聚苯乙烯泡沫球添加量对刚玉-莫来石多孔陶瓷性能与结构的影响
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摘要
为了制备密度小、高温性能优异的刚玉-莫来石多孔陶瓷,在以莫来石细粉、板状刚玉细粉、α-Al_2O_3微粉、SiO_2微粉为主要原料,硅溶胶和ρ-Al_2O_3为结合剂配制的浆料中,分别添加占浆料体积10%、30%和50%的聚苯乙烯泡沫球为造孔剂,采用振动浇注成型,在1 500℃烧后制备了刚玉-莫来石多孔陶瓷,并探究了聚苯乙烯泡沫球添加量对多孔陶瓷的性能、相组成以及显微结构的影响。结果表明:随着聚苯乙烯泡沫球造孔剂添加量的增加,试样的常温弯曲强度、常温压缩强度、高温抗折强度、容重、热导率均明显下降。聚苯乙烯泡沫球氧化后形成直径约为2 mm的气孔,同时基质中颗粒之间的部分烧结生成了大量的微气孔,且1 500℃热处理后试样中原位生成了大量的莫来石,使得试样在1 500℃热处理后膨胀;当聚苯乙烯泡沫球加入量为浆料总体积50%时,试样的显气孔率达到61%,1 400℃下的高温抗折强度高达2. 64 MPa,满足密度小、高温性能优异的要求。
This work aims at preparing alumina-mullite ceramics with low density and excellent hot performance. The slurries were prepared using mullite powder,tabular corundum powder,α-Al_2O_3 micropowder and silica fume as the main raw materials,silica sol and ρ-Al_2O_3 as binders,and polystyrene spheres as pore-forming agent. The volume percent of polystyrene sphere accounts for 10%,30% and 50%. The specimens were shaped by the vibration casting,and fired at 1 500 ℃. Effects of polystyrene sphere addition on physical properties,phase composition and microstructures of porous ceramics were investigated. It shows that: with the polystyrene sphere addition increasing,the cold modulus of rupture,cold crushing strength,hot modulus of rupture,volume density and the thermal conductivity of the specimens decrease obviously.After oxidation,the polystyrene spheres form pores with the diameter of about 2 mm,a large amount of micro-pores generate through the partial sintering of particles in the matrix,and much mullite in-situ forms in the specimen fired at 1 500 ℃,so the specimen expands. For the specimen prepared from the slurry containing 50% polystyrene sphere,the apparent porosity reaches 61%,and the modulus of rupture at 1 400 ℃ is 2. 64 MPa,so it realizes low density and excellent hot performance.
This work aims at preparing alumina-mullite ceramics with low density and excellent hot performance. The slurries were prepared using mullite powder,tabular corundum powder,α-Al_2O_3 micropowder and silica fume as the main raw materials,silica sol and ρ-Al_2O_3 as binders,and polystyrene spheres as pore-forming agent. The volume percent of polystyrene sphere accounts for 10%,30% and 50%. The specimens were shaped by the vibration casting,and fired at 1 500 ℃. Effects of polystyrene sphere addition on physical properties,phase composition and microstructures of porous ceramics were investigated. It shows that: with the polystyrene sphere addition increasing,the cold modulus of rupture,cold crushing strength,hot modulus of rupture,volume density and the thermal conductivity of the specimens decrease obviously.After oxidation,the polystyrene spheres form pores with the diameter of about 2 mm,a large amount of micro-pores generate through the partial sintering of particles in the matrix,and much mullite in-situ forms in the specimen fired at 1 500 ℃,so the specimen expands. For the specimen prepared from the slurry containing 50% polystyrene sphere,the apparent porosity reaches 61%,and the modulus of rupture at 1 400 ℃ is 2. 64 MPa,so it realizes low density and excellent hot performance.
引文
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[3]宋绍雷,甄强,王方方,等.低品位煤矸石制备多孔莫来石研究[J].耐火材料,2014,48(1):18-21.
[4]苗正,李楠,鄢文.原料配比对钙长石-莫来石复相多孔陶瓷显微结构与性能的影响[J].耐火材料,2015,49(4):259-263.
[5]LIU Q,XUE T,YANG L,et al.Controllable synthesis of hierarchical porous mullite fiber network for gas filtration[J].J Eur Ceram Soc,2016,36(7):1691-1697.
[6]GUO H S,LI W F,YE F B.Low-cost porous mullite ceramic membrane supports fabricated from kyanite by casting and reaction sintering[J].Ceramics International,2016,42(4):4819-4826.
[7]袁永兵,刘开琪,刘永锋.木炭添加量对多孔莫来石陶瓷性能的影响[J].耐火材料,2014,48(5):356-358.
[8]曹贺辉,王刚,袁波,等.泡沫注凝法制备刚玉-莫来石多孔陶瓷[J].耐火材料,2013,47(5):334-337.
[9]董宾宾,王刚,袁波,等.Si O2微粉对发泡法-凝胶注模制备氧化铝多孔陶瓷性能的影响[J].耐火材料,2015,49(4):269-272.
[10]王刚,袁波,韩建燊,等.发泡法制备氧化铝基多孔陶瓷(Ⅱ):氧化铝复相多孔陶瓷的制备、组成、结构和性能[J].耐火材料,2017,51(5):329-333.
[11]HUA K H,SHUI A Z,XU L F,et al.Fabrication and characterization of anorthite-mullite-corundum porous ceramics from construction waste[J].Ceramics International,2016,42(5):6080-6087.
[12]HUA K H,XI X A,XU L F,et al.Effects of Al F3,and Mo O3,on properties of Mullite whisker reinforced porous ceramics fabricated from construction waste[J].Ceramics International,2016,42(15):17179-17184.
[13]SOUSA L L D,SALOMAO R,ARANTES V L.Development and characterization of porous moldable refractory structures of the alumina-mullite-quartz system[J].Ceramics International,2017,43(1):1362-1370.
[14]AHMAD R,ANWAR M S,KIM J,et al.Porosity features and gas permeability analysis of bi-modal porous alumina and mullite for filtration applications[J].Ceramics International,2016,42(16):18711-18717.
[15]HOU Z P,CUI B X,LIU L L,et al.Effect of the different additives on the fabrication of porous kaolin-based mullite ceramics[J].Ceramics International,2016,42(15):17254-17258.
[16]韩火年,李强,洪昱斌,等.莫来石-刚玉多孔陶瓷膜支撑体的制备[J].功能材料,2011,42(3):425-428.
[17]WHITE L S,MIGENDA J,GAO X,et al.Synthesis of silicon dioxide,silicon,and silicon carbide mesoporous spheres from polystyrene sphere templates[J].J Sol-Gel Sci Techy,2015,74(3):575-584.