颗粒、晶须强韧化碳化硅陶瓷及在密封环中的应用
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摘要
碳化硅陶瓷具有比重小、硬度高、比强度高、耐磨、耐腐蚀、耐高温、抗热震性能良好等特点,被誉为第四代机械密封材料,广泛用于各类特殊工况条件下工业设备和装置的机械密封。目前,工业化生产的碳化硅陶瓷密封环主要采用反应烧结法制备；由于游离硅的存在,反应烧结碳化硅密封环的耐高温性、耐腐蚀性较差,力学性能偏低,对应用环境和工况条件有诸多限制。而对使用温度、耐腐蚀性能等要求较高的密封环则采用无压固相烧结法制备；该烧结方法制得的密封环硬度高、弹性模量大,但抗弯强度和断裂韧性依然较低,且摩擦系数较大,自身组对时磨损量大,在使用过程中的可靠性差,工作寿命较短；此外,该烧结方法还存在烧结温度高(最高达2300℃)、能耗大等问题,较高的生产成本限制了碳化硅密封环的推广应用。由此,国内外众多学者致力于研究低温液相烧结技术制备高强度、高韧性碳化硅陶瓷,并取得一定的成效。但目前低温液相烧结技术的研究基本处于实验室阶段,尚未见其应用于碳化硅密封环的工业化生产。
本文以工业级碳化硅微粉为主要原料,采用无压液相烧结技术开展碳化硅陶瓷的强韧化研究,并应用于碳化硅密封环的工业生产。通过在SiC基体中引入力学性能优异的第二相材料提高其抗弯强度和断裂韧性,以石墨颗粒为添加剂改善SiC复合陶瓷的自润滑性能,实现了高性能SiC密封环的低成本生产。主要研究结果如下：
(一)以纳米和微米SiC晶须、纳米SiC、SiB6、TiN颗粒作为第二相材料,系统研究了pH值、分散剂种类及其含量对第二相材料在水介质中分散的影响机制,考察了SiC复合料浆的流变特性、喷雾造粒及复合粉体的成型性能。研究结果表明：1)pH值对微米SiC晶须、纳米SiC晶须和纳米SiC颗粒的分散有一定影响,但随着沉降时间的延长,其影响逐渐变弱；2)六偏磷酸钠对五种第二相材料均具有良好的分散效果,在一定添加量和沉降时间下,第二相材料水基悬浮液的沉降高度均在94.0%以上,六偏磷酸钠主要以提高颗粒间的静电斥力来实现晶须或颗粒的分散；3)羧甲基纤维素钠对微米SiC晶须有很好的分散效果,其添加量为4.0wt%,沉降时间为22.0h,微米SiC晶须悬浮液的相对沉降高度为98.0%,羧甲基纤维素钠主要通过增大晶须表面的亲水性和提高晶须表面的电位绝对值实现分散；4)SiC基复合料浆呈现出剪切变稀特性,具有塑性流体的特征；喷雾造粒后,SiC复合造粒粉具有良好的流动特性和成型性能。
(二)分别以纳米SiB6颗粒、微米ZrB2颗粒、纳米或微米SiC晶须、纳米SiC颗粒／微米SiC晶须、纳米TiN颗粒／微米SiC晶须为第二相材料,采用无压液相烧结技术,制备出SiC/nmSiB6、SiC/μmZrB2、SiC/μmSiCw、SiC/nmSiCw、SiC/nmSiC/μmSiCw、SiC/nmTiN/μmSiCw等六种SiC复合陶瓷,分析了第二相材料对碳化硅陶瓷力学性能的影响规律。研究结果表明：1)第二相材料对碳化硅陶瓷力学性能的影响与其自身材料特性、增强相组成、添加量、烧结制度有关,且对同一陶瓷材料的不同力学性能的影响规律也不尽相同；2)添加纳米SiB6颗粒总体上提高了碳化硅陶瓷的维氏硬度和断裂韧性,而添加微米ZrB2颗粒均能在一定程度上提高抗弯强度、维氏硬度、断裂韧性；3)微米和纳米SiC晶须对碳化硅陶瓷力学性能的影响随添加量增加和烧结温度升高具有不同的变化规律,综合而言,SiC晶须能明显提高碳化硅陶瓷的维氏硬度和断裂韧性,纳米SiC晶须添加量为10wt%时,维氏硬度可达33.6GPa,而微米SiC晶须添加量为30wt%时,断裂韧性可达8.4MPa·m1/2;4)同时引入纳米SiC颗粒和微米SiC晶须后,随着纳米SiC颗粒与微米SiC晶须质量比的增加,复合陶瓷的抗弯强度和维氏硬度总体上呈增加趋势,而断裂韧性则先降低后升高；5)同时引入纳米TiN颗粒和微米SiC晶须后,复合陶瓷的抗弯强度明显提高,而维氏硬度和断裂韧性随烧结温度的升高呈现不同的变化规律,添加2.5wt%纳米TiN颗粒和2.5wt%微米SiC晶须的复合陶瓷抗弯强度可达1123MPa,断裂韧性可达8.9MPa·m1/2。
(三)结合SiC/nmSiB6、SiC/μmZrB2、SiC/μmSiCw、SiC/nmSiCw、SiC/nmSiC/μmSiCw、SiC/nmTiN/μmSiCw等SiC复合陶瓷的力学性能和显微结构,探讨了颗粒、晶须对碳化硅陶瓷的强韧化机制。研究结果表明：1)单独引入纳米SiB6、TiN、SiC和微米ZrB2颗粒时,颗粒通过对基体晶界的钉扎作用,来抑制复合陶瓷晶粒异常长大,形成晶粒尺寸细小、分布均匀的显微结构,降低了陶瓷中晶粒的临界缺陷尺寸；与基体间线膨胀系数失配所产生的残余应力,有效提高了强度；同时产生裂纹偏转和裂纹桥联,提高了断裂韧性；此外合理的晶粒级配改善了晶界结构,提高了强度；2)高长径比的微米和纳米SiC晶须引入后,在基体中产生裂纹偏转和裂纹桥联,提高了断裂韧性；其与基体间弹性模量差异导致的残余应力,有效提高了强度；同时陶瓷中存在的孔隙可以吸收能量,提高了断裂韧性；3)纳米TiN/微米SiC晶须、纳米SiC/微米SiC晶须同时引入,集成颗粒、晶须的增强增韧机制,产生了明显的协同效应,有效改善了碳化硅陶瓷的力学性能。
(四)以石墨为润滑添加剂,初步探讨了石墨含量和烧结温度对SiC/石墨复合陶瓷的自润滑性能和力学性能的影响,并揭示了其自润滑机制。研究结果表明：1)随着石墨添加量的增加,SiC/石墨复合陶瓷的抗弯强度和维氏硬度不断降低,但摩擦系数也明显减小,当石墨含量为10wt%、烧结温度为1850℃,碳化硅陶瓷的摩擦系数由未添加的0.46降至0.21,显示了良好的自润滑性能；2)含石墨碳化硅陶瓷密封材料的自润滑机制主要为片状结构石墨的低摩擦、自润滑特性可以改善碳化硅密封环的自润滑性能；其次,脱落的石墨磨屑部分粘附于密封端面,部分破碎、细化后粘附于其他硬性磨粒表面形成保护层,隔绝了磨粒与端面或密封端面之间的直接接触,从而改善碳化硅密封环的摩擦性能。
(五)借助工业生产设备及工艺技术,采用无压液相烧结技术,生产出高强度、高韧性或自润滑性能优异的碳化硅陶瓷密封环,并取得一定的经济效益和社会效益。研究结果表明：1)生产出同时含2.5wt%微米SiC晶须和2.5wt%纳米TiN颗粒的碳化硅复合陶瓷密封环,其抗弯强度和断裂韧性远高于该公司现有密封产品,其他性能可以满足使用需求；2)生产出含石墨碳化硅陶瓷密封环,其摩擦系数低于现有产品,力学性能虽低于现有产品,但能够满足行业标准；3)两种新型碳化硅陶瓷密封环的崩口率低、可加工性能良好、产品报废率低、成品率高,可节约能耗20%-30%。
Silicon carbide ceramic has been widely used in the mechanical sealing of industrial equipments used in all kinds of special conditions, which has become the fourth mechanical seals because of its low weight, high strength, high hardness, resistance to abrasion and corrosion, good chemical stability and so on. The present industrial silicon carbide seals are mainly prepared by reaction-bonding method, which can not be used in some complicated conditions because of their low high-temperature resistance, abrasion resistance and mechanical properties. Seals with excellent mechanical properties and good corrosion resistance are produced by solid state pressureless sintering, and have high hardness and elastic modulus. However, their flexural strength and fracture toughness are still not high enough and they are easy to wear due to high friction coefficient and low self-lubrication, which reduces their reliability and working life. In addition, solid state pressureless sintering needs a temperature as high as 2300℃and a large amount of energy, which raises the cost and restricts the extension of use of silicon carbide seals. A large number of scholars have studied silicon carbide ceramics prepared by liquid phase pressureless sintering, but industrial liquid phase sintered silicon carbide seals are hardly reported.
With industrial silicon carbide powders as matrix, liquid phase pressureless sintering was applied in the manufacutre of silicon carbide seals. The paper focused on the preparation of silicon carbide ceramics reinforced by particles or/and whiskers and their application in silicon carbide seals. The secondary phases with high mechanical properties were added to improve the flexural strength and fracture toughness of silicon carbide ceramics. In addition, self-lubricating graphite was also added to improve the friction properties of silicon carbide ceramics. Silicon carbide seals with high performances were produced by industrial producing process with a low cost. The main results are as follows:
Nanometer and micrometer SiC whiskers, SiC nanoparticles. SiB6 nanoparticles. TiN nanoparticles were used as the secondary materials, and the effects of pH value, the kind and amount of dispersants on the dispersion of the secondary materials in aqueous media and the rheology and spray-drying of silicon carbide composite slurry were investigated. The results showed:(1) pH value has an effect on the dispersion of SiC nanoparticles, nanometer and micrometer SiC whiskers, but the effects of pH value disappeared when the sedimentation time lasted longer. (2) Sodium polyphosphate could disperse the secondary materials mentioned above, and the relative sedimentation height was all above 94.0% when its content was appropriate. The main mechanism of sodium polyphosphate was improving the static electricity among whiskers. (3) Carboxyl methyl cellulose sodium could disperse micrometer SiC whiskers effectively. When the content of carboxyl methyl cellulose sodium was 4.0wt% and the sedimentation time was 22.0 hours, the relative sedimentation height of micrometer SiC whiskers was 98.0% and the dispersion modes of carboxyl methyl cellulose were increasing the hydrophilicity and zeta potential of micrometer SiC whiskers. (4) Silicon carbide composite slurry showed a shear thinning rheology. which had the characteristics of pseudoplastic fluid. Silicon carbide composite granules were prepared by spray-drying and had a good flow characteristics and forming properties.
Six kinds of materials were used as the secondary phases, which were SiB(, nanoparticles, micrometer ZrB2 particles, nanometer or micrometer SiC whiskers, SiC nanoparticles as well as micrometer SiC whiskers, TiN nanoparticles as well as micrometer SiC whiskers. SiC/nmSiB6, SiC/μmZrB2, SiC/μmSiCw, SiC/nmSiCw, SiC/nmSiC/μmSiCw, SiC/nmTiN/μmSiCw composite ceramics were prepared using liquid phase pressureless sintering, and the effects of the secondary phases on silicon carbide ceramics were investigated. The results showed:(1) Effects of the secondary phases on silicon carbide ceramics depended on the composition and properties of the secondary materials and the processing conditions. (2) The addition of SiB6 nanoparticles and micrometer ZrB2 particles can improve Vickers hardness and fracture toughness of silicon carbide composites, while ZrB2 could also improve flexural strength. (3) Effects of nanometer and micrometer SiC whiskers on silicon carbide ceramics varied with their contents and sintering temperature. When the content of micrometer SiC whiskers was 30wt%, the maximum fracture toughness was 8.4MPa·m1/2. When the content of nanometer SiC whiskers was 10wt%, Vickers hardness was 33.6GPa, which was maximum. (4) When both SiC nanoparticles and micrometer SiC whiskers were added, flexural strength and Vickers hardness of SiC/nmSiC/μmSiCw composites increased with the increase of the mass ratio of SiC nanoparticles to micrometer SiC whiskers, while fracture toughness decreased firstly and increased then. (5) When TiN nanoparticles as well as micrometer SiC whiskers were added, flexural strength of SiC/nmTiN/μmSiCw composites increased obviously while Vickers hardness and fracture toughness varied with the increase of temperature. SiC/nmTiN/μmSiCw composite with 2.5wt% TiN nanoparticles and 2.5wt% micrometer SiC whiskers had the highest flexural strength and fracture toughness. which were 1123MPa and 8.9MPa-m1/2 respectively.
The strengthening and toughening mechanisms of silicon carbide ceramics by particles or/and whiskers were investigated on the basis of the above experiments. The results showed:(1) The strengthening and toughening mechanisms of SiB6 nanoparticles, TiN nanoparticles, SiC nanoparticles and micrometer ZrB2 particles to silicon carbide ceramics were as follows:1) Inhibiting the normal growth of grains by the pinning effect of these particles to the grain boundaries of the matrix, which was beneficial for homogeneous microstructure with fine grains.2) The residual stress induced by the differences of linear expansion coefficients between these particles and silicon carbide matrix strengthened the ceramics.3) Crack deflection and crack bridging improved fracture toughness.4) Reasonable aggregate gradation of grains improved the microstructure of grain boundary, which lead to the improvement of flexural strength. (2) The strengthening and toughening mechanisms of nanometer and micrometer SiC whiskers were as follows:1) Crack deflection and crack bridging improved fracture toughness.2) The residual stress induced by the differences of elastic modulus between silicon carbide whiskers and silicon carbide matrix improved flexural strength.3) The pores in ceramics could absorb some fracture energy. (3) When TiN or SiC nanoparticles as well as micrometer SiC whiskers were added at the same time, the synergistic effects of the strengthing and toughening mechanisms of nanoparticles and whiskers could be obtained, which improved the mechanical properties of silicon carbide ceramics effectively.
With graphite as lubricant, SiC/graphite composite ceramics were prepared and effects of graphite content and sintering temperature on the self-lubrication and mechanical properties of the composites were investigated. Self-lubricating mechanisms were analyzed. The results showed that:(1) Flexural strength and Vickers hardness of SiC/graphite composites decreased with the increase of graphite content, while frictional coefficient also decreased. When the content of graphite was 1 Owt% and the sintering temperature was 1850℃, the frictional coefficient decreased from 0.46 (without graphite) to 0.21, which indicated good self-lubrication. (2) The self-lubricating mechanisms of graphite to silicon carbide ceramics were as follows:1) Some graphite separated from ceramic matrix attached to the frictional surface and the self-lubricating property of seals was improved by the structure of graphite.2) The graphite particles were broken into tiny pieces and they formed a layer on the surface of seal faces, which were separated from each other, and frictional properties were improved.
Silicon carbide seals with excellent mechanical or self-lubricating properties were industrially produced using liquid phase pressureless sintering, and some economic and social profits were obtained. The results showed that:1) Silicon carbide seals with 2.5wt% micrometer SiC whiskers as well as 2.5wt% TiN nanoparticles had much higher flexural strength and fracture toughness than the present seals. Friction coefficient of the one with 10wt% graphite was lower than that of the present products. Although their mechanical properties were relatively lower, they could meet the standard of mechanical seals.2) The machining properties and producing efficiency of the two kinds of new seals were improved, and 20%～30% energy was saved.
本文以工业级碳化硅微粉为主要原料,采用无压液相烧结技术开展碳化硅陶瓷的强韧化研究,并应用于碳化硅密封环的工业生产。通过在SiC基体中引入力学性能优异的第二相材料提高其抗弯强度和断裂韧性,以石墨颗粒为添加剂改善SiC复合陶瓷的自润滑性能,实现了高性能SiC密封环的低成本生产。主要研究结果如下：
(一)以纳米和微米SiC晶须、纳米SiC、SiB6、TiN颗粒作为第二相材料,系统研究了pH值、分散剂种类及其含量对第二相材料在水介质中分散的影响机制,考察了SiC复合料浆的流变特性、喷雾造粒及复合粉体的成型性能。研究结果表明：1)pH值对微米SiC晶须、纳米SiC晶须和纳米SiC颗粒的分散有一定影响,但随着沉降时间的延长,其影响逐渐变弱；2)六偏磷酸钠对五种第二相材料均具有良好的分散效果,在一定添加量和沉降时间下,第二相材料水基悬浮液的沉降高度均在94.0%以上,六偏磷酸钠主要以提高颗粒间的静电斥力来实现晶须或颗粒的分散；3)羧甲基纤维素钠对微米SiC晶须有很好的分散效果,其添加量为4.0wt%,沉降时间为22.0h,微米SiC晶须悬浮液的相对沉降高度为98.0%,羧甲基纤维素钠主要通过增大晶须表面的亲水性和提高晶须表面的电位绝对值实现分散；4)SiC基复合料浆呈现出剪切变稀特性,具有塑性流体的特征；喷雾造粒后,SiC复合造粒粉具有良好的流动特性和成型性能。
(二)分别以纳米SiB6颗粒、微米ZrB2颗粒、纳米或微米SiC晶须、纳米SiC颗粒／微米SiC晶须、纳米TiN颗粒／微米SiC晶须为第二相材料,采用无压液相烧结技术,制备出SiC/nmSiB6、SiC/μmZrB2、SiC/μmSiCw、SiC/nmSiCw、SiC/nmSiC/μmSiCw、SiC/nmTiN/μmSiCw等六种SiC复合陶瓷,分析了第二相材料对碳化硅陶瓷力学性能的影响规律。研究结果表明：1)第二相材料对碳化硅陶瓷力学性能的影响与其自身材料特性、增强相组成、添加量、烧结制度有关,且对同一陶瓷材料的不同力学性能的影响规律也不尽相同；2)添加纳米SiB6颗粒总体上提高了碳化硅陶瓷的维氏硬度和断裂韧性,而添加微米ZrB2颗粒均能在一定程度上提高抗弯强度、维氏硬度、断裂韧性；3)微米和纳米SiC晶须对碳化硅陶瓷力学性能的影响随添加量增加和烧结温度升高具有不同的变化规律,综合而言,SiC晶须能明显提高碳化硅陶瓷的维氏硬度和断裂韧性,纳米SiC晶须添加量为10wt%时,维氏硬度可达33.6GPa,而微米SiC晶须添加量为30wt%时,断裂韧性可达8.4MPa·m1/2;4)同时引入纳米SiC颗粒和微米SiC晶须后,随着纳米SiC颗粒与微米SiC晶须质量比的增加,复合陶瓷的抗弯强度和维氏硬度总体上呈增加趋势,而断裂韧性则先降低后升高；5)同时引入纳米TiN颗粒和微米SiC晶须后,复合陶瓷的抗弯强度明显提高,而维氏硬度和断裂韧性随烧结温度的升高呈现不同的变化规律,添加2.5wt%纳米TiN颗粒和2.5wt%微米SiC晶须的复合陶瓷抗弯强度可达1123MPa,断裂韧性可达8.9MPa·m1/2。
(三)结合SiC/nmSiB6、SiC/μmZrB2、SiC/μmSiCw、SiC/nmSiCw、SiC/nmSiC/μmSiCw、SiC/nmTiN/μmSiCw等SiC复合陶瓷的力学性能和显微结构,探讨了颗粒、晶须对碳化硅陶瓷的强韧化机制。研究结果表明：1)单独引入纳米SiB6、TiN、SiC和微米ZrB2颗粒时,颗粒通过对基体晶界的钉扎作用,来抑制复合陶瓷晶粒异常长大,形成晶粒尺寸细小、分布均匀的显微结构,降低了陶瓷中晶粒的临界缺陷尺寸；与基体间线膨胀系数失配所产生的残余应力,有效提高了强度；同时产生裂纹偏转和裂纹桥联,提高了断裂韧性；此外合理的晶粒级配改善了晶界结构,提高了强度；2)高长径比的微米和纳米SiC晶须引入后,在基体中产生裂纹偏转和裂纹桥联,提高了断裂韧性；其与基体间弹性模量差异导致的残余应力,有效提高了强度；同时陶瓷中存在的孔隙可以吸收能量,提高了断裂韧性；3)纳米TiN/微米SiC晶须、纳米SiC/微米SiC晶须同时引入,集成颗粒、晶须的增强增韧机制,产生了明显的协同效应,有效改善了碳化硅陶瓷的力学性能。
(四)以石墨为润滑添加剂,初步探讨了石墨含量和烧结温度对SiC/石墨复合陶瓷的自润滑性能和力学性能的影响,并揭示了其自润滑机制。研究结果表明：1)随着石墨添加量的增加,SiC/石墨复合陶瓷的抗弯强度和维氏硬度不断降低,但摩擦系数也明显减小,当石墨含量为10wt%、烧结温度为1850℃,碳化硅陶瓷的摩擦系数由未添加的0.46降至0.21,显示了良好的自润滑性能；2)含石墨碳化硅陶瓷密封材料的自润滑机制主要为片状结构石墨的低摩擦、自润滑特性可以改善碳化硅密封环的自润滑性能；其次,脱落的石墨磨屑部分粘附于密封端面,部分破碎、细化后粘附于其他硬性磨粒表面形成保护层,隔绝了磨粒与端面或密封端面之间的直接接触,从而改善碳化硅密封环的摩擦性能。
(五)借助工业生产设备及工艺技术,采用无压液相烧结技术,生产出高强度、高韧性或自润滑性能优异的碳化硅陶瓷密封环,并取得一定的经济效益和社会效益。研究结果表明：1)生产出同时含2.5wt%微米SiC晶须和2.5wt%纳米TiN颗粒的碳化硅复合陶瓷密封环,其抗弯强度和断裂韧性远高于该公司现有密封产品,其他性能可以满足使用需求；2)生产出含石墨碳化硅陶瓷密封环,其摩擦系数低于现有产品,力学性能虽低于现有产品,但能够满足行业标准；3)两种新型碳化硅陶瓷密封环的崩口率低、可加工性能良好、产品报废率低、成品率高,可节约能耗20%-30%。
Silicon carbide ceramic has been widely used in the mechanical sealing of industrial equipments used in all kinds of special conditions, which has become the fourth mechanical seals because of its low weight, high strength, high hardness, resistance to abrasion and corrosion, good chemical stability and so on. The present industrial silicon carbide seals are mainly prepared by reaction-bonding method, which can not be used in some complicated conditions because of their low high-temperature resistance, abrasion resistance and mechanical properties. Seals with excellent mechanical properties and good corrosion resistance are produced by solid state pressureless sintering, and have high hardness and elastic modulus. However, their flexural strength and fracture toughness are still not high enough and they are easy to wear due to high friction coefficient and low self-lubrication, which reduces their reliability and working life. In addition, solid state pressureless sintering needs a temperature as high as 2300℃and a large amount of energy, which raises the cost and restricts the extension of use of silicon carbide seals. A large number of scholars have studied silicon carbide ceramics prepared by liquid phase pressureless sintering, but industrial liquid phase sintered silicon carbide seals are hardly reported.
With industrial silicon carbide powders as matrix, liquid phase pressureless sintering was applied in the manufacutre of silicon carbide seals. The paper focused on the preparation of silicon carbide ceramics reinforced by particles or/and whiskers and their application in silicon carbide seals. The secondary phases with high mechanical properties were added to improve the flexural strength and fracture toughness of silicon carbide ceramics. In addition, self-lubricating graphite was also added to improve the friction properties of silicon carbide ceramics. Silicon carbide seals with high performances were produced by industrial producing process with a low cost. The main results are as follows:
Nanometer and micrometer SiC whiskers, SiC nanoparticles. SiB6 nanoparticles. TiN nanoparticles were used as the secondary materials, and the effects of pH value, the kind and amount of dispersants on the dispersion of the secondary materials in aqueous media and the rheology and spray-drying of silicon carbide composite slurry were investigated. The results showed:(1) pH value has an effect on the dispersion of SiC nanoparticles, nanometer and micrometer SiC whiskers, but the effects of pH value disappeared when the sedimentation time lasted longer. (2) Sodium polyphosphate could disperse the secondary materials mentioned above, and the relative sedimentation height was all above 94.0% when its content was appropriate. The main mechanism of sodium polyphosphate was improving the static electricity among whiskers. (3) Carboxyl methyl cellulose sodium could disperse micrometer SiC whiskers effectively. When the content of carboxyl methyl cellulose sodium was 4.0wt% and the sedimentation time was 22.0 hours, the relative sedimentation height of micrometer SiC whiskers was 98.0% and the dispersion modes of carboxyl methyl cellulose were increasing the hydrophilicity and zeta potential of micrometer SiC whiskers. (4) Silicon carbide composite slurry showed a shear thinning rheology. which had the characteristics of pseudoplastic fluid. Silicon carbide composite granules were prepared by spray-drying and had a good flow characteristics and forming properties.
Six kinds of materials were used as the secondary phases, which were SiB(, nanoparticles, micrometer ZrB2 particles, nanometer or micrometer SiC whiskers, SiC nanoparticles as well as micrometer SiC whiskers, TiN nanoparticles as well as micrometer SiC whiskers. SiC/nmSiB6, SiC/μmZrB2, SiC/μmSiCw, SiC/nmSiCw, SiC/nmSiC/μmSiCw, SiC/nmTiN/μmSiCw composite ceramics were prepared using liquid phase pressureless sintering, and the effects of the secondary phases on silicon carbide ceramics were investigated. The results showed:(1) Effects of the secondary phases on silicon carbide ceramics depended on the composition and properties of the secondary materials and the processing conditions. (2) The addition of SiB6 nanoparticles and micrometer ZrB2 particles can improve Vickers hardness and fracture toughness of silicon carbide composites, while ZrB2 could also improve flexural strength. (3) Effects of nanometer and micrometer SiC whiskers on silicon carbide ceramics varied with their contents and sintering temperature. When the content of micrometer SiC whiskers was 30wt%, the maximum fracture toughness was 8.4MPa·m1/2. When the content of nanometer SiC whiskers was 10wt%, Vickers hardness was 33.6GPa, which was maximum. (4) When both SiC nanoparticles and micrometer SiC whiskers were added, flexural strength and Vickers hardness of SiC/nmSiC/μmSiCw composites increased with the increase of the mass ratio of SiC nanoparticles to micrometer SiC whiskers, while fracture toughness decreased firstly and increased then. (5) When TiN nanoparticles as well as micrometer SiC whiskers were added, flexural strength of SiC/nmTiN/μmSiCw composites increased obviously while Vickers hardness and fracture toughness varied with the increase of temperature. SiC/nmTiN/μmSiCw composite with 2.5wt% TiN nanoparticles and 2.5wt% micrometer SiC whiskers had the highest flexural strength and fracture toughness. which were 1123MPa and 8.9MPa-m1/2 respectively.
The strengthening and toughening mechanisms of silicon carbide ceramics by particles or/and whiskers were investigated on the basis of the above experiments. The results showed:(1) The strengthening and toughening mechanisms of SiB6 nanoparticles, TiN nanoparticles, SiC nanoparticles and micrometer ZrB2 particles to silicon carbide ceramics were as follows:1) Inhibiting the normal growth of grains by the pinning effect of these particles to the grain boundaries of the matrix, which was beneficial for homogeneous microstructure with fine grains.2) The residual stress induced by the differences of linear expansion coefficients between these particles and silicon carbide matrix strengthened the ceramics.3) Crack deflection and crack bridging improved fracture toughness.4) Reasonable aggregate gradation of grains improved the microstructure of grain boundary, which lead to the improvement of flexural strength. (2) The strengthening and toughening mechanisms of nanometer and micrometer SiC whiskers were as follows:1) Crack deflection and crack bridging improved fracture toughness.2) The residual stress induced by the differences of elastic modulus between silicon carbide whiskers and silicon carbide matrix improved flexural strength.3) The pores in ceramics could absorb some fracture energy. (3) When TiN or SiC nanoparticles as well as micrometer SiC whiskers were added at the same time, the synergistic effects of the strengthing and toughening mechanisms of nanoparticles and whiskers could be obtained, which improved the mechanical properties of silicon carbide ceramics effectively.
With graphite as lubricant, SiC/graphite composite ceramics were prepared and effects of graphite content and sintering temperature on the self-lubrication and mechanical properties of the composites were investigated. Self-lubricating mechanisms were analyzed. The results showed that:(1) Flexural strength and Vickers hardness of SiC/graphite composites decreased with the increase of graphite content, while frictional coefficient also decreased. When the content of graphite was 1 Owt% and the sintering temperature was 1850℃, the frictional coefficient decreased from 0.46 (without graphite) to 0.21, which indicated good self-lubrication. (2) The self-lubricating mechanisms of graphite to silicon carbide ceramics were as follows:1) Some graphite separated from ceramic matrix attached to the frictional surface and the self-lubricating property of seals was improved by the structure of graphite.2) The graphite particles were broken into tiny pieces and they formed a layer on the surface of seal faces, which were separated from each other, and frictional properties were improved.
Silicon carbide seals with excellent mechanical or self-lubricating properties were industrially produced using liquid phase pressureless sintering, and some economic and social profits were obtained. The results showed that:1) Silicon carbide seals with 2.5wt% micrometer SiC whiskers as well as 2.5wt% TiN nanoparticles had much higher flexural strength and fracture toughness than the present seals. Friction coefficient of the one with 10wt% graphite was lower than that of the present products. Although their mechanical properties were relatively lower, they could meet the standard of mechanical seals.2) The machining properties and producing efficiency of the two kinds of new seals were improved, and 20%～30% energy was saved.
引文
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