A method of repairing a gutter joint

Abstract

The application relates to a method for repairing a drainage groove joint, which comprises the following steps: sequentially performing impurity cleaning, first filling treatment and second filling treatment on the drainage groove joint, and performing polishing treatment after drying; and sequentially performing coating treatment, polishing treatment and baking treatment on the inner lining of the drainage groove by using paint, so as to complete the repair of the drainage groove joint. By means of the two-step filling treatment, the repaired material at the joint can be more easily cleaned after the high-purity aluminum liquid flows through the drainage groove once. In combination with the coating and baking treatment, the repaired drainage groove joint will not be cracked and peeled off, will not pollute the high-purity aluminum liquid, and the high-purity aluminum liquid can smoothly flow in the drainage groove and will not seep into the joint, so that the effective repair of the drainage groove joint is realized.

Description

Technical Field

[0001] This invention relates to the field of high-purity metal smelting and casting technology, and specifically to a method for repairing the joint of a flow channel. Background Technology

[0002] High-purity aluminum and high-purity aluminum alloys are widely used as interconnect materials in integrated circuits, primarily produced through PVD coating of high-purity aluminum or high-purity aluminum alloy sputtering targets. The purity of high-purity aluminum and high-purity aluminum alloy sputtering targets is generally required to be above 5N (99.999% wt). Sputtering targets are typically made from high-purity aluminum or high-purity aluminum alloy ingots, which are produced through the melting and casting of high-purity aluminum raw materials and alloys. Therefore, the production process for high-purity aluminum and high-purity aluminum alloy sputtering targets is: high-purity aluminum or raw materials with added high-purity alloys → high-purity aluminum ingots or high-purity aluminum alloy ingots → high-purity aluminum sputtering targets or high-purity aluminum alloy sputtering targets.

[0003] The process of obtaining high-purity aluminum ingots from high-purity aluminum raw materials through smelting and casting requires extremely high purity. Improper control can lead to the introduction of impurity elements, resulting in ingots that cannot meet purity standards. The current high-purity aluminum smelting and casting process includes: 1) providing high-purity aluminum raw materials, with the addition of high-purity metal raw materials as needed; 2) melting the raw materials in a smelting furnace; 3) degassing and slag removal after reaching the required alloy content; 4) introducing the high-purity aluminum liquid in the smelting furnace into a crystallizer through a guide channel to form ingots under cooling.

[0004] In the process described in 4) above, the distance between the furnace and the crystallizer is generally quite long, and the diversion channel may be curved due to equipment layout and other reasons. The inside of the diversion channel is usually lined with spliced ​​refractory material, and there are usually tiny gaps of 2-5mm between the linings. These gaps can easily trap impurities such as dust, loose refractory material, and rust. If not treated, these impurities can be easily introduced and cause contamination when high-purity metal flows through them.

[0005] CN 104313574A discloses a repair method for a feed chute used in non-ferrous metal mining, mainly including the following steps: disassembling and cleaning the equipment to determine the worn parts and their dimensions; dry-burning the worn parts using a semiconductor laser; mixing WC powder and Fe6 powder in a mechanical powder mixer to obtain Fe6+WC alloy powder; cladding the worn parts of the feed chute with the alloy powder using a high-power semiconductor laser; machining the surface of the clad feed chute and inspecting for defects; verifying the dimensions of the remanufactured feed chute, and completing assembly after it passes inspection. However, this repair method still carries the risk of introducing impurities from the alloy powder when used for guiding the flow of liquid high-purity metals.

[0006] CN 203741360U discloses a taphole for a refractory prefabricated component of an oxygen-enriched vertical shaft furnace, comprising at least two prefabricated components, I and II, made of different refractory materials. Prefabricated components I and II are arranged vertically and bonded together as a single structure. The lower end face of prefabricated component I and the upper end face of prefabricated component II each have grooves that, when mated, form a flow channel for molten iron in the oxygen-enriched vertical shaft furnace. The mating surface between prefabricated components I and II is a convex-concave surface designed to meet sealing requirements. However, this sealing method, when used in the gap of a channel for ultra-high purity aluminum flow, easily introduces impurities.

[0007] In view of the shortcomings of existing technologies, there is an urgent need to provide a repair method for the joints of the drainage channel that does not introduce impurities and has a good repair effect. Summary of the Invention

[0008] The purpose of this invention is to provide a method for repairing the joint of a drainage channel. The method involves a two-step filling process using different materials, combined with coating and baking treatments. The repaired drainage channel joint will not crack or fall off, will not contaminate the high-purity aluminum liquid, and the high-purity aluminum liquid will flow smoothly in the drainage channel without seeping into the joint.

[0009] To achieve this objective, the present invention adopts the following technical solution:

[0010] This invention provides a method for repairing the joint of a drainage channel, the method comprising the following steps:

[0011] The joints of the drainage channel are sequentially cleaned of impurities, filled with a first filling treatment and a second filling treatment, and then polished after drying. The inner lining of the drainage channel is coated with paint, polished, and baked in sequence to complete the repair of the joints of the drainage channel.

[0012] The repair method for the joint of the drainage channel provided by the present invention, through a two-step filling process, makes it easier to clean the repair material at the joint after the high-purity aluminum liquid has flowed through the drainage channel once. Combined with coating and baking treatment, the repaired drainage channel joint will not crack or fall off, will not contaminate the high-purity aluminum liquid, and the high-purity aluminum liquid flows smoothly in the drainage channel without seeping into the joint.

[0013] Preferably, the material used in the first filling process includes refractory wool.

[0014] Preferably, the refractory cotton comprises aluminosilicate cotton.

[0015] Preferably, the filling height of the first filling treatment is 1 / 3 to 2 / 3 of the depth of the drainage channel joint, for example, it can be 1 / 3, 1 / 2 or 2 / 3, but is not limited to the listed values. Other unlisted values ​​within the range are also applicable.

[0016] In order to reduce the introduction of impurities into the drainage channel, the repair is a one-time repair, that is, the high-purity aluminum liquid needs to be refilled and repaired after flowing through the drainage channel once. The refractory cotton is elastic, and the bottom of the joint is easier to clean than refractory mud.

[0017] Preferably, the material used in the second filling treatment includes refractory mortar.

[0018] Preferably, the refractory mortar comprises aluminum oxide, silicon oxide, and calcium oxide.

[0019] Preferably, the alumina content in the refractory mortar is >80wt%, for example, it can be 81wt%, 83wt%, 85wt%, 88wt% or 90wt%, but is not limited to the listed values. Other unlisted values ​​within the range are also applicable.

[0020] Preferably, the second filling process is to fill the remaining depth of the drainage channel joint.

[0021] Preferably, the top surface of the second filling treatment is 0.5-1 mm higher than the surface of the inner lining, for example, it can be 0.5 mm, 0.6 mm, 0.8 mm, 0.9 mm or 1 mm, but is not limited to the listed values. Other unlisted values ​​within the range are also applicable.

[0022] If the height of the top surface of the second filling treatment is too low above the surface of the lining, grooves will be formed after the refractory mortar solidifies, and cracks will be formed due to shrinkage. If the height is too high, it will be difficult to clean later. Therefore, it is necessary to control the height range.

[0023] Preferably, the drying includes air drying or oven drying.

[0024] Preferably, the polishing process is performed using sandpaper.

[0025] Preferably, the sandpaper is 1000-2000# sandpaper, such as 1000#, 1500# or 2000#, but not limited to the listed values. Other unlisted values ​​within the range are also applicable.

[0026] Preferably, the top surface of the filler after the grinding process is flush with the surface of the inner lining.

[0027] Preferably, the polishing process further includes a step of cleaning impurities using a dust collection device.

[0028] Preferably, the coating comprises a boron nitride coating.

[0029] Boron nitride coatings have high temperature resistance and ultra-high lubrication and release properties. Therefore, using boron nitride coatings can reduce the frictional resistance of molten metal flow and reduce the risk of impurities being introduced into the molten metal due to excessive resistance.

[0030] Preferably, the coating process is carried out until the coating is visually uniform.

[0031] Preferably, the coating process is followed by a natural air-drying step before the polishing process.

[0032] Preferably, the polishing medium includes a cleaning cloth.

[0033] Preferably, the polishing process is performed until the surface roughness of the lining is <1μm, for example, it can be 0.9μm, 0.8μm, 0.7μm, 0.6μm or 0.5μm, but is not limited to the listed values. Other unlisted values ​​within the range are also applicable.

[0034] The polishing process makes the surface of the coated lining very smooth, which is conducive to the smooth flow of high-purity aluminum liquid.

[0035] Preferably, the polishing process further includes a step of cleaning impurities using a dust collection device.

[0036] Preferably, the baking temperature is 200-500℃, for example, 200℃, 250℃, 300℃, 400℃ or 500℃, but not limited to the listed values. Other unlisted values ​​within the range are also applicable.

[0037] If the baking temperature is too high, the surface will crack due to excessively rapid drying; if the baking temperature is too low, the moisture cannot be dried, which may cause cracks or peeling during subsequent use, leading to contamination.

[0038] Preferably, the baking time is ≥4h, for example, it can be 4h, 4.5h, 5h, 5.5h or 6h, but is not limited to the listed values. Other unlisted values ​​within the range are also applicable.

[0039] If the baking time is too short, the moisture cannot be dried, which can easily cause cracks or peeling during subsequent use, leading to contamination.

[0040] As a preferred embodiment of the repair method of the present invention, the repair method includes the following steps:

[0041] The joints of the drainage channel are cleaned of impurities, filled with refractory cotton for the first filling treatment and refractory mortar for the second filling treatment. After natural air drying or oven drying, they are polished with 1000-2000# sandpaper, and then the impurities are cleaned with a dust collection device.

[0042] The first filling process involves filling to a height of 1 / 3 to 2 / 3 of the depth of the drainage channel joint; the second filling process involves filling the remaining depth of the drainage channel joint; the top surface of the second filling process is 0.5-1 mm higher than the surface of the inner lining; the grinding process is performed until the top surface of the second filling process is flush with the surface of the inner lining.

[0043] The inner lining of the drainage channel is coated with boron nitride paint, air-dried, and polished with a cleaning cloth until the surface roughness of the inner lining is <1μm. Impurities are removed using a dust collection device, and then the lining is baked at 200-500℃ for ≥4h to complete the repair of the joint of the drainage channel.

[0044] Compared with the prior art, the present invention has the following beneficial effects:

[0045] The repair method for the joint of the drainage channel provided by this invention, through a two-step filling process, makes it easier to clean the repair material at the joint after the high-purity aluminum liquid has flowed through the drainage channel once. Combined with coating and baking treatment, the repaired drainage channel joint will not crack or fall off, will not contaminate the high-purity aluminum liquid, and the high-purity aluminum liquid flows smoothly in the drainage channel without seeping into the joint, thus achieving effective repair of the drainage channel joint. Attached Figure Description

[0046] Figure 1 This is a top view of the drainage channel provided in Embodiment 1 of the present invention;

[0047] Among them: 1, the joint of the drainage channel; 2, the inner lining. Detailed Implementation

[0048] The technical solution of the present invention will be further illustrated below through specific embodiments. Those skilled in the art should understand that the embodiments described are merely illustrative of the present invention and should not be construed as limiting the invention in any way.

[0049] Example 1

[0050] This embodiment provides a method for repairing the joint of a drainage channel, the top view of which is shown below. Figure 1 As shown, the repair method includes the following steps:

[0051] The impurities in the joint 1 of the diversion channel are cleaned, aluminum silicate cotton is used for the first filling treatment, and refractory mortar is used for the second filling treatment. After natural drying, it is polished with 1500# sandpaper, and then the impurities are cleaned with a vacuum cleaner.

[0052] The first filling treatment has a filling height of 1 / 2 the depth of the drainage channel joint 1; the second filling treatment is to fill the remaining depth of the drainage channel joint 1; the top surface of the second filling treatment is 0.8 mm higher than the surface of the inner lining 2; the refractory mortar is composed of alumina, silicon oxide and calcium oxide; the mass percentage of alumina in the refractory mortar is 85 wt%; the grinding treatment is performed until the top surface of the second filling treatment is flush with the surface of the inner lining 2;

[0053] The inner lining 2 of the drainage channel is uniformly coated with boron nitride paint, naturally dried, and polished with a cleaning cloth until the surface roughness of the inner lining 2 is 0.5μm. Impurities are removed using a dust collection device, and then it is baked at 300℃ for 5 hours to complete the repair of the joint 1 of the drainage channel.

[0054] The impurity content of the high-purity aluminum liquid was measured, and the impurity content was measured again after flowing through the diversion tank. The impurity content did not increase significantly.

[0055] Example 2

[0056] This embodiment provides a method for repairing the joint of a drainage channel, the repair method including the following steps:

[0057] The impurities in the joint 1 of the diversion channel are cleaned, aluminum silicate cotton is used for the first filling treatment, and refractory mortar is used for the second filling treatment. After natural drying, it is polished with 2000# sandpaper, and then the impurities are cleaned with a vacuum cleaner.

[0058] The first filling treatment has a filling height of 1 / 3 of the depth of the drainage channel joint 1; the second filling treatment is to fill the remaining depth of the drainage channel joint 1; the top surface of the second filling treatment is 0.5 mm higher than the surface of the inner lining 2; the refractory mortar is composed of alumina, silicon oxide, and calcium oxide; the mass percentage of alumina in the refractory mortar is 81 wt%; the grinding treatment is performed until the top surface of the second filling treatment is flush with the surface of the inner lining 2;

[0059] The inner lining 2 of the drainage channel is uniformly coated with boron nitride paint, naturally dried, and polished with a cleaning cloth until the surface roughness of the inner lining 2 is 0.9μm. Impurities are removed using a dust collection device, and then it is baked at 200℃ for 6 hours to complete the repair of the joint 1 of the drainage channel.

[0060] The impurity content of the high-purity aluminum liquid was measured, and the impurity content was measured again after flowing through the diversion tank. The impurity content did not increase significantly.

[0061] Example 3

[0062] This embodiment provides a method for repairing the joint of a drainage channel, the repair method including the following steps:

[0063] The impurities in the joint 1 of the diversion channel are cleaned, aluminum silicate cotton is used for the first filling treatment, and refractory mortar is used for the second filling treatment. After drying, it is polished with 1000# sandpaper, and then the impurities are cleaned with a vacuum cleaner.

[0064] The first filling treatment has a filling height of 2 / 3 of the depth of the drainage channel joint 1; the second filling treatment is to fill the remaining depth of the drainage channel joint 1; the top surface of the second filling treatment is 1 mm higher than the surface of the inner lining 2; the refractory mortar is composed of alumina, silicon oxide and calcium oxide; the mass percentage of alumina in the refractory mortar is 90 wt%; the grinding treatment is performed until the top surface of the second filling treatment is flush with the surface of the inner lining 2;

[0065] The inner lining 2 of the drainage channel is uniformly coated with boron nitride paint, naturally dried, and polished with a cleaning cloth until the surface roughness of the inner lining 2 is 0.7μm. Impurities are removed using a dust collection device, and then it is baked at 500℃ for 4 hours to complete the repair of the joint 1 of the drainage channel.

[0066] The impurity content of the high-purity aluminum liquid was measured, and the impurity content was measured again after flowing through the diversion tank. The impurity content did not increase significantly.

[0067] Example 4

[0068] This embodiment provides a method for repairing the joint of the drainage channel. The difference from Embodiment 1 is that the top surface of the filling treatment in the second filling process is 0.2 mm higher than the surface of the inner lining 2. The rest is the same as in Embodiment 1.

[0069] Because the top surface of the filler in the second filling process is too low, shrinkage after solidification will cause cracks, resulting in the infiltration of high-purity aluminum liquid and the introduction of impurities. The impurity content was measured before and after the high-purity aluminum liquid flowed through the diversion tank, and the impurity content increased by 21%.

[0070] Example 5

[0071] This embodiment provides a method for repairing the joint of the drainage channel. The difference from Embodiment 1 is that, except for adjusting the baking temperature to 550°C, the rest is the same as Embodiment 1.

[0072] Due to excessively high baking temperatures, surface cracks occurred, leading to the infiltration of high-purity aluminum liquid and the introduction of impurities. The impurity content was measured before and after the high-purity aluminum liquid flowed through the diversion tank, and the impurity content increased by 25%.

[0073] Example 6

[0074] This embodiment provides a method for repairing the joint of the drainage channel. The difference from Embodiment 1 is that, except for adjusting the baking temperature to 150°C, the rest is the same as Embodiment 1.

[0075] Due to the excessively low baking temperature, the surface coating peeled off directly, resulting in the introduction of impurities. The impurity content was measured before and after the high-purity aluminum liquid flowed through the diversion tank, and the impurity content increased by 24%.

[0076] Example 7

[0077] This embodiment provides a method for repairing the joint of the drainage channel. The difference from Embodiment 1 is that, except for adjusting the baking time to 3 hours, the rest is the same as Embodiment 1.

[0078] Due to the short baking time, cracks appeared in the surface coating, resulting in the introduction of impurities. The impurity content was measured before and after the high-purity aluminum liquid flowed through the diversion tank, and the impurity content increased by 21%.

[0079] Comparative Example 1

[0080] This comparative example provides a method for repairing the joint of the diversion channel. The difference from Example 1 is that there is no first filling treatment, and the diversion channel joint 1 is filled entirely with refractory mortar. The rest is the same as Example 1.

[0081] The impurity content of the high-purity aluminum liquid was measured, and the impurity content was measured again after it flowed through the diversion tank. The impurity content did not increase significantly, but the subsequent cleaning was too cumbersome and not conducive to production.

[0082] Comparative Example 2

[0083] This comparative example provides a method for repairing the joint of the drainage channel. The difference between this example and Example 1 is that there is no coating treatment, polishing treatment, or baking treatment. All other aspects are the same as in Example 1.

[0084] Because no protective layer was applied to the surface, it is very easy to introduce impurities from refractory material shedding. The impurity content was measured before and after the high-purity aluminum liquid flowed through the diversion tank, and the impurity increased by 125%.

[0085] In summary, the repair method for the joint of the drainage channel provided by this invention, through a two-step filling process, makes it easier to clean the repair material at the joint after the high-purity aluminum liquid has flowed through the drainage channel once. Combined with coating and baking treatment, the repaired drainage channel joint will not crack or fall off, will not contaminate the high-purity aluminum liquid, and the high-purity aluminum liquid flows smoothly in the drainage channel without seeping into the joint, thus achieving effective repair of the drainage channel joint.

[0086] The above description is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention fall within the protection and disclosure scope of the present invention.

Claims

1. A method for repairing the joint of a drainage channel, characterized in that, The repair method includes the following steps: The joints of the drainage channel are cleaned of impurities, filled with a first filling treatment and a second filling treatment in sequence, and then polished after drying. The inner lining of the drainage channel is coated with paint in sequence, then air-dried, polished and baked to complete the repair of the joints of the drainage channel. The material used for the first filling process includes refractory cotton; the filling height of the first filling process is 1 / 3 to 2 / 3 of the depth of the drainage channel joint; The second filling process is to fill the remaining depth of the drainage channel joint; the top surface of the filling process is 0.5-1 mm higher than the surface of the inner lining; the material used in the second filling process includes refractory mortar; the composition of the refractory mortar includes alumina, silicon dioxide and calcium oxide; The coating includes boron nitride coating; The baking temperature is 200-500℃; the baking time is ≥4h.

2. The repair method according to claim 1, characterized in that, The refractory cotton includes aluminum silicate cotton.

3. The repair method according to claim 1, characterized in that, The refractory mortar contains an alumina content of >80 wt%.

4. The repair method according to claim 1, characterized in that, The drying process includes air drying or oven drying.

5. The repair method according to claim 1, characterized in that, The polishing process is performed using sandpaper.

6. The repair method according to claim 5, characterized in that, The sandpaper is 1000-2000# sandpaper.

7. The repair method according to claim 1, characterized in that, The grinding process continues until the top surface of the filling material is flush with the surface of the inner lining during the second filling process.

8. The repair method according to claim 1, characterized in that, The polishing process also includes a step of cleaning impurities using a dust extraction device.

9. The repair method according to claim 1, characterized in that, The polishing medium used includes a cleaning cloth.

10. The repair method according to claim 1, characterized in that, The polishing process is performed until the surface roughness of the lining is <1μm.

11. The repair method according to claim 1, characterized in that, The polishing process is followed by a step of cleaning impurities using a dust extraction device.

12. The repair method according to claim 1, characterized in that, The repair method includes the following steps: The joints of the drainage channel are cleaned of impurities, filled with refractory cotton for the first filling treatment and refractory mortar for the second filling treatment. After natural air drying or oven drying, they are polished with 1000-2000# sandpaper, and then the impurities are cleaned with a dust collection device. The first filling process involves filling to a height of 1 / 3 to 2 / 3 of the depth of the drainage channel joint; the second filling process involves filling the remaining depth of the drainage channel joint; the top surface of the second filling process is 0.5-1 mm higher than the surface of the inner lining; the grinding process is performed until the top surface of the second filling process is flush with the surface of the inner lining. The inner lining of the drainage channel is coated with boron nitride paint, air-dried, and polished with a cleaning cloth until the surface roughness of the inner lining is <1μm. Impurities are removed using a dust collection device, and then the lining is baked at 200-500℃ for ≥4h to complete the repair of the joint of the drainage channel.

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