere or a sphere with a foam structure, when the ceramic prefabricated body or the ceramic wear-resistant structure is acted by an external force, the base body can provide the largest supporting effect for the outer surface, the wear resistance is good, the ceramic prefabricated body or the ceramic wear-resistant structure and a metal melt are compounded together through casting to form the wear-resistant part with a three-dimensional two-phase intercommunication integrated structure, the distribution positions and the arrangement mode of the ceramic prefabricated body or the ceramic wear-resistant structure in the wear-resistant part are configured according to the strength and the number of friction actions executed by each part of the wear-resistant part, and the ceramic prefabricated body or the ceramic wear-resistant structure can be configured according to different degrees and different strengths of wear of different parts of the wear-resistant part in the actual application process of industrial wear-resistant, the wear-resistant part meets the wear-resistant requirement of a special part of the wear-resistant part, improves the integral wear-resistant toughness of the wear-resistant part, prolongs the service life, reduces the maintenance period, improves the working efficiency of the integral wear-resistant part, and is worthy of popularization.

Drawings

FIG. 1 is a schematic view of a foam structure hemisphere ceramic preform according to an embodiment;

FIG. 2 is a schematic view of a grinding roll of a vertical cement mill according to an embodiment.

Detailed Description

In order to better understand the technical scheme of the invention, the invention is further explained by combining the drawings and the specific embodiments in the specification.