阅读说明：本技术 一种耐磨锆铝复合球及制备方法 (Wear-resistant zirconium-aluminum composite ball and preparation method thereof ) 是由 杨海涛 夏维煌 黄旭高 唐彦军 唐涛 于 2021-08-24 设计创作，主要内容包括：本发明公开了一种耐磨锆铝复合球及制备方法,所述耐磨锆铝复合球由氧化铝粉、废锆刚玉粉和烧结助剂制成,其化学组分按质量分数计包括：Al-(2)O-(3)75～90％,ZrO-(2)1～15％,SiO-(2)1～6％,CaO+MgO+稀土1～5％,K-(2)O+Na-(2)O 0～2％。所述耐磨锆铝复合球的耐磨性能和机械性能良好,原料成本低廉、来源丰富,可实现固体废弃物利用。(The invention discloses a wear-resistant zirconium-aluminum composite ball and a preparation method thereof, wherein the wear-resistant zirconium-aluminum composite ball is prepared from alumina powder, waste zirconium corundum powder and a sintering aid, and comprises the following chemical components in parts by mass: al (Al) 2 O 3 75～90％，ZrO 2 1～15％，SiO 2 1-6% of CaO, MgO and rare earth, 1-5% of K 2 O+Na 2 0-2% of O. The wear-resistant zirconium-aluminum composite ball has good wear resistance and mechanical property, low cost of raw materials and rich sources, and can realize the utilization of solid wastes.)

1. The wear-resistant zirconium-aluminum composite ball is characterized by being prepared from alumina powder, waste zirconium-corundum powder and a sintering aid, and comprising the following chemical components in parts by mass: al (Al)₂O₃ 75～90％，ZrO₂ 1～15％，SiO₂1-6% of CaO, MgO and rare earth, 1-5% of K₂O+Na₂O 0～2％。

2. The wear-resistant zirconium-aluminum composite ball as claimed in claim 1, wherein the wear-resistant zirconium-aluminum composite ball comprises the following raw materials in parts by mass: 50-90% of alumina powder, 1-45% of waste zirconium corundum powder and 1-20% of sintering aid.

3. The wear-resistant zirconium-aluminum composite ball as claimed in claim 2, wherein the alumina powder is one or more of industrial alumina powder, bauxite, waste corundum bricks and waste ceramic roller bars;

the chemical components of the alumina powder comprise the following components in percentage by mass: al (Al)₂O₃≥65％，SiO₂≤20％，K₂O+Na₂O≤2％。

4. The wear-resistant zirconium-aluminum composite ball according to claim 2, wherein the waste zirconium corundum powder is waste zirconium corundum bricks, and the chemical components of the waste zirconium corundum powder comprise the following components in percentage by mass: ZrO (ZrO)₂≥25％，SiO₂Not more than 20%, K₂O+Na₂O≤2％。

5. The wear-resistant zirconium-aluminum composite ball of claim 1, wherein the sintering aid comprises one or more of talc, dolomite, wollastonite, bentonite, kaolin, garnet, titanium dioxide, magnesite, and calcium carbonate.

6. The wear-resistant zirconium-aluminum composite ball of claim 1, wherein the volume density of the wear-resistant zirconium-aluminum composite ball is 3.6 to 3.8g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

7. A preparation method of the wear-resistant zirconium-aluminum composite balls as claimed in any one of claims 1 to 6, characterized by comprising the following steps:

s1, adding the raw materials of the wear-resistant zirconium-aluminum composite balls into a ball mill according to the proportion, adding the dispersion solution, and uniformly mixing to obtain slurry;

s2, granulating the slurry to obtain dry powder;

s3, carrying out cold isostatic pressing or pellet forming on the powder, and then drying to prepare a blank pellet;

and S4, sintering the blank balls in a kiln, cooling the kiln, and taking out to obtain the wear-resistant zirconium-aluminum composite balls.

8. The method for preparing wear-resistant zirconium-aluminum composite balls according to claim 7, wherein in the step of S1, the dispersion solution is a mixture of polyacrylamide, polyvinyl alcohol and water, and the weight ratio of the three is: the dosage of the polyacrylamide: the dosage of polyvinyl alcohol: the dosage of water is (0.1-2): (0.3-3): (96-99);

the granularity of the slurry is D90 is less than or equal to 6 mu m.

9. The method for preparing the wear-resistant zirconium-aluminum composite ball according to claim 7, wherein in the step of S3, the drying conditions are as follows: drying at 50-70 ℃ for 20-30 h;

in step S4, the sintering conditions are:

heating to 200-300 ℃ at the speed of 1-5 ℃/min, preserving the heat for 2-4h,

then heating to 650 plus 750 ℃ at the speed of 1-5 ℃/min, preserving the heat for 3-6h,

then heating to 1000-1200 ℃ at the speed of 1-5 ℃/min, preserving the heat for 1-3h,

then heating to 1350-.

10. The method for preparing the wear-resistant zirconium-aluminum composite ball as claimed in claim 7, wherein the volume density of the wear-resistant zirconium-aluminum composite ball is 3.6-3.8 g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

Technical Field

The invention relates to the field of ceramic balls, in particular to a wear-resistant zirconium-aluminum composite ball and a preparation method thereof.

Background

The ball milling and crushing process is an important basic composition of modern industry. The grinding media balls are the consumable in which consumption is greatest. At present, the alumina grinding ball is the most widely used ceramic grinding medium material and is widely used in the fields of building ceramics, daily ceramics, electronic ceramics, cement mines and the like.

Most of the alumina grinding balls used in the domestic market are single alumina ceramic balls, and obvious ball crushing phenomenon exists in the using process, so that the application of the alumina grinding balls in a continuous ball mill is greatly reduced. The broken ball condition can cause the unbalance of the size grading of the grinding medium, and the ball milling efficiency is influenced. Meanwhile, the abrasion caused by ball crushing is far higher than that under normal conditions, so that the ball crushing rate of the grinding medium balls is very necessary to be further reduced on the premise of ensuring certain specific gravity, abrasion performance and production cost. A small amount of zirconia is added into alumina to form a zirconium-aluminum composite ball, so that the overall strength of the composite ball is improved, and the reduction of the breakage rate is an important measure for the wear-resistant ball.

The zirconium-aluminum series composite balls are active in the market and research and development fields at present. Despite the advantages of high strength and high toughness, the high cost of the steel also makes the market promotion difficult at present. For example, chinese patent application No. 201810958754.6 discloses a high wear-resistant zirconium-aluminum composite ball and a production process thereof, wherein the formula comprises the following components in parts by mass: 95% or more of Al₂O₃≥80％；15％≥ZrO₂≥3％；7％≥ Y₂O₃+SiO₂+CeO₂More than or equal to 1 percent; CaO and MgO in 6-1 wt%, and the used material includes superfine powder and RE material Y₂O₃And the raw material cost is too high. The Chinese patent with application number of 201010257485.4 discloses a zirconium-aluminum composite ceramic bead and a production process thereof, and is characterized in that zirconium silicate and alpha-Al are used as raw materials₂O₃The preparation method comprises the steps of taking feldspar and calcined kaolin as raw materials, taking mullite powder as seed crystal, and preparing the zirconium-aluminum complex phase ceramic beads by adopting a rolling balling method. The raw materials used by the method are fine powder, high-cost zirconium silicate powder and the like, and the cost of the raw materials is high.

Disclosure of Invention

The invention aims to solve the technical problem of providing a wear-resistant zirconium-aluminum composite ball which has good wear resistance and mechanical property, low cost of raw materials and rich sources and can realize the utilization of solid wastes.

The technical problem to be solved by the invention is also to provide the preparation method of the wear-resistant zirconium-aluminum composite ball, which is simple in process and can realize solid waste utilization.

In order to achieve the technical effects, the invention provides a wear-resistant zirconium-aluminum composite ball which is prepared from alumina powder, waste zirconium corundum powder and a sintering aid, and comprises the following chemical components in parts by mass: al (Al)₂O₃ 75～90％，ZrO₂ 1～15％，SiO₂1-6% of CaO, MgO and rare earth, 1-5% of K₂O+Na₂O 0～2％。

Preferably, the wear-resistant zirconium-aluminum composite ball comprises the following raw materials in parts by mass: 50-90% of alumina powder, 1-45% of waste zirconium corundum powder and 1-20% of sintering aid.

Preferably, the alumina powder is one or more of industrial alumina powder, bauxite, waste corundum bricks and waste ceramic roller bars;

the chemical components of the alumina powder comprise the following components in percentage by mass: al (Al)₂O₃≥65％，SiO₂≤20％， K₂O+Na₂O≤2％。

Preferably, useless zirconium corundum powder chooses for use useless zirconium corundum brick, the chemical composition of useless zirconium corundum powder includes according to the mass fraction: ZrO (ZrO)₂≥25％，SiO₂Not more than 20%, K₂O+Na₂O≤2％。

Preferably, the sintering aid comprises one or more of talc, dolomite, wollastonite, bentonite, kaolin, garnet, titanium dioxide, magnesite, calcium carbonate.

Preferably, the volume density of the wear-resistant zirconium-aluminum composite ball is 3.6-3.8 g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

The invention also provides a preparation method of the wear-resistant zirconium-aluminum composite ball, which comprises the following steps:

s1, blank preparation and ball milling: adding the raw materials of the wear-resistant zirconium-aluminum composite balls into a ball mill according to a ratio, adding a dispersion solution, and uniformly mixing to obtain slurry;

s2, drying and granulating: granulating the slurry to obtain dry powder;

s3, forming and drying: carrying out cold isostatic pressing on the powder or forming pellets, and then drying to prepare blank balls;

s4, sintering: and sintering the blank balls in a kiln, cooling the kiln, and taking out the cooled blank balls to obtain the wear-resistant zirconium-aluminum composite balls.

Preferably, in the step S1, the dispersion solution is a mixture of polyacrylamide, polyvinyl alcohol and water, and the weight ratio of the three is: the dosage of the polyacrylamide: the dosage of polyvinyl alcohol: the dosage of water is (0.1-2): (0.3-3): (96-99);

the granularity of the slurry is D90 is less than or equal to 6 mu m.

Preferably, in the step S3, the drying conditions are: drying at 50-70 ℃ for 20-30 h;

in step S4, the sintering conditions are:

heating to 200-300 ℃ at the speed of 1-5 ℃/min, preserving the heat for 2-4h,

then heating to 650 plus 750 ℃ at the speed of 1-5 ℃/min, preserving the heat for 3-6h,

then heating to 1000-1200 ℃ at the speed of 1-5 ℃/min, preserving the heat for 1-3h,

then heating to 1350-.

Preferably, the volume density of the wear-resistant zirconium-aluminum composite ball is 3.6-3.8 g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

The implementation of the invention has the following beneficial effects:

1. the invention provides a wear-resistant zirconium-aluminum composite ball, which comprises the following chemical components in percentage by mass: al (Al)₂O₃ 75～90％，ZrO₂ 1～15％，SiO₂1-6% of CaO, MgO and rare earth, 1-5% of K₂O+Na₂0-2% of O, good wear resistance and mechanical property, and volume density of 3.6-3.8 g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

2. The invention provides a wear-resistant zirconium-aluminum composite ball which comprises the following raw materials: alumina powder, waste zirconium corundum powder and sintering aid. The waste zirconium corundum powder is derived from waste zirconium corundum bricks, monoclinic zirconia in the waste zirconium corundum bricks is used as a second-phase component with the largest content except alumina, a small amount of monoclinic zirconia is introduced to play a second-phase reinforcing mechanism, and meanwhile, the phase change volume effect of the monoclinic zirconia can play a microcrack toughening effect, so that the mechanical property of the zirconium-aluminum composite ball is further improved, and the wear resistance of the zirconium-aluminum composite ball is further improved.

3. The wear-resistant zirconium-aluminum composite ball provided by the invention has the advantages of low raw material cost, rich sources, sufficient varieties and flexible collocation, wherein the alumina powder is derived from one or more of industrial alumina powder, bauxite, waste corundum bricks containing a large amount of alumina and waste ceramic roller bars, and the waste zirconium corundum powder is derived from the waste zirconium corundum bricks. By adopting the fixed waste as the main raw material, the cost can be reduced, the raw material source can be enlarged, and the optimized reutilization of the solid waste can be realized.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail below.

In order to achieve the technical effect, the invention provides a wear-resistant zirconium-aluminum composite ball, which comprises the following chemical components in percentage by mass: al (Al)₂O₃ 75～90％，ZrO₂ 1～15％，SiO₂1-6% of CaO, MgO and rare earth, 1-5% of K₂O+Na₂0-2% of O, good wear resistance and mechanical property, and volume density of 3.6-3.8 g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

According to the invention, the zirconium oxide toughened alumina is used, the silicon dioxide is added in the formula as a glass phase to wrap the periphery of the alumina, and a proper amount of calcium oxide, magnesium oxide and rare earth are added, so that the density and the wear resistance of the zirconium-aluminum composite ball are improved, the final performance and the low cost of the product are optimized by strictly limiting the total content of alkali metal oxides, and the wear-resistant zirconium-aluminum composite ball with good mechanical property and wear resistance can be prepared according to the chemical component proportion provided by the invention.

The invention provides a wear-resistant zirconium-aluminum composite ball which comprises the following raw materials: alumina powder, waste zirconium corundum powder and sintering aid. Specifically, the wear-resistant zirconium-aluminum composite ball comprises the following raw materials in parts by mass: 50-90% of alumina powder, 1-45% of waste zirconium corundum powder and 1-20% of sintering aid;

the waste zirconium corundum powder is derived from waste zirconium corundum bricks, monoclinic zirconia in the zirconium corundum bricks is used as a second-phase component with the largest content except alumina, a small amount of monoclinic zirconia is introduced to play a second-phase reinforcing mechanism, and meanwhile, the phase change volume effect of the monoclinic zirconia can play a microcrack toughening effect, so that the mechanical property of the zirconium-aluminum composite ball is further improved, and the wear resistance of the zirconium-aluminum composite ball is further improved.

In addition, the wear-resistant zirconium-aluminum composite ball is low in raw material cost, rich in sources, sufficient in types and flexible in collocation, wherein the alumina powder is derived from one or more of industrial alumina powder, bauxite, waste corundum bricks containing a large amount of alumina and waste ceramic roller bars, and the waste zirconium corundum powder is derived from the waste zirconium corundum bricks. By adopting the fixed waste as the main raw material, the cost can be reduced, the raw material source can be enlarged, and the optimized reutilization of the solid waste can be realized.

Specifically, the wear-resistant zirconium-aluminum composite ball comprises the following raw materials in parts by mass: 50-90% of alumina powder, 1-45% of waste zirconium corundum powder and 1-20% of sintering aid. The alumina powder is the highest component, because alumina has the advantages of high mechanical strength, high hardness, good chemical resistance and thermal conductivity, and the like. Based on the above characteristics of alumina, the zirconium-aluminum composite balls are endowed with good wear resistance and mechanical strength. The alumina powder is derived from one or more of industrial alumina powder, bauxite, waste corundum bricks and waste ceramic roller bars.

Wherein the industrial alumina powder is alpha-Al as the main component₂O₃The mineral powder of (1). Chemical method for removing Si, Fe from high-aluminium bauxite ore,Ti and other impurities, and calcining at 1300-1400 ℃ to obtain alpha-Al₂O₃. The industrial alumina powder has low price, wide source and high purity of alumina.

Bauxite is also called alumina or bauxite, the main component of which is alumina, which is hydrated alumina containing impurities and is a soil-like mineral. China has abundant bauxite resources, wide purchasing channels and economy.

The corundum brick is a refractory product with alumina content higher than 90% and corundum as main crystal phase. The waste corundum brick is cheap, contains a large amount of available alumina and is a high-quality raw material for producing the zirconium-aluminum composite balls.

The waste ceramic roller bar materials refer to scrap materials generated in the production process of the ceramic roller bar materials, and the waste ceramic roller bar materials cannot be recycled in large quantity and are accumulated inside and outside a factory, so that resources are wasted, and the environment is polluted. The waste ceramic roller bar contains high-content alumina and silica, and the zirconium-aluminum composite ball is prepared by taking the waste ceramic roller bar as a raw material, so that the cost of the zirconium-aluminum composite ball is reduced, the resource reutilization is realized, and the environmental load is reduced.

In the invention, in the raw materials of the zirconium-aluminum composite ball, the mass fraction of the alumina powder is 50-90%, preferably 60-80%. The alumina powder comprises a plurality of chemical components, wherein Al is counted by mass fraction₂O₃≥65％，SiO₂≤20％，K₂O+Na₂O is less than or equal to 2 percent. Preferably, the Al₂O₃75-99% of SiO₂0 to 10%, K₂O+Na₂O is 0 to 1%.

In the formula of the zirconium-aluminum composite ball, besides alumina powder, waste zirconium corundum powder is also an important raw material, the waste zirconium corundum powder is derived from waste zirconium corundum bricks, and the zirconium corundum bricks are ZrO prepared by using industrial alumina powder and selected zircon sand as raw materials₂Refractory products with the content of 33 to 45 percent. The waste zirconia corundum bricks are rich in alumina and zirconia, and monoclinic zirconia in the zirconia corundum bricks is used as a second phase with the largest content except aluminaThe components and a small amount of monoclinic zirconia are introduced to play a second phase reinforcing mechanism, and the phase change volume effect of the monoclinic zirconia can play a microcrack toughening effect, so that the mechanical property of the zirconium-aluminum composite ball is further improved, and the wear resistance of the zirconium-aluminum composite ball is further improved.

In the raw materials of the zirconium-aluminum composite ball, the waste zirconium corundum powder accounts for 1-45% by mass, and preferably the waste zirconium corundum powder accounts for 15-35%. The waste zirconium corundum powder contains a plurality of chemical components, wherein ZrO is calculated according to mass fraction₂≥25％，SiO₂Less than or equal to 20 percent of Na₂O is less than or equal to 2 percent. Preferably, ZrO₂30 to 45 percent of SiO₂0 to 10%, K₂O+Na₂O is 0 to 1%.

In addition, the raw materials of the zirconium-aluminum composite balls comprise a certain proportion of sintering aids, and the sintering aids comprise one or more of talc, dolomite, wollastonite, bentonite, kaolin, garnet, titanium dioxide, magnesite and calcium carbonate. It should be noted that, the kind and amount of the sintering aid can be selected appropriately to meet different requirements. In the raw materials of the zirconium-aluminum composite ball, the sintering aid is 0-20% by mass, and preferably the sintering aid is 1-10%.

The volume density of the wear-resistant zirconium-aluminum composite ball prepared by the raw materials and the mixture ratio is 3.6-3.8 g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

Correspondingly, the preparation method of the wear-resistant zirconium-aluminum composite ball comprises the following steps:

s1, blank preparation and ball milling: adding the raw materials of the wear-resistant zirconium-aluminum composite balls into a ball mill according to a ratio, adding a dispersion solution, and uniformly mixing to obtain slurry;

s2, drying and granulating: granulating the slurry to obtain dry powder;

s3, forming and drying: carrying out cold isostatic pressing on the powder or forming pellets, and then drying to prepare blank balls;

s4, sintering: and sintering the blank balls in a kiln, cooling the kiln, and taking out the cooled blank balls to obtain the wear-resistant zirconium-aluminum composite balls.

The preparation method of the wear-resistant zirconium-aluminum composite ball provided by the invention has the advantages that the process is simple, the raw materials adopt various solid wastes, the comprehensive utilization of the solid wastes can be realized, and the detailed description of the preparation method is provided below.

Specifically, in the step S1, the raw materials and the mixture ratio of the wear-resistant zirconium-aluminum composite ball are described as follows:

the wear-resistant zirconium-aluminum composite ball comprises the following components in parts by mass: 50-90% of alumina powder, 1-45% of waste zirconium corundum powder and 1-20% of sintering aid. The wear-resistant zirconium-aluminum composite ball comprises the following chemical components in parts by mass: al (Al)₂O₃ 75～90％，ZrO₂ 1～15％，SiO₂1-6% of CaO, MgO and rare earth, 1-5% of K₂O+Na₂O 0～2％。

The alumina powder is derived from one or more of industrial alumina powder, bauxite, waste corundum bricks and waste ceramic roller bars. In the raw materials of the zirconium-aluminum composite ball, the mass fraction of the alumina powder is 50-90%, preferably 60-80%. The alumina powder comprises a plurality of chemical components, wherein Al is counted by mass fraction₂O₃≥65％，SiO₂≤20％，K₂O+Na₂O is less than or equal to 2 percent. Preferably, Al₂O₃75-99% of SiO₂0 to 10%, K₂O+Na₂O is 0 to 1%.

The waste zirconium corundum powder is derived from waste zirconium corundum bricks, and in the raw materials of the zirconium-aluminum composite balls, the waste zirconium corundum powder accounts for 1-45% by mass fraction, and preferably, the waste zirconium corundum powder accounts for 15-35%. The waste zirconium corundum powder contains a plurality of chemical components, wherein ZrO is calculated according to mass fraction₂≥25％，SiO₂Less than or equal to 20 percent of Na₂O is less than or equal to 2 percent. Preferably, ZrO₂30 to 45 percent of SiO₂0 to 10%, K₂O+Na₂O is 0 to 1%.

The sintering aid comprises one or more of talc, dolomite, wollastonite, bentonite, kaolin, garnet, titanium dioxide, magnesite and calcium carbonate. It should be noted that, the kind and amount of the sintering aid can be selected appropriately to meet different requirements. In the raw materials of the zirconium-aluminum composite ball, the sintering aid is 0-20% by mass, and preferably the sintering aid is 1-10%. And adding the raw materials of the wear-resistant zirconium-aluminum composite ball into a ball mill according to a ratio, adding the dispersion solution, and uniformly mixing to obtain slurry. The dispersion solution is a mixture of polyacrylamide, polyvinyl alcohol and water, and the weight ratio of the polyacrylamide to the polyvinyl alcohol to the water is as follows: the dosage of the polyacrylamide: the dosage of polyvinyl alcohol: the dosage of water is (0.1-2): (0.3-3): (96-99). Preferably, the amount of the polyacrylamide is 0.1-0.3%, the amount of the polyvinyl alcohol is 0.3-0.7%, and the balance is water. More preferably, the amount of the polyacrylamide is 0.2%, the amount of the polyvinyl alcohol is 0.4%, and the balance is water.

The mixed slurry is uniformly ground in a ball mill, the particle size of the obtained slurry is reduced along with the improvement of the grinding force, preferably, the particle size of the ground slurry is D90 not more than 6 μm, it is required to be noted that the particle size of the ground slurry is not smaller as better, and generally, the particle size of the ground slurry is D90 of 2-6 μm.

And S2, granulating the slurry to obtain dry powder. Preferably, the slurry is granulated by a spray granulation tower to obtain dry powder. The spray granulation tower has high drying speed, the surface area of the material liquid is greatly increased after atomization, 95-98% of water can be instantly evaporated in hot air flow, and the drying time is only ten seconds to tens of seconds. The obtained powder has uniform particle size, good fluidity and high product purity.

And S3, carrying out cold isostatic pressing or pellet forming on the powder, and then drying to prepare a blank pellet. Wherein the drying conditions are as follows: drying at 50-70 ℃ for 20-30 h, preferably drying at 55-65 ℃ for 24 h.

And S4, sintering the blank balls in a kiln to obtain the wear-resistant zirconium-aluminum composite balls. Wherein the sintering conditions are as follows:

heating to 200-300 ℃ at the speed of 1-5 ℃/min, and preserving heat for 2-4 h;

then heating to 650 plus 750 ℃ at the speed of 1-5 ℃/min, and preserving the heat for 3-6 h;

then heating to 1000-1200 ℃ at the speed of 1-5 ℃/min, and preserving the heat for 1-3 h;

then heating to 1350-.

By adopting the sintering conditions, free water and organic matters can be completely burnt out in the sintering process, and meanwhile, the final microstructure of the product can be ensured to be uniform and compact by proper temperature rise speed and heat preservation time.

It should be noted that the actual sintering conditions of the wear-resistant zirconium-aluminum composite ball need to be determined after the raw material composition, the preparation process and the final product performance requirements of the wear-resistant zirconium-aluminum composite ball are comprehensively considered.

The finally prepared wear-resistant zirconium-aluminum composite ball has good mechanical strength and wear resistance, and specifically, the volume density of the wear-resistant zirconium-aluminum composite ball is 3.6-3.8 g/cm³The grain size is less than or equal to 6 mu m, the abrasion is less than or equal to 0.02 percent, and the compressive strength of a ball with the diameter of 20mm is more than or equal to 50 kN.

For a better understanding of the inventive aspects, the present specification provides the following examples to illustrate:

example 1

A wear-resistant zirconium-aluminum composite ball and a preparation method thereof,

the formula of the raw materials comprises the following components in percentage by mass: 68% of industrial alumina powder, 25% of waste zirconium corundum powder, 1% of talcum, 5% of dolomite and 1% of bentonite.

The chemical components are as follows by mass fraction: al (Al)₂O₃ 81.6％，ZrO₂ 7.6％，SiO₂ 5.2％，CaO 1.7％， MgO 1.4％，K₂O 0.5％，Na₂O 0.7％。

The preparation method of the wear-resistant zirconium-aluminum composite ball comprises the following steps:

s1, blank preparation and ball milling: the raw materials are weighed according to the proportion and added into a ball mill, water, polyacrylamide and polyvinyl alcohol PVA are added, wherein the adding amount of the polyacrylamide is 0.2 percent, the adding amount of the polyvinyl alcohol is 0.4 percent, and the balance is water according to the mass fraction. Ball milling is carried out for a plurality of hours to ensure that the granularity D90 of the slurry is less than or equal to 6 mu m.

S2, drying and granulating: and (4) feeding the slurry into a spray granulation tower for granulation to obtain dry powder.

S3, forming and drying: and (3) carrying out cold isostatic pressing on the powder, wherein the forming pressure is 100MPa, the diameter of a formed rough blank ball is 23mm, drying the rough blank ball for 24 hours at the temperature of 65 ℃, and then sintering.

S4, sintering: and sintering the blank balls in a kiln, cooling the kiln, and taking out the cooled blank balls to obtain the wear-resistant zirconium-aluminum composite balls. The sintering condition is that the temperature is raised to 200 ℃ at the speed of 2 ℃/min, and then the temperature is kept for 2 h; raising the temperature to 750 ℃ again at the speed of 2 ℃/min, and preserving the heat for 3 h; then heating to 1200 ℃ at the speed of 2 ℃/min, and preserving heat for 3 h; then the temperature is raised to 1500 ℃ at the speed of 5 ℃/min, and the temperature is kept for 3 h.

Example 2

The formula of the raw materials comprises the following components in percentage by mass: 74% of industrial alumina powder, 20% of waste zirconium corundum powder, 5% of dolomite and 1% of bentonite.

The chemical components are as follows by mass fraction: al (Al)₂O₃ 85.2％，ZrO₂ 6.1％，SiO₂ 4.9％，CaO 1.6％， MgO 1.7％，K₂O 0.5％，Na₂O 0.7％。

The preparation method of the wear-resistant zirconium-aluminum composite ball comprises the following steps:

s1, material mixing and ball milling: the raw materials are weighed according to the proportion and added into a ball mill, water and polyacrylamide and polyvinyl alcohol PVA are added, wherein the addition amount of the polyacrylamide is 0.2 percent, the addition amount of the polyvinyl alcohol is 0.4 percent, and the balance is water according to the mass fraction. Ball milling is carried out for a plurality of hours to ensure that the granularity D90 of the slurry is less than or equal to 5 mu m.

S2, drying and granulating: and (4) feeding the slurry into a spray granulation tower for granulation to obtain dry powder.

S3, molding and sintering: and (3) pelletizing and forming the powder, wherein the diameter of the pellets is 23mm, drying the rough blank balls for 24 hours at 65 ℃, and then sintering.

S4, sintering: and sintering the blank balls in a kiln, cooling the kiln, and taking out the cooled blank balls to obtain the wear-resistant zirconium-aluminum composite balls. The sintering conditions are as follows: heating to 200 ℃ at the speed of 3 ℃/min, and then preserving heat for 2 h; heating to 750 ℃ at the speed of 3 ℃/min again, and preserving heat for 3 h; then heating to 1200 ℃ at the speed of 3 ℃/min, and preserving heat for 3 h; then the temperature is raised to 1500 ℃ at the speed of 5 ℃/min, and the temperature is kept for 3 h.

Example 3

The formula of the raw materials comprises the following components in percentage by mass: 69% of industrial alumina powder, 10% of waste ceramic roller bar material, 15% of waste zirconium corundum powder, 5% of dolomite and 1% of bentonite.

The chemical components are as follows by mass fraction: al (Al)₂O₃ 85.7％，ZrO₂ 5.0％，SiO₂ 5.5％，CaO 1.6％， MgO 1.1％，K₂O 0.5％，Na₂O 0.6％。

The preparation method of the wear-resistant zirconium-aluminum composite ball comprises the following steps:

s1, material mixing and ball milling: the raw materials are weighed according to the proportion and added into a ball mill, water and polyacrylamide and polyvinyl alcohol PVA are added, wherein the addition amount of the polyacrylamide is 0.2 percent, the addition amount of the polyvinyl alcohol is 0.4 percent, and the balance is water according to the mass fraction. Ball milling is carried out for a plurality of hours to ensure that the granularity D90 of the slurry is less than or equal to 6 mu m.

S2, drying and granulating: and (4) feeding the slurry into a spray granulation tower for granulation to obtain dry powder.

S3, molding and sintering: and (3) pelletizing and forming the powder, wherein the diameter of the pellets is 23mm, drying the rough blank balls for 24 hours at 65 ℃, and then sintering.

S4, sintering: and sintering the blank balls in a kiln, cooling the kiln, and taking out the cooled blank balls to obtain the wear-resistant zirconium-aluminum composite balls. The sintering conditions are as follows: heating to 200 ℃ at the speed of 3 ℃/min, and then preserving heat for 2 h; heating to 750 ℃ at the speed of 3 ℃/min again, and preserving heat for 3 h; then heating to 1200 ℃ at the speed of 3 ℃/min, and preserving heat for 3 h; then raising the temperature to 1480 ℃ at the speed of 5 ℃/min, and preserving the temperature for 3 h.

Example 4

The formula of the raw materials comprises the following components in percentage by mass: 69% of industrial alumina powder, 10% of bauxite, 15% of waste zirconium corundum powder, 5% of dolomite and 1% of bentonite.

The chemical components are as follows by mass fraction: al (Al)₂O₃ 85.5％，ZrO₂ 4.5％，SiO₂ 5.2％，CaO 1.7％， MgO 1.2％，K₂O 0.5％，Na₂O 0.8％。

The preparation method of the wear-resistant zirconium-aluminum composite ball comprises the following steps:

s1, material mixing and ball milling: the raw materials are weighed according to the proportion and added into a ball mill, water and polyacrylamide and polyvinyl alcohol PVA are added, wherein the addition amount of the polyacrylamide is 0.2 percent, the addition amount of the polyvinyl alcohol is 0.4 percent, and the balance is water according to the mass fraction. Ball milling is carried out for a plurality of hours to ensure that the granularity D90 of the slurry is less than or equal to 6 mu m.

S2, drying and granulating: and (4) feeding the slurry into a spray granulation tower for granulation to obtain dry powder.

S3, molding and sintering: and (3) pelletizing and forming the powder, wherein the diameter of the pellets is 23mm, drying the rough blank balls for 24 hours at 65 ℃, and then sintering.

S4, sintering: and sintering the blank balls in a kiln, cooling the kiln, and taking out the cooled blank balls to obtain the wear-resistant zirconium-aluminum composite balls. The sintering conditions are as follows: heating to 200 ℃ at the speed of 2 ℃/min, and then preserving heat for 2 h; heating to 750 ℃ again at the speed of 2 ℃/min, and then, heating for 3 h; then heating to 1200 ℃ at the speed of 2 ℃/min, and preserving heat for 3 h; then raising the temperature to 1480 ℃ at the speed of 5 ℃/min, and preserving the temperature for 3 h.

The wear-resistant zirconium-aluminum composite balls obtained in the embodiments 1 to 4 are tested, and the density, wear, grain size and compressive strength of the wear-resistant zirconium-aluminum composite balls are tested, wherein a wear tester is used for testing wear, a scanning electron microscope is used for representing the grain size of the wear-resistant zirconium-aluminum composite balls, a compressive strength tester is used for testing the compressive strength of the wear-resistant zirconium-aluminum composite balls with the diameter of 20mm, and the test results are shown in table 1.

Table 1 results of performance test of the wear-resistant zirconium-aluminum composite balls obtained in examples 1 to 4

From the above table, it can be seen that the compressive strength of the wear-resistant zirconium-aluminum composite balls obtained in examples 1 to 4, which are balls with a diameter of 20mm, is greater than 50kN, which shows that the wear-resistant zirconium-aluminum composite balls provided by the invention have good mechanical strength. The equivalent wear of the wear-resistant zirconium-aluminum composite balls obtained in the embodiments 1 to 4 is 0.08 to 0.1 per thousand, which shows that the wear-resistant zirconium-aluminum composite balls provided by the invention have good wear resistance.

While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.