Formula and production process of metal ceramic composite wear-resistant body

Abstract

The invention relates to the technical field of metal ceramic composite wear-resistant balls, and discloses a formula and a production process of a metal ceramic composite wear-resistant body, and the metal ceramic composite wear-resistant body comprises a base material and a hardening material, the base material comprises the following components in percentage by weight: 72%-85% of aluminum oxide, 7%-12% of iron oxide red, 1%-2.7% of talc, 0.5%-2.3% of manganese oxide, 0.3%-1.1% of yttrium oxide and 0.5%-1.6% of titanium oxide, and the hardened material comprises the following components in percentage by weight: 0.7%-3.2% of zirconium oxide, 0.8%-2.6% of chromium oxide and 2.5%-4.2% of kaolin. By adding iron oxide red, aluminum oxide, talc, manganese oxide and yttrium oxide, the component density in the wear-resistant body is reduced, and zirconium oxide and chromium oxide are added to enhance the strength of the grinding body, so that the overall weight of the grinding body is reduced after the grinding body is added into a ball mill, the eccentric condition of the ball mill in the running process is avoided, and the service life of the ball mill is prolonged. And meanwhile, the power consumption of the grinding body in the using process is also reduced, so that the practicability and the application value of the grinding body are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of cermet composite wear-resistant balls, and specifically to a formula and production process of a cermet composite wear-resistant body. Background Art

[0002] Wear-resistant steel balls, also known as wear-resistant media for grinders, are consumables. Their main use is to grind materials to make them finer to meet the usage standards, and they are mainly used in fields such as mines, power plants, cement plants, steel plants, silica sand plants, and coal chemical industries.

[0003] During the use of existing wear-resistant balls, although they can grind materials and effectively ensure the stability of the media for grinding materials, during the use of existing steel balls and wear-resistant balls, due to the large weight of the steel balls, the steel balls will increase the centrifugal force of the rotating parts of the ball mill during the operation of the ball mill. This will not only cause the rotating parts of the ball mill to be prone to eccentricity, but also increase the operating current of the motor. Therefore, we have proposed a cermet composite wear-resistant body. Summary of the Invention

[0004] The present invention provides a formula and production process of a cermet composite wear-resistant body, which has the advantages of effectively reducing the eccentricity phenomenon during the operation of the ball mill, reducing power consumption, and having a lower wear rate, and solves the problems raised in the above background art.

[0005] The present invention provides the following technical solution: A formula of a cermet composite wear-resistant body includes a base material and a hardening material; The base material includes: alumina, accounting for 72% - 85%, iron oxide red, accounting for 7% - 12%, talc, 1% - 2.7%, manganese oxide, accounting for 0.5% - 2.3%, yttrium oxide, accounting for 0.3% - 1.1%, and titanium oxide, accounting for 0.5% - 1.6%; The hardening material includes zirconia, accounting for 0.7% - 3.2%, chromium oxide, accounting for 0.8% - 2.6%, and kaolin, accounting for 2.5% - 4.2%.

[0006] Preferably, the cermet composite balls prepared from the base material and the hardening material have three diameters, namely 40mm, 50mm, and 60mm, and the cermet composite balls can be used in combination with high-chromium steel balls.

[0007] A production process of a cermet composite wear-resistant body includes the following steps: Step S1: Ball milling processing of raw materials; Step S2: Spray granulation of the slurry; Step S3: Molding; Making raw materials for grinding bodies and pressing raw materials; Step S4: Drying and firing; Step S5: Final product inspection and warehousing.

[0008] Preferably, raw materials are taken for ball milling, and the corresponding proportions of base materials and hardening materials are weighed; Water is added, and water accounting for 45% - 48% of the material consumption is added according to the materials; A diluent is added, and it is added to the ball mill at 0.15% - 0.20% of the mass of the raw materials; The ball mill is started. After running for a certain period of time, the particle size distribution of the slurry is detected by a laser particle size analyzer; The slurry is discharged, and after removing rust and impurities by sieving, the slurry is put into a mixing tank.

[0009] Preferably, spray drying is carried out. The slurry is sent to a spray drying tower through a slurry pump and granulated by atomization and heating; The granulated powder is put into a silo for aging for 48 - 72h for standby.

[0010] Preferably, the grinding media is made. After the granulated powder is evenly distributed, it is transferred to the silo of a dry bag type briquetting press, and the granulated powder is filled into the mold through an automatic feeding system; Pressing: The equipment is pressurized to 26 - 30 MPa to press the granulated material. After pressing and forming, it is automatically demolded; Secondary pressing: The grinding media after the first pressing is bagged and sealed, and after being evacuated, it is placed in an isostatic pressing device for secondary pressing at a pressure value of 130 - 160 MPa; Recovery: After pressing, it is demolded and put into a plastic basket for standby; Making the lining plate: The granulated powder is transferred to the silo of a dry pressing press. After filling the mold, the granulated powder is pressed by the equipment pressurized to 20 - 30 MPa; Recovery: The semi-finished lining plates are stacked on the semi-finished product rack for standby.

[0011] Preferably, drying: The formed semi-finished products are loaded onto a kiln car, and the semi-finished products are dried, controlling the moisture content ≤ 0.5%; Firing: After the semi-finished products are dried, they enter a shuttle kiln and are fired according to the formulated firing curve.

[0012] The present invention has the following beneficial effects: 1. For the formula and production process of the cermet composite wear-resistant body, by adding iron oxide red, alumina, talc, manganese oxide and yttrium oxide components, the component density in the wear-resistant body is reduced. Then, zirconia and chromium oxide are added to strengthen the strength of the grinding media, so as to ensure that the overall weight of the grinding media is reduced after being added to the ball mill, avoiding the eccentricity of the ball mill during operation, and at the same time reducing the power consumption during the use of the grinding media, thereby improving the practicability and application value of the grinding media.

[0013] 2. The formula and production process of the cermet composite wear-resistant body. The overall weight of the grinding body prepared by this formula is reduced, and the cermet composite wear-resistant ball is made of inorganic non-metallic material with a covalent bond structure, which eliminates electrostatic adsorption and reduces the phenomenon of over-grinding, thus ensuring the grinding effect and grinding accuracy of the wear-resistant body on the material during use. The ball consumption ratio of the cermet composite wear-resistant ball to the high-chromium steel ball (section) is 1:2.5 to 1:3. That is, if the loss of steel ball (section) for producing one ton of cement is 25 grams, the loss of the cermet composite wear-resistant ball is about 8 grams, and the crushing rate is less than 3‰, thereby improving the wear resistance of the wear-resistant ball. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a schematic diagram of the formula components of the present invention; Figure 2 It is a schematic diagram of the production process flow of the present invention; Figure 3 It is a schematic diagram of the detailed parameters of the cermet composite wear-resistant body of the present invention; Figure 4 It is a schematic diagram of the quality inspection report of the traditional wear-resistant body; Figure 5 It is a schematic diagram of the quality inspection report of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0015] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0016] Please refer to Figures 1-5 , a formula of a cermet composite wear-resistant body, including a base material and a hardening material; The base material includes: alumina, accounting for 72% - 85%, iron oxide red, accounting for 7% - 12%, talc, 1% - 2.7%, manganese oxide, accounting for 0.5% - 2.3%, yttrium oxide, accounting for 0.3% - 1.1%, titanium oxide, accounting for 0.5% - 1.6%; The hardening material includes zirconia, accounting for 0.7% - 3.2%, chromium oxide, accounting for 0.8% - 2.6%, kaolin, accounting for 2.5% - 4.2%.

[0017] As a preferred technical solution of the present invention: The cermet composite balls prepared from the base material and the hardening material have three diameters, namely 40mm, 50mm, and 60mm, and the cermet composite balls can be used in combination with high-chromium steel balls.

[0018] In the above content, by adding components such as yttrium oxide, iron oxide red, alumina, talc, and manganese oxide, the proportion of components with a relatively large density inside the wear-resistant body is reduced during the preparation process. At the same time, by coordinating the ratio of zirconia and chromium oxide, the wear-resistant body has high strength and the characteristic of low density, thereby ensuring that the overall weight and load of the ball mill are reduced during the use process, reducing the probability of eccentricity during the operation of the ball mill, and also reducing the power consumption during the operation of the motor, thereby improving the practicality and application value of the wear-resistant body.

[0019] A production process of a cermet composite wear-resistant body includes the following steps. Step S1: Ball milling of raw materials; Step S2: Spray granulation of the slurry; Step S3: Molding; manufacturing raw materials for grinding bodies and pressing raw materials; Step S4: Drying and firing; Step S5: Final product inspection and warehousing.

[0020] In the above steps, the production operation of the wear-resistant body can be completed through the processing and granulation technologies of the existing technology, so as to ensure that production personnel can complete the production operation of the wear-resistant body with the technology they are familiar with, thereby reducing the technical difficulty and requirements in the production process of the wear-resistant body and further improving the practicality of the wear-resistant body.

[0021] As a preferred technical solution of the present invention: Take raw materials for ball milling, weigh the corresponding proportion of base materials and hardening materials; Add water, and add water with a proportion of 45% - 48% according to the amount of materials taken; Add a diluent, and add it to the ball mill at 0.15% - 0.20% of the mass of the raw materials; Start the ball mill. After running for a certain time, use a laser particle size analyzer to detect the particle size distribution of the slurry; Discharge the slurry, remove rust and impurities by sieving, and then put the slurry into the mixing tank.

[0022] In the above content, the diluents are actually organic solvents that are cheaper than resins, so they also play a role in reducing processing costs. The purpose of adding solvents is mainly for technological requirements. Because the addition of solvents can be used as a temporary measure to reduce the viscosity of polymers, so as to process polymers into products, thereby improving the efficiency of users in preparing the wear-resistant body. And the overall purity of the slurry after the steps of rust removal and impurity removal is improved, so as to ensure the strength and integrity of the wear-resistant body during the preparation process, and further ensure the overall strength of the wear-resistant body after preparation.

[0023] As a preferred technical solution of the present invention: Spray drying, the slurry is sent to the spray drying tower by a slurry pump and granulated through atomization and heating; Warehousing, the granulated powder is placed in the silo and aged for 48 - 72h for standby.

[0024] As a preferred technical solution of the present invention: Manufacturing grinding media, after leveling the granulated powder, it is transferred to the silo of a dry - bag type briquetting machine, and the granulated powder is filled into the mold through an automatic feeding system; Pressing, the equipment is pressurized to 26 - 30MPa to press the granulated material, and after pressing and forming, it is automatically demolded; Secondary pressing, the grinding media pressed for the first time is bagged and sealed, and after vacuum pumping, it is placed in an isostatic pressing device and pressed for the second time at a pressure value of 130 - 160MPa; Recovery, after pressing, it is demolded and placed in a plastic basket for standby; Manufacturing the lining plate, transfer the granulated powder to the silo of a dry - pressing press, fill the mold, and press the granulated powder with the equipment pressurized to 20 - 30MPa; Recovery, stack the semi - finished lining plates on the semi - finished product rack for standby.

[0025] As a preferred technical solution of the present invention: Drying: The formed semi - finished products are loaded onto the kiln car, and the semi - finished products are dried, controlling the moisture content ≤ 0.5%; Firing: After the semi - finished products are dried, they enter the shuttle kiln and are fired according to the formulated firing curve.

[0026] Wear resistance experiment of composite ceramic balls: Experimental equipment: Drum - type ball mill.

[0027] Experimental materials: Calcined bauxite with a particle size of 1 - 3mm Grinding media: Composite ceramic balls, high - chromium steel balls.

[0028] The first group of experiments: All use high - chromium steel balls for grinding experiments. The sphere diameters are 40mm, 50mm, and 60mm respectively. Weigh 1000KG of calcined bauxite and put it into the mill. According to different specifications, weigh 1000KG of high - chromium steel balls and put them into the mill in proportion. The ball - mill rotation speed is 23 revolutions per minute. Run for 200h and then stop the mill. Clean the floating ash on the ball surface, weigh the weight of the steel balls after grinding, obtain the wear loss, and calculate the hourly loss rate to be 0.022%. The power consumption is 2080 degrees.

[0029] The second group of experiments: All use composite ceramic balls for grinding experiments. The sphere diameters are 40mm, 50mm, and 60mm respectively. Weigh 1000kg of calcined bauxite and put it into the mill. The ball - mill rotation speed is 23 revolutions per minute. Run for 200h and then stop the mill. Clean the floating ash on the ball surface, weigh the weight of the composite balls after grinding, obtain the wear loss, and calculate the hourly loss rate to be 0.008%. The power consumption is 880 degrees.

[0030] The third group of experiments: Use iron balls and porcelain balls with equal surface areas. Weigh them proportionally according to the specifications of various balls. The total weight of the two types of balls is 1000 kg. Weigh 1000 kg of bauxite and put it into the mill. Then put the weighed steel balls and porcelain balls into the mill. The rotational speed of the ball mill is 23 revolutions per minute. Run for 200 hours and then discharge the mill. Weigh the steel balls and porcelain balls after grinding respectively to obtain the loss amount, and calculate the hourly loss rate of the two types of balls. The hourly loss rate of the steel balls is: 0.0140%. The hourly loss rate of the porcelain balls is: 0.0068%. The power consumption is 1120 degrees.

[0031] A method for using a cermet composite wear-resistant body: includes the following steps: S1: In the first bin (coarse grinding), it is recommended to use a mixture of steel balls (segments) and cermet composite wear-resistant balls. The specific quantity refers to the weight of the original steel balls (segments). Configure them according to the same grading (or use steel balls for large balls and cermet composite wear-resistant balls for medium and small balls). The weight ratio of the cermet composite wear-resistant balls to the steel balls is 1:2, and the volume ratio is 1:1; S2: In the second bin (fine grinding), all use cermet composite wear-resistant balls. The dosage is configured with reference to 60% of the weight of the original steel balls (segments) used. The recommended ball grading is φ13:φ15:φ17:φ20 = 20%:30%:30%:20%.

[0032] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprises", "comprising" or any other variation thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article or device.

[0033] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A formula of a metal-ceramic composite wear-resistant body, characterized in that: Includes base material and hardened material; The basic materials include: aluminum oxide, accounting for 72% to 85%, iron oxide red, accounting for 7% to 12%, talc, accounting for 1% to 2.7%, manganese oxide, accounting for 0.5% to 2.3%, yttrium oxide, accounting for 0.3% to 1.1%, titanium oxide, accounting for 0.5% to 1.6%; The hardening material includes zirconium oxide, accounting for 0.7% to 3.2%, chromium oxide, accounting for 0.8% to 2.6%, and kaolin, accounting for 2.5% to 4.2%.

2. The formula of a metal-ceramic composite wear-resistant body according to claim 1, characterized in that: The diameters of the metal-ceramic composite balls made of the base material and the hardened material are three types, namely 40 mm, 50 mm and 60 mm, and the metal-ceramic composite balls can be mixed with high-chromium steel balls for use.

3. The production process of a metal-ceramic composite wear-resistant body according to claim 2 comprises the following steps, characterized in that: Step S1: ball milling of raw materials; Step S2: slurry spray granulation; Step S3: forming; making abrasive body raw materials and pressing raw materials; Step S4: drying and sintering; Step S5: Finished product inspection and storage.

4. The formula and production process of a metal-ceramic composite wear-resistant body according to claim 3, characterized in that: Step S1 specifically includes: Take the raw materials for ball milling, and weigh the corresponding proportions of base material and hardening material; Add water, adding 45% to 48% water according to the amount of material used; Add diluent into the ball mill at 0.15% to 0.20% of the raw material mass; After the ball mill is turned on and runs for a certain period of time, the particle size distribution of the slurry is detected using a laser particle size analyzer; Release the slurry, sieve to remove rust and impurities, and then put the slurry into the mixing tank.

5. The formula of a metal-ceramic composite wear-resistant body and its production process according to claim 3, characterized in that: Step S2 specifically includes: Spray drying: the slurry is pumped into a spray drying tower through a slurry pump and granulated by atomization heating; Put the granulated powder in the silo for 48-72 hours for use.

6. The formula and production process of a metal-ceramic composite wear-resistant body according to claim 3, characterized in that: Step S3 specifically includes: To make a grinding body, the granulated powder is transferred to the silo of a dry bag briquette press after homogenization, and the granulated powder is filled into the grinding tool through an automatic feeding system; Pressing: the equipment pressurizes the granules to 26~30MPa, and the granules are automatically ejected from the mold after being pressed into shape; Secondary pressing: the ground body pressed once is bagged and sealed, and after vacuuming, it is placed in an isostatic pressing device for secondary pressing at a pressure value of 130-160 MPa; After recycling and pressing, remove the film and put it into a plastic basket for later use; Make the liner, transfer the granulated powder to the silo of the press, fill the mold and then press the granulated powder through the equipment to 20~30MPa; Recycling, stack the semi-finished lining products on the semi-finished product shelf for later use.

7. The formula and production process of a metal-ceramic composite wear-resistant body according to claim 3, characterized in that: Step S5 specifically includes: Drying: The semi-finished products are loaded onto the kiln car and dried to control the moisture content to ≤0.5%; Firing: After the semi-finished product is dried, it enters the shuttle kiln and is fired according to the specified firing curve.

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