High-strength anti-aluminum liquid wetting castable products and processes for aluminum melting furnaces

Abstract

This invention provides a high-strength, aluminum-molten metal-resistant castable for aluminum melting furnaces, along with its manufacturing process, belonging to the technical field of refractory materials for aluminum melting furnaces. The refractory castable of this invention is produced by uniformly mixing corundum with a particle size ≤5mm, Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, alumina micropowder with a particle size ≤5μm, silica micropowder with a particle size ≤2μm, an anti-wetting agent, a sintering aid, a composite reinforcing agent, a composite explosion-proof agent, a binder, and a water-reducing agent. This high-strength, aluminum-molten metal-resistant castable for aluminum melting furnaces is obtained by selecting corundum and Al2O3-MgO-CaO multiphase material as the main raw materials, supplemented with a sintering aid, a composite reinforcing agent, and a composite explosion-proof agent, to promote the sintering of the castable components at medium temperatures, effectively improving the castable's resistance to aluminum molten metal wetting and its physical properties under operating conditions.

Description

Technical Field

[0001] This invention belongs to the technical field of refractory materials for aluminum melting furnaces, and relates to a high-strength anti-aluminum liquid wetting castable product and process for aluminum melting furnaces. Background Technology

[0002] Currently, the linings of aluminum melting furnaces mostly use Al2O3-SiO2 system refractory castables or high-alumina bricks, with high-alumina bauxite as the main raw material. Molten aluminum is chemically active and readily reacts with SiO2 in refractory materials to form Si and Al2O3. This not only easily forms hard corundum nodules on the furnace lining surface, damaging the furnace lining structure, but also allows the Si produced in the reaction to enter the molten aluminum, reducing its quality. Chinese invention patent application number 201010141976.2 uses calcium hexaaluminate as the main raw material, which is expensive; Chinese invention patent applications 200910227629.9, 201610145233.X, 202310583558.6, and 201710141935.5 use fused silica, bauxite, fused mullite, olivine, and zircon sand as the main raw materials, respectively, and the SiO2 contained therein will pollute the aluminum liquid; the pickling process in Chinese invention patent application number 200910227630.1 will cause environmental pollution; and the Chinese invention patent application number 202110664442.6 uses metallic aluminum powder that reacts violently with water, which can easily cause problems during casting. The following issues were identified: bulging and cracking of the refractory material; the silicon carbide raw material used in Chinese invention patent application number 200910227628.4 is easily oxidized during use; the vanadium-iron slag used in Chinese invention patent application number 201610770745.5 has a loose structure, making separation difficult and costly; Chinese invention patent application number 202111314447.2 uses fluorite as the main raw material, which is easily decomposed at high temperatures; the preparation process of Chinese invention patent application number 201710457328.X is long and not conducive to industrial production; and the use of corundum hollow spheres pretreated with aluminum titanate in Chinese invention patent application number 202010847377.6 reduces the strength and corrosion resistance of the castable. With the increasing market demand for high-quality aluminum and aluminum alloys, there is an urgent need for a high-strength castable resistant to aluminum molten metal wetting to prevent contamination of the aluminum molten metal by the refractory lining of the aluminum melting furnace during smelting. Summary of the Invention

[0003] This invention provides a high-strength aluminum-resistant molten aluminum-wetting castable product and process for aluminum melting furnaces. It selects corundum and Al2O3-MgO-CaO multiphase materials as the main raw materials, and supplements them with sintering aids, composite reinforcing agents and composite anti-explosion agents to promote the sintering of each component of the castable at medium temperature, effectively improving the molten aluminum-wetting resistance and physical properties of the castable under working conditions.

[0004] To achieve the above technical effects, the present invention adopts the following technical solution:

[0005] This invention discloses a high-strength, aluminum-resistant molten aluminum-wetting castable for aluminum melting furnaces, characterized in that it is composed of the following raw materials by mass percentage:

[0006] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99%, and the mass percentage is 50-70%;

[0007] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, and a mass percentage of 15-30%;

[0008] Alumina micro powder with a particle size ≤5μm, wherein w(Al2O3)≥99% and the mass percentage is 3-5%;

[0009] Silica micro powder with a particle size ≤2μm, wherein w(SiO2)≥96% and the mass percentage is 3-5%;

[0010] Anti-wetting agent, 1-5% by weight;

[0011] Sintering aid, with a mass percentage of 1-3%;

[0012] Composite reinforcing agent, with a mass percentage of 0.1-0.5%;

[0013] Composite explosion-proof agent, with a mass percentage of 0.1-0.3%;

[0014] Water-reducing agent, with a mass percentage of 0.1-0.3%;

[0015] The binder has a mass percentage of 4-6%.

[0016] Preferably, the corundum is one or more of white corundum, brown corundum, and dense corundum; the particle composition is: 25-45% of particles with a diameter of 5-3 mm, 30-60% of particles with a diameter of 3-1 mm, and 10-20% of particles with a diameter of 1-0 mm.

[0017] Preferably, the phase composition of the Al2O3-MgO-CaO multiphase material includes Ca2Mg2Al. 28 O 46 ,CaMg2Al 16 O 27 、CaAl 12 O 19 One or more of MgAl2O4.

[0018] Preferably, the anti-wetting agent is one or more of BaSO4 and BaCl2; the sintering aid is one or more of MgCO3 and MgCl2.

[0019] Preferably, the composite reinforcing agent has a composition ratio of aluminum silicate fiber: barium sulfate whisker material = 1:1; the composite explosion-proof agent has a composition ratio of polypropylene: azodicarbonamide = 1:2.

[0020] Preferably, the water-reducing agent is one or more of sodium tripolyphosphate, sodium hexametaphosphate, and polycarboxylic acid polymers; the binder is one or more of pure calcium aluminate cement and high-alumina cement.

[0021] A manufacturing process for a high-strength, aluminum-resistant molten aluminum-wetting castable for aluminum melting furnaces includes the following steps:

[0022] 1) Ingredients: The prepared Al2O3-MgO-CaO multiphase material, alumina micro powder, silica micro powder and additives are premixed in a planetary ball mill for 30 minutes;

[0023] 2) Mixing: After the corundum raw material is mixed evenly in the mixer, the mixing powder is added and then dry-mixed. Then water is added and kneaded for 2-3 minutes. The water-reducing agent is pre-dissolved in water and added.

[0024] 3) Molding: Fix the mold on the vibration table and fill it while vibrating. The vibration time should not exceed 3 minutes.

[0025] 4) Curing: Place the sample with the mold under conditions of humidity not less than 90% and temperature of 20℃±1℃ for 24 hours before demolding;

[0026] 5) Drying: Place the green sample at 110℃ and dry for 24 hours;

[0027] 6) Firing: The dried sample was kept in a high-temperature furnace at 900℃ for 3 hours.

[0028] Preferably, the premixing time in step 1) is 30 min; the stirring time in step 2) is 30 s, and the dry mixing time is 60 s.

[0029] The beneficial effects of this invention are as follows:

[0030] This invention belongs to the technical field of refractory materials for aluminum melting furnaces. The refractory castable is made by uniformly mixing corundum with a particle size ≤5mm, Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, alumina micro powder with a particle size ≤5μm, silica micro powder with a particle size ≤2μm, anti-wetting agent, sintering aid, composite reinforcing agent, composite explosion-proof agent, binder and water-reducing agent to obtain a high-strength anti-aluminum liquid wetting castable for aluminum melting furnaces.

[0031] This invention uses corundum as aggregate and introduces Al2O3-MgO-CaO multiphase material into the matrix to improve the wettability of the castable to molten aluminum. It also incorporates high-efficiency additives to improve its sintering performance and physical properties under operating conditions. Specifically, this is achieved by: 1) selecting corundum and Al2O3-MgO-CaO multiphase material as the main raw materials, effectively improving the strength and wettability of the castable to molten aluminum, and avoiding the introduction of impurities into the molten aluminum; and 2) adding sintering aids to the material to promote the sintering of the various components of the castable at medium temperatures. 3) Adding aluminum silicate fiber + barium sulfate whisker composite reinforcing agent to the material improves the strength of the castable under working conditions and effectively extends the service life of the castable on the basis of the original cement + micro powder combination; 4) Adding polypropylene + azodicarbonamide composite explosion-proof agent to the material, through the combination of organic fiber heating and foaming, forms a mesh capillary venting hole inside the castable, reduces the steam pressure generated during firing, and prevents the castable from cracking. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are merely preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a cross-sectional view of Example 1 after aluminum alloy etching.

[0034] Figure 2 This is a cross-sectional view of Example 2 after aluminum alloy etching.

[0035] Figure 3 This is a cross-sectional view of Example 3 after aluminum alloy etching.

[0036] Figure 4 This is a cross-sectional view of Example 4 after aluminum alloy etching.

[0037] Figure 5 This is a cross-sectional view of Example 5 after aluminum alloy etching.

[0038] Figure 6 This is a cross-sectional view of Example 6 after aluminum alloy etching.

[0039] Figure 7 This is a cross-sectional view of Example 7 after aluminum alloy etching.

[0040] Figure 8 This is a cross-sectional view of Example 8 after aluminum alloy etching.

[0041] Figure 9This is a cross-sectional view of Example 9 after aluminum alloy etching.

[0042] Figure 10 This is a cross-sectional view of Example 10 after aluminum alloy etching. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0044] Example 1

[0045] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0046] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% (i.e., the mass percentage of Al2O3 ≥ 99%), and the mass percentage is 70%;

[0047] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 15%;

[0048] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0049] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% (i.e., the mass percentage of SiO2 ≥ 50%), w(CaO) ≥ 48% (i.e., the mass percentage of CaO ≥ 48%), and the mass percentage is 3%;

[0050] The anti-wetting agent is BaCl2, with a mass percentage of 2%;

[0051] The sintering aid is MgCO3, with a mass percentage of 1%.

[0052] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0053] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0054] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0055] The binder is pure calcium aluminate cement, with a mass percentage of 4.6%.

[0056] The manufacturing process of the high-strength anti-aluminum-molten-wetting castable for aluminum melting furnaces in this embodiment includes the following steps:

[0057] 1) Ingredients: The fine powders of Al2O3-MgO-CaO multiphase material, alumina micro powder, and silica micro powder prepared in the above proportions, along with additives, are premixed in a planetary ball mill for 30 minutes; the additives include anti-wetting agents, sintering aids, composite reinforcing agents, composite explosion-proof agents, water-reducing agents, and binders.

[0058] 2) Mixing: Mix the corundum raw material in a mixer for 30 seconds, add the mixing powder and dry mix for 60 seconds, then add water and knead for 2-3 minutes. The water-reducing agent is pre-dissolved in water and added.

[0059] 3) Molding: Fix the mold on the vibration table and fill it while vibrating. The vibration time should not exceed 3 minutes.

[0060] 4) Curing: Place the sample with the mold under conditions of humidity not less than 90% and temperature of 20℃±1℃ for 24 hours before demolding;

[0061] 5) Drying: Place the green sample at 110℃ and dry for 24 hours;

[0062] 6) Firing: The dried sample was kept in a high-temperature furnace at 900℃ for 3 hours.

[0063] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0064] Example 2

[0065] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0066] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and mass percentage is 65%;

[0067] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 20%;

[0068] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0069] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0070] The anti-wetting agent is BaCl2, with a mass percentage of 2%;

[0071] The sintering aid is MgCO3, with a mass percentage of 1%.

[0072] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0073] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0074] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0075] The binder is pure calcium aluminate cement, with a mass percentage of 4.6%.

[0076] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0077] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0078] Example 3

[0079] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0080] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0081] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and the mass percentage is 60%;

[0082] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 25%;

[0083] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0084] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0085] The anti-wetting agent is BaCO3, with a mass percentage of 2%;

[0086] The sintering aid is MgCO3, with a mass percentage of 1%.

[0087] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0088] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0089] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0090] The binder is pure calcium aluminate cement, with a mass percentage of 4.6%.

[0091] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0092] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0093] Example 4

[0094] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0095] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and mass percentage is 55%;

[0096] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 30%;

[0097] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0098] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0099] The anti-wetting agent is BaCO3, with a mass percentage of 2%;

[0100] The sintering aid is MgCO3, with a mass percentage of 1%.

[0101] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0102] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0103] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0104] The binder is pure calcium aluminate cement, with a mass percentage of 4.6%.

[0105] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0106] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0107] Example 5

[0108] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0109] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and the mass percentage is 67%;

[0110] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 15%;

[0111] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0112] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0113] The anti-wetting agent is BaCl2, with a mass percentage of 5%.

[0114] The sintering aid is MgCO3, with a mass percentage of 1%.

[0115] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0116] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0117] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0118] The binder is pure calcium aluminate cement, with a mass percentage of 4.6%.

[0119] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0120] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0121] Example 6

[0122] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0123] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and the mass percentage is 69%;

[0124] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 15%;

[0125] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0126] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0127] The anti-wetting agent is BaCl2, with a mass percentage of 2%;

[0128] The sintering aid is MgCO3, with a mass percentage of 2%.

[0129] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0130] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0131] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0132] The binder is pure calcium aluminate cement, with a mass percentage of 4.6%.

[0133] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0134] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0135] Example 7

[0136] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0137] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and the mass percentage is 68%;

[0138] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 15%;

[0139] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0140] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0141] The anti-wetting agent is BaCl2, with a mass percentage of 2%;

[0142] The sintering aid is MgCO3, with a mass percentage of 3%.

[0143] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0144] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0145] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0146] The binder is pure calcium aluminate cement, with a mass percentage of 4.6%.

[0147] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0148] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0149] Example 8

[0150] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0151] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and the mass percentage is 70%;

[0152] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 15%;

[0153] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0154] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0155] The anti-wetting agent is BaCl2, with a mass percentage of 2%;

[0156] The sintering aid is MgCO3, with a mass percentage of 1%.

[0157] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.3%.

[0158] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0159] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0160] The binder is high-alumina cement, with a mass percentage of 4.4%.

[0161] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0162] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0163] Example 9

[0164] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0165] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and the mass percentage is 70%;

[0166] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 15%;

[0167] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0168] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0169] The anti-wetting agent is BaCl2, with a mass percentage of 2%;

[0170] The sintering aid is MgCO3, with a mass percentage of 1%.

[0171] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.5%.

[0172] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.1%.

[0173] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0174] The binder is high-alumina cement, with a mass percentage of 4.2%.

[0175] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0176] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0177] Example 10

[0178] The high-strength anti-aluminum liquid wetting castable for the aluminum melting furnace in this embodiment is prepared from the following raw materials by mass percentage: wherein, the raw materials include:

[0179] Corundum with a particle size ≤ 5 mm, wherein w(Al2O3) ≥ 99% and the mass percentage is 70%;

[0180] Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, with a mass percentage of 15%;

[0181] Alumina micro powder with a particle size ≤ 5 μm, wherein w(Al2O3) ≥ 99% and the mass percentage is 4%;

[0182] Silica micro powder with a particle size ≤ 5 μm, wherein w(SiO2) ≥ 50% and w(CaO) ≥ 48% by mass percentage is 3%;

[0183] The anti-wetting agent is BaCl2, with a mass percentage of 2%;

[0184] The sintering aid is MgCO3, with a mass percentage of 1%.

[0185] The composite reinforcing agent is composed of aluminum silicate fiber and barium sulfate whisker material in a 1:1 ratio, with a mass percentage of 0.1%.

[0186] The composite explosion-proof agent is composed of polypropylene and azodicarbonamide in a ratio of 1:2, with a mass percentage of 0.3%.

[0187] The water-reducing agent is sodium tripolyphosphate, with a mass percentage of 0.2%.

[0188] The binder is high-alumina cement, with a mass percentage of 4.4%.

[0189] The above raw materials are mixed according to the specified ratio, and then mixed evenly in a mixer. The mixture is placed on a vibrating table and vibrated to form the shape. After drying, the green body is fired in a high-temperature furnace at 900℃ for 3 hours. Other process steps are the same as in Example 1.

[0190] The performance and effects of the high-strength anti-aluminum liquid wetting castable prepared for aluminum melting furnace are shown in Tables 1 and 2.

[0191] Figures 1-10The images show cross-sectional views of the aluminum alloys after etching in Examples 1-10. The static crucible method was used to test the etching effect of the aluminum alloy on the castable. In this invention, 7075 aluminum alloy was selected for the etching resistance test. First, the castable was made into a crucible sample. The sample was heated to 850°C in a high-temperature furnace and held for 72 hours to allow the aluminum alloy to fully melt. Then, it was cooled to room temperature with the furnace. The crucible was then cut along its central axis to observe the alloy morphology and crucible nodule formation.

[0192] Table 1:

[0193]

[0194] Table 2:

[0195]

[0196] The above description is only for illustrating the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-strength, aluminum-resistant molten aluminum-wetting castable for aluminum melting furnaces, characterized in that: It consists of the following raw materials by weight percentage: Corundum with a particle size ≤5mm, wherein w(Al2O3)≥99% and mass percentage is 50-70%; Al2O3-MgO-CaO multiphase material with a particle size ≤0.074mm, in a mass percentage of 15-30%; Alumina micro powder with a particle size ≤5μm, wherein w(Al2O3)≥99% and mass percentage is 3-5%; Silica micro powder with a particle size ≤2μm, wherein w(SiO2)≥96% and mass percentage is 3-5%; Anti-wetting agent, 1-5% by weight; Sintering aid, 1-3% by mass; Composite reinforcing agent, with a mass percentage of 0.1% to 0.5%; Composite explosion-proof agent, with a mass percentage of 0.1% to 0.3%; Water-reducing agent, with a mass percentage of 0.1% to 0.3%; The binder has a mass percentage of 4-6%. The Al2O3-MgO-CaO composite material has a phase composition of one or more of Ca2Mg2Al 28 O 46 and CaMg2Al 16 O 27 ​ The composite reinforcing agent has a composition ratio of aluminum silicate fiber: barium sulfate whisker material = 1:1; the composite explosion-proof agent has a composition ratio of polypropylene: azodicarbonamide = 1:

2. The water-reducing agent is one or more of sodium tripolyphosphate and sodium hexametaphosphate; the binder is one or more of pure calcium aluminate cement and high-alumina cement. The anti-wetting agent is one or more of BaSO4 and BaCl2; the sintering aid is one or more of MgCO3 and MgCl2.

2. The high-strength anti-aluminum-molten-wetting castable for aluminum melting furnaces according to claim 1, characterized in that: The corundum is one or more of white corundum, brown corundum, and dense corundum; the particle composition is: 25-45% of particles with a diameter of 5-3 mm, 30-60% of particles with a diameter of 3-1 mm, and 10-20% of particles with a diameter of 1-0 mm.

3. The production process of a high-strength anti-aluminum-molten-wetting castable for aluminum melting furnaces according to claim 1 or 2 includes the following steps: 1) Ingredients: The prepared Al2O3-MgO-CaO multiphase material, alumina micro powder, silica micro powder and additives are premixed in a planetary ball mill for 30 minutes to obtain a mixed powder; 2) Mixing: After the corundum raw material is mixed evenly in the mixer, the mixing powder is added and then dry-mixed. Then water is added and kneaded for 2-3 minutes. The water-reducing agent is pre-dissolved in water and added. 3) Molding: Fix the mold on the vibration table and fill it while vibrating. The vibration time should not exceed 3 minutes. 4) Curing: Place the sample with the mold under conditions of humidity not less than 90% and temperature of 20℃±1℃ for 24 hours before demolding; 5) Drying: Place the green sample at 110℃ and dry for 24 hours; 6) Firing: The dried sample is kept in a high-temperature furnace at 900℃ for 3 hours.

4. The production process of a high-strength anti-aluminum-molten-wetting castable for aluminum melting furnaces according to claim 3, characterized in that: In step 2), the stirring time is 30 seconds and the dry mixing time is 60 seconds.

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