High-performance wear-resistant ceramic material and method for producing same

Abstract

The application relates to a high-performance wear-resistant ceramic material and a preparation method thereof, and belongs to the technical field of ceramic materials, which comprises the following raw materials: 20-25 parts of potash feldspar, 50-60 parts of aluminum oxide, 3-5 parts of sintering aids, 10-14 parts of clay, 4-6 parts of reinforcing phases and 8-12 parts of modified binders; in the technical scheme, a lignin phenolic prepolymer and a phenolic compound are combined to obtain a lignin-based phenolic resin; the lignin-based phenolic resin is combined with silanized reinforcing materials to obtain a composite material; the composite material is combined with a functional polymer to obtain a modified binder; the potash feldspar, the aluminum oxide, the sintering aids, the clay and the reinforcing phases are mixed with the modified binder after being ball milled, granulated, compression molded and sintered, and finally the high-performance wear-resistant ceramic material is obtained; the modified binder effectively improves the mechanical properties, the thermal stability and the wear resistance of the ceramic material, and enhances the densification degree of the ceramic material, and the overall comprehensive performance is good.

Description

Technical Field

[0001] This invention belongs to the field of ceramic materials technology, specifically relating to a high-performance wear-resistant ceramic material and its preparation method. Background Technology

[0002] Ceramic materials are a class of inorganic non-metallic materials made from natural or synthetic compounds through molding and high-temperature sintering. These materials possess excellent properties such as high melting point, high hardness, and oxidation resistance, making them suitable not only as structural and cutting tool materials but also widely used in functional materials due to their unique physicochemical properties. In industrial applications, particularly in critical components such as ceramic valves, ceramic cylinder valve plates, and mechanical seals, their wear resistance, corrosion resistance, and stability are significantly reduced due to prolonged exposure to high wear, strong corrosion, or extreme conditions (such as high temperature, high pressure, and media containing solid particles). Traditional metallic materials (such as stainless steel and hard alloys), due to their lower hardness and insufficient corrosion resistance, are prone to severe wear, leading to a substantial reduction in component lifespan. Frequent component replacement not only increases maintenance costs but also affects the continuous and stable operation of equipment. Therefore, the application of wear-resistant ceramic materials in ceramic valves and valve plates is particularly important. The preparation of high-performance wear-resistant ceramic materials aims to meet the application requirements of ceramic valves and valve plates under harsh operating conditions, providing them with longer service life, higher safety, and lower maintenance costs. Therefore, there is an urgent need to develop a high-performance wear-resistant ceramic material with excellent comprehensive properties in order to expand its application scope in more industrial fields.

[0003] In the existing technology, in order to improve the mechanical properties of high-performance wear-resistant ceramic materials, fillers are usually added for blending and sintering. However, due to the uneven dispersion of fillers in the matrix, local agglomeration is easily formed, which not only affects the compactness of the ceramic material, but also generates pore defects during sintering, leading to a further reduction in the mechanical properties and wear resistance of the ceramic material. In addition, although traditional wear-resistant ceramic materials have high hardness and corrosion resistance, they have poor toughness and insufficient thermal shock resistance. When subjected to impact loads or undergoing complex working conditions such as thermal cycling, they are prone to brittle fracture, thus limiting their application range. Summary of the Invention

[0004] The purpose of this invention is to provide a high-performance wear-resistant ceramic material and its preparation method. The method involves combining lignin-based phenolic resin with phenolic compounds to obtain a lignin-based phenolic resin; combining the lignin-based phenolic resin from step S1 with a silanized reinforcing material to obtain a composite material; combining the composite material from step S2 with a functional polymer to obtain a modified binder; ball milling potassium feldspar, alumina, sintering aid, clay, and reinforcing phase, followed by mixing with the modified binder, granulation, pressing, and sintering to finally obtain the high-performance wear-resistant ceramic material. The modified binder effectively improves the mechanical properties, thermal stability, and wear resistance of the ceramic material, and also increases its densification. Furthermore, it exhibits good environmental friendliness, thus enhancing the overall performance of the ceramic material.

[0005] The technical problem to be solved by this invention is as follows: In the prior art, in order to improve the mechanical properties of high-performance wear-resistant ceramic materials, fillers are usually added for blending and sintering. However, due to the uneven dispersion of fillers in the matrix, local agglomeration is easily formed, which not only affects the compactness of the ceramic material, but also generates pore defects during sintering, resulting in a further reduction in the mechanical properties and wear resistance of the ceramic material. In addition, although traditional wear-resistant ceramic materials have high hardness and corrosion resistance, they have poor toughness and insufficient thermal shock resistance. When subjected to impact loads or undergoing complex working conditions such as thermal cycling, they are prone to brittle fracture, thus limiting their application range.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] A high-performance wear-resistant ceramic material comprises the following raw materials in parts by weight: 20-25 parts potassium feldspar, 50-60 parts alumina, 3-5 parts sintering aid, 10-14 parts clay, 4-6 parts reinforcing phase, and 8-12 parts modified binder.

[0008] The preparation method of the modified adhesive includes the following steps:

[0009] A1: By combining lignin phenol prepolymer and phenolic compounds, lignin-based phenolic resin is obtained;

[0010] A2: Combine the lignin-based phenolic resin from step S1 with the silanized reinforcing material to obtain a composite material;

[0011] A3: Combine the composite material from step S2 with a functional polymer to obtain a modified adhesive.

[0012] Further, step A1 specifically includes:

[0013] Phenolic compounds are mixed evenly with lignin phenol prepolymer, then heated to 85-95℃ and held for 50-70 min, then cooled to 55-65℃, formaldehyde solution and sodium hydroxide are added and stirred evenly. After reacting at 55-65℃ for 20-40 min, the temperature is further increased to 95-105℃ and reacted for 2-3 h. After the reaction is completed, the mixture is cooled to room temperature, washed with anhydrous ethanol and deionized water, filtered, and finally vacuum dried at 60-70℃ to obtain lignin-based phenolic resin.

[0014] In the above reaction process, both the lignin phenol prepolymer and the phenolic compound have phenolic hydroxyl groups, and their ortho and para positions have active hydrogen atoms. Under alkaline conditions, the active hydrogen atoms at the ortho and para positions of the lignin phenol prepolymer and the phenolic compound can combine with formaldehyde through a condensation reaction, and finally generate lignin-based phenolic resin.

[0015] Further, the mass ratio of the phenolic compound, lignin phenol prepolymer, formaldehyde solution, and sodium hydroxide is 0.1-0.2:0.9-1.1:0.4-0.6:0.05-0.07.

[0016] Furthermore, the phenolic compound is composed of resveratrol and cashew phenol in a mass ratio of 0.7-0.8:0.5-0.6.

[0017] Furthermore, the preparation method of the lignin phenol prepolymer includes the following steps:

[0018] Alkali lignin, sodium hydroxide, and phenol are mixed and stirred evenly. The mixture is then heated to 85-95℃ and reacted for 1-1.5 hours. After the reaction is complete, the mixture is cooled to room temperature and then added to deionized water to precipitate the lignin. The precipitate is filtered, washed with anhydrous ethanol and deionized water, and finally dried under vacuum at 60-70℃ to obtain the lignin phenol prepolymer.

[0019] In the above reaction process, phenol and alkali lignin combine under alkaline conditions through a phenolation reaction, thereby introducing a new phenolic structure, improving the reactivity of alkali lignin, and finally combining phenol and alkali lignin to obtain lignin phenol prepolymer.

[0020] Furthermore, the mass ratio of the alkali lignin, sodium hydroxide, and phenol is 0.3-0.5:0.04-0.06:0.9-1.1.

[0021] Furthermore, step A2 specifically involves:

[0022] The photoinitiator, isopropanol, lignin-based phenolic resin from step A1, and silanized reinforcing material are mixed evenly, and then stirred and reacted at room temperature and under ultraviolet light for 22-24 hours. After the reaction is completed, the mixture is centrifuged for 3-5 minutes, washed with isopropanol, and finally vacuum dried at 45-55℃ to obtain the composite material.

[0023] In the above reaction process, the lignin-based phenolic resin has carbon-carbon double bonds, and the silanized reinforcing material has thiol groups. Under the action of the photoinitiator, the carbon-carbon double bonds in the lignin-based phenolic resin can react and combine with the thiol groups in the silanized reinforcing material, thus combining the lignin-based phenolic resin and the silanized reinforcing material to finally obtain a composite material.

[0024] Furthermore, the mass ratio of the photoinitiator, isopropanol, lignin-based phenolic resin, and silanized reinforcing material is 0.004-0.006:15-25:0.9-1.1:0.3-0.5.

[0025] Furthermore, the photoinitiator is 2,2-dimethoxy-2-phenylacetophenone.

[0026] Furthermore, the preparation method of the silanized reinforced material includes the following steps:

[0027] The reinforcing material, ethanol, and silane coupling agent are mixed and reacted at 85-95℃ for 46-50h. After the reaction is completed, the mixture is cooled to room temperature, centrifuged for 5-10min, washed with ethanol, and finally vacuum dried at 45-55℃ to obtain the silanized reinforcing material.

[0028] In the above reaction process, the reinforcing material has hydroxyl groups. After the silane coupling agent is hydrolyzed, silanol groups are generated. The silanol groups in the silane coupling agent can react and combine with the hydroxyl groups in the reinforcing material, grafting the silane coupling agent onto the surface of the reinforcing material, and finally obtaining the silanized reinforcing material.

[0029] Furthermore, the mass ratio of the reinforcing material, ethanol, and silane coupling agent is 0.6-0.8:30-40:4-5.

[0030] Furthermore, the silane coupling agent is 3-mercaptopropyltrimethoxysilane.

[0031] Furthermore, the method for preparing the reinforcing material includes the following steps:

[0032] The pretreated fiber material was added to a toluene solution, followed by triethoxymethylsilane, and stirred until homogeneous. Then, hydrochloric acid solution was added to adjust the pH of the system to 2.5-3.5. The reaction was carried out under a nitrogen atmosphere at 70-80℃ for 4-6 hours. After the reaction was completed, the mixture was cooled to room temperature, filtered, washed with deionized water and anhydrous ethanol, and finally dried at 60-70℃ to obtain the reinforcing material.

[0033] In the above reaction process, the surface of the pretreated fiber material has hydroxyl groups. Triethoxymethylsilane can combine with the hydroxyl groups on the surface of the pretreated fiber material after hydrolysis and condensation, thereby growing silicon nanowires in situ on the surface of the pretreated fiber material, and finally obtaining the reinforcing material.

[0034] Furthermore, the mass ratio of the pretreated fiber material, toluene solution, and triethoxymethylsilane is 0.9-1.1:80-100:9-10.

[0035] Furthermore, the specific processing procedure for the pretreated fiber material is as follows:

[0036] The fiber material is added to acetone and heated in an oil bath at 55-65℃ for 7-9 hours. After heating, it is washed with deionized water and then vacuum dried at 75-85℃ for 0.5-1.5 hours. Then it is immersed in a piranha solution and stirred at 85-95℃ for 25-35 minutes. It is then washed with deionized water and finally vacuum dried at 75-85℃ for 2-3 hours to obtain the pretreated fiber material.

[0037] Furthermore, the mass ratio of the fiber material, acetone, and piranha solution is 0.8-1.2:25-35:25-35.

[0038] Furthermore, the fiber material is composed of basalt fiber and chopped carbon fiber mixed in a mass ratio of 0.8-0.9:0.6-0.7.

[0039] Furthermore, step A3 specifically involves:

[0040] Concentrated sulfuric acid was added to the functional polymer, followed by the composite material from step A2, and the mixture was stirred until homogeneous. The mixture was then reacted at 135-145℃ for 1-2 hours. After the reaction was completed, sodium hydroxide solution was added to adjust the pH of the system to 7-8. The mixture was then filtered, washed with deionized water, and the pH of the filtrate was adjusted to 5-5.5 with sulfuric acid solution. The filtrate was centrifuged for 5-10 minutes and finally dried at 35-45℃ to obtain the modified binder.

[0041] In the above reaction process, the functional polymer has hydroxyl groups, and the composite material also has phenolic hydroxyl groups. The hydroxyl groups in the functional polymer can react and combine with the phenolic hydroxyl groups in the composite material under acid catalysis, thus combining the functional polymer and the composite material to finally obtain the modified adhesive.

[0042] Furthermore, the mass ratio of the concentrated sulfuric acid, the functional polymer, and the composite material is 0.1-0.2: 4.9-5.1: 0.9-1.1.

[0043] Furthermore, the functional polymer is composed of polypropylene glycol and hyperbranched polyester in a mass ratio of 1-1.2:0.7-0.8.

[0044] Furthermore, the preparation method of the hyperbranched polyester includes the following steps:

[0045] Trimethylolpropane, p-toluenesulfonic acid, and N,N-dimethylformamide were mixed evenly and heated to 140°C to obtain component A. 2,2-Dimethylolpropionic acid was added to N,N-dimethylformamide and stirred until completely dissolved to obtain component B. Component B was added to component A and reacted at 140°C for 6 hours. After the reaction was completed, the mixture was cooled to room temperature, and N,N-dimethylformamide was removed by rotary evaporation at 65°C to finally obtain hyperbranched polyester.

[0046] Furthermore, the mass ratio of trimethylolpropane, p-toluenesulfonic acid, and N,N-dimethylformamide is 0.3:0.02:20.

[0047] Furthermore, the mass ratio of 2,2-dimethylolpropionic acid to N,N-dimethylformamide is 0.8:35.

[0048] Furthermore, the mass ratio of component A to component B is 1:1.

[0049] A method for preparing a high-performance wear-resistant ceramic material includes the following steps:

[0050] S1: Ball milling: Weigh the raw materials by mass, add potassium feldspar, alumina, sintering aid, clay and reinforcing phase into a ball mill for mixing and ball milling to obtain a premix;

[0051] S2: Spray granulation: The premix obtained in step S1 is mixed with the modified binder and then spray granulated to obtain ceramic powder;

[0052] S3: Press molding: The ceramic powder obtained in step S2 is placed in a mold for pressing molding to obtain a ceramic blank;

[0053] S4: Sintering: The ceramic blank obtained in step S3 is placed in a sintering furnace and sintered under inert gas protection. After cooling to room temperature with the furnace, a high-performance wear-resistant ceramic material is obtained.

[0054] Further, in step S1, the sintering aid is composed of lanthanum oxide and molybdenum trioxide mixed in a mass ratio of 0.6-0.7:0.4-0.5.

[0055] Furthermore, in step S1, the clay is at least one of bentonite, kaolin, and montmorillonite.

[0056] Furthermore, in step S1, the reinforcing phase is composed of nano-silica and nano-zirconia mixed in a mass ratio of 2:1.

[0057] Furthermore, in step S1, the ball milling speed is 300-500 r / min, and the ball milling time is 6-8 h.

[0058] Further, in step S2, during the spray granulation and spray drying process, the inlet hot air temperature of the dryer is 310-330℃, and the outlet temperature is 90-110℃. After granulation, a loose bulk density of 0.9-1 g / cm³ is obtained. 3 Ceramic powder.

[0059] Furthermore, in step S3, the pressure of the compression molding is 110-130 MPa.

[0060] Further, in step S4, the sintering process is as follows: first, the temperature is raised to 800-1000℃ at a rate of 4-6℃ / min, and then raised to 2000-2200℃ at a rate of 7-10℃ / min, with a sintering time of 1-2 hours.

[0061] A high-performance wear-resistant ceramic material is prepared by the above-mentioned method for preparing high-performance wear-resistant ceramic materials.

[0062] The beneficial effects of this invention are:

[0063] (1) In the technical solution of this invention, lignin-based phenolic resin is obtained by combining lignin phenol prepolymer and phenolic compounds. Phenolic resin is commonly used as the matrix resin of heat-resistant adhesives. It has excellent mechanical properties, high temperature resistance and chemical stability, and can provide stable bonding performance in complex environments. However, phenol and formaldehyde are often used in the preparation of phenolic resin, which have certain toxicity and will cause harm to the environment and human health. The alkali lignin in the lignin prepolymer can provide hydroxyl and aldehyde groups at the same time, thereby reducing the use of phenol and formaldehyde and achieving the purpose of environmental protection. However, the added lignin prepolymer will also cause a certain degree of decrease in the mechanical properties, thermal properties and wear resistance of phenolic resin. By adding phenolic compounds composed of resveratrol and cashew nut phenol, the mechanical properties, thermal stability and wear resistance of phenolic resin can be effectively improved. The combination of resveratrol and cashew nut phenol can play a synergistic role and improve the mechanical properties, thermal stability and wear resistance of phenolic resin. The composite material exhibits improved antioxidant, mechanical, and wear-resistant properties, and resveratrol and cashew nut shells can provide reaction sites for subsequent reactions. A lignin-based phenolic resin is combined with a silanized reinforcing material to obtain a composite material. The silanized reinforcing material is prepared by grafting the reinforcing material with a silane coupling agent. The silane coupling agent not only improves the dispersibility of the reinforcing material and prevents its agglomeration, but also enhances the bonding force between the reinforcing material and the lignin-based phenolic resin, increasing their compatibility and thus further improving the mechanical properties, thermal stability, wear resistance, and adhesive properties of the phenolic resin. A reinforcing material is prepared by mixing basalt fibers and chopped carbon fibers, with silicon nanowires grown in situ on the surface of the fiber material. The basalt fibers and chopped carbon fibers work synergistically to effectively improve the flexural strength, fracture toughness, and wear resistance of the ceramic material, and the in-situ growth of silicon nanowires on the surface of the fiber material further improves the corrosion resistance, mechanical properties, and wear resistance of the ceramic material.

[0064] (2) In the technical solution of the present invention, the composite material is combined with the functional polymer to obtain the modified binder; the functional polymer is composed of polypropylene glycol and hyperbranched polyester, which play a synergistic role and can better enhance the heat resistance, mechanical strength and flexibility of phenolic resin. Combining the composite material with the functional polymer can further improve the mechanical properties, thermal stability, wear resistance and heat resistance of ceramic materials, and reduce the harm to the environment. In addition, it can further improve the adhesion between the modified binder and other raw materials, and enhance the densification degree and mechanical properties of ceramic materials; after ball milling potassium feldspar, alumina, sintering aid, clay and reinforcing phase, it is mixed with the modified binder and sprayed. The process involves atomization, pressing, and sintering to obtain a high-performance wear-resistant ceramic material. The sintering aid is a mixture of lanthanum oxide and molybdenum trioxide. Lanthanum oxide and molybdenum trioxide can inhibit abnormal grain growth, making the ceramic structure more uniform and dense, and further improving the sintering performance of the ceramic. The sintering aid significantly improves the densification degree and mechanical properties of the ceramic during the sintering process. The reinforcing phase is a mixture of nano-silica and nano-zirconia. The two can also synergistically improve the densification degree, mechanical properties, and wear resistance of the ceramic. In addition, the prepared high-performance wear-resistant ceramic material can play a good reinforcing role in components such as ceramic valves and ceramic valve plates, effectively improving their wear resistance, corrosion resistance, thermal stability, and mechanical properties.

[0065] (3) In the technical solution of the present invention, a modified binder is obtained by combining lignin phenol prepolymer and phenolic compounds, then combining them with silanized reinforcing materials, and then combining them with functional polymers. Potassium feldspar, alumina, sintering aid, clay and reinforcing phase are ball-milled and then mixed with the modified binder. After granulation, pressing and sintering, a high-performance wear-resistant ceramic material is finally obtained. This not only improves the mechanical properties, thermal stability and wear resistance of ceramic materials, but also the obtained ceramic material has a good degree of densification, good environmental protection and good comprehensive performance. In addition, the obtained high-performance wear-resistant ceramic material has a good application effect in ceramic valves, ceramic valve plates and other components, which can effectively improve the service life of these components, improve their durability under harsh working conditions, reduce maintenance costs and significantly improve their comprehensive performance. Detailed Implementation

[0066] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0067] The specific parameters of the raw materials used in this invention are as follows:

[0068] Resveratrol, CAS No.: 501-36-0, Trade Code: R817262, provided by Shanghai Maclean Biochemical Technology Co., Ltd.; Cashew phenol, CAS No.: 501-24-6, provided by Zhongshan Dixin Chemical Co., Ltd.; Alkali lignin, CAS: 9005-53-2, provided by Shanghai Aladdin Biochemical Technology Co., Ltd.; 3-Mercaptopropyltrimethoxysilane, CAS No.: 4420-74-0, provided by Shandong Jinyufeng New Material Co., Ltd.; Basalt fiber, density: 3.52 g / cm³, particle size: 3.08 μm, provided by Shijiazhuang Xinsheng Mineral Products Co., Ltd.; Short-cut carbon fiber, thickness: 6-7 μm, provided by Shanghai Lishuo Composite Materials Technology Co., Ltd.; Polypropylene glycol, CAS No.: 25322-69-4, Trade Code: P 815574, provided by Shanghai Maclean Biochemical Technology Co., Ltd.; Nano silica, CAS No.: 7631-86-9, Product No.: A61745, provided by Saen Chemical Technology (Shanghai) Co., Ltd.; Nano zirconium oxide, CAS No.: 1399-6-6, Model: M100, provided by Qinghe County Chaotai Metal Materials Co., Ltd.; Bentonite, CAS No.: 1302-78-9, Product No.: B953740, provided by Shanghai Maclean Biochemical Technology Co., Ltd.; Kaolin, CAS No.: 1332-58-7, Product No.: K812209, provided by Shanghai Maclean Biochemical Technology Co., Ltd.; Montmorillonite, CAS No.: 1318-93-0, Product No.: M813515, provided by Shanghai Maclean Biochemical Technology Co., Ltd.

[0069] The preparation method of hyperbranched polyester includes the following steps:

[0070] Trimethylolpropane, p-toluenesulfonic acid, and N,N-dimethylformamide were mixed evenly at a mass ratio of 0.3:0.02:20 and heated to 140°C to obtain component A. 2,2-Dimethylolpropionic acid was added to N,N-dimethylformamide at a mass ratio of 0.8:35 and stirred until completely dissolved to obtain component B. Component B was added to component A at a mass ratio of 1:1, and the mixture was reacted at 140°C for 6 hours. After the reaction was completed, the mixture was cooled to room temperature, and N,N-dimethylformamide was removed by rotary evaporation at 65°C to obtain the hyperbranched polyester.

[0071] Example 1

[0072] The specific steps for preparing the modified adhesive are as follows:

[0073] A1: The phenolic compound and lignin phenol prepolymer were mixed evenly according to the mass ratio of phenolic compound, lignin phenol prepolymer, formaldehyde solution, and sodium hydroxide of 0.1:0.9:0.4:0.05. The mixture was then heated to 85℃ and kept at that temperature for 70 min. After cooling to 55℃, 37wt% formaldehyde solution and sodium hydroxide were added and stirred evenly. The mixture was reacted at 55℃ for 40 min, then heated to 95℃ and reacted for 3 h. After the reaction was completed, the mixture was cooled to room temperature and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of the lignin phenol prepolymer, and each time the mass of deionized water was 15 times the mass of the lignin phenol prepolymer). After filtration, the mixture was vacuum dried at 60℃ for 48 h to obtain lignin-based phenolic resin. The phenolic compound was composed of resveratrol and cashew phenol in a mass ratio of 0.7:0.5.

[0074] The preparation method of lignin phenol prepolymer includes the following steps:

[0075] The alkali lignin, sodium hydroxide, and phenol were mixed and stirred evenly according to a mass ratio of 0.3:0.04:0.9. The mixture was then heated to 85°C and reacted for 1.5 hours. After the reaction was completed, the mixture was cooled to room temperature and then added to deionized water (the mass of deionized water was 15 times the mass of phenol) to precipitate the phenol. The precipitate was filtered and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of phenol, and each time the mass of deionized water was 15 times the mass of phenol). Finally, the mixture was vacuum dried at 60°C for 24 hours to obtain the lignin phenol prepolymer.

[0076] A2: Following a mass ratio of 0.004:15:0.9:0.3 for 2,2-dimethoxy-2-phenylacetophenone, isopropanol, lignin-based phenolic resin, and silanized reinforcing material, mix the 2,2-dimethoxy-2-phenylacetophenone, isopropanol, lignin-based phenolic resin from step A1, and silanized reinforcing material thoroughly. Then, stir and react for 22 hours at room temperature under ultraviolet light irradiation (UV wavelength 365 nm, light intensity 25 W / cm²). 2 After the reaction was completed, the mixture was centrifuged at 15,000 rpm for 5 min, washed 5 times with isopropanol (each time the mass of isopropanol was 50% of the mass of the above isopropanol), and finally vacuum dried at 45℃ for 24 h to obtain the composite material.

[0077] The preparation method of silanized reinforced materials includes the following steps:

[0078] The reinforcing material, ethanol, and 3-mercaptopropyltrimethoxysilane were mixed in a mass ratio of 0.6:30:4 and reacted at 85°C for 50 h. After the reaction was completed, the mixture was cooled to room temperature, centrifuged at 15000 rpm for 10 min, washed three times with ethanol (each time the ethanol mass was 40% of the above ethanol mass), and finally vacuum dried at 45°C for 24 h to obtain the silanized reinforcing material.

[0079] The preparation method of the reinforcing material includes the following steps:

[0080] The pretreated fiber material, toluene solution, and triethoxymethylsilane were mixed in a mass ratio of 0.9:80:9. The pretreated fiber material was added to the toluene solution, followed by the triethoxymethylsilane, and stirred until homogeneous. Then, 32 wt% hydrochloric acid solution was added to adjust the pH of the system to 2.5. The reaction was carried out under a nitrogen atmosphere at 70°C for 6 hours. After the reaction was completed, the mixture was cooled to room temperature, filtered, and washed three times each with deionized water and anhydrous ethanol (each time the mass of deionized water was 15% of the mass of the toluene solution, and each time the mass of anhydrous ethanol was 10% of the mass of the toluene solution). Finally, the mixture was dried at 60°C for 12 hours to obtain the reinforcing material.

[0081] The specific processing procedure for the pretreated fiber materials is as follows:

[0082] The fiber material was added to acetone at a mass ratio of 0.8:25:25 and heated in an oil bath at 55°C for 9 hours. After heating, it was washed three times with deionized water (each time the mass of deionized water was 40% of the mass of acetone), then vacuum dried at 75°C for 1.5 hours, and then immersed in the piranha solution (the piranha solution was composed of 98wt% concentrated sulfuric acid and 30wt% hydrogen peroxide solution mixed in a volume ratio of 7:3). It was stirred at 85°C for 35 minutes, then washed three times with deionized water (each time the mass of deionized water was 50% of the mass of acetone), and finally vacuum dried at 75°C for 3 hours to obtain the pretreated fiber material, which was composed of basalt fiber and chopped carbon fiber mixed in a mass ratio of 0.8:0.6.

[0083] A3: According to the mass ratio of concentrated sulfuric acid, functional polymer, and composite material of 0.1:4.9:0.9, 98wt% concentrated sulfuric acid was added to the functional polymer, followed by the composite material from step A2, and the mixture was stirred evenly. The mixture was then reacted at 135℃ for 2 hours. After the reaction was completed, 0.2mol / L sodium hydroxide solution was added to adjust the pH of the system to 7. The mixture was filtered, washed three times with deionized water (the mass of deionized water was 10 times the mass of concentrated sulfuric acid), and then the pH of the system was adjusted to 5 with 5mol / L sulfuric acid solution. The mixture was centrifuged at 10000rpm for 10 minutes and finally dried at 35℃ for 48 hours to obtain the modified adhesive. The functional polymer was composed of polypropylene glycol and hyperbranched polyester mixed in a mass ratio of 1:0.7.

[0084] A high-performance wear-resistant ceramic material comprises the following raw materials in parts by weight: 20 parts potassium feldspar, 50 parts alumina, 3 parts sintering aid, 10 parts bentonite, 4 parts reinforcing phase, and 8 parts modified binder.

[0085] The sintering aid is composed of lanthanum oxide and molybdenum trioxide mixed in a mass ratio of 0.6:0.4; the reinforcing phase is composed of nano-silica and nano-zirconium oxide mixed in a mass ratio of 2:1.

[0086] The preparation method includes the following steps:

[0087] S1: Ball milling: Weigh the raw materials by mass, add potassium feldspar, alumina, sintering aid, bentonite and reinforcing phase into a ball mill for mixing and ball milling. The ball milling speed is 300 r / min and the ball milling time is 8 h. Zirconia balls are used as grinding balls. The mass of the grinding balls is 4 times the total mass of potassium feldspar, alumina, sintering aid, clay and reinforcing phase (i.e., the ball-to-material ratio is 4:1) to obtain a premix with a particle size of 0.5 μm.

[0088] S2: Granulation: The premix obtained in step S1 is mixed with the modified binder, and then spray granulation is performed. During spray drying, the inlet hot air temperature of the dryer is 310℃ and the outlet temperature is 90℃. After granulation, a loose density of 0.9 g / cm³ is obtained. 3 Ceramic powder;

[0089] S3: Compression molding: The ceramic powder obtained in step S2 is placed in a mold for compression molding to obtain a ceramic blank, wherein the compression molding pressure is 110MPa;

[0090] S4: Sintering: The ceramic blank obtained in step S3 is placed in a sintering furnace and sintered under the protection of an inert gas (argon). After cooling to room temperature with the furnace, a high-performance wear-resistant ceramic material is obtained. The sintering process is as follows: first, the temperature is raised to 800℃ at a rate of 4℃ / min, and then raised to 2000℃ at a rate of 7℃ / min. The sintering time is 2h.

[0091] Example 2

[0092] The specific steps for preparing the modified adhesive are as follows:

[0093] A1: The phenolic compound, lignin phenol prepolymer, formaldehyde solution, and sodium hydroxide were mixed evenly according to a mass ratio of 0.15:1:0.5:0.06. The mixture was then heated to 90℃ and held for 60 min, followed by cooling to 60℃. 37 wt% formaldehyde solution and sodium hydroxide were added and stirred evenly. The mixture was reacted at 60℃ for 30 min, then heated to 100℃ and reacted for 2.5 h. After the reaction was completed, the mixture was cooled to room temperature and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of the lignin phenol prepolymer, and each time the mass of deionized water was 15 times the mass of the lignin phenol prepolymer). After filtration, the mixture was vacuum dried at 65℃ for 48 h to obtain lignin-based phenolic resin. The phenolic compound was composed of resveratrol and cashew phenol in a mass ratio of 0.75:0.55.

[0094] The preparation method of lignin phenol prepolymer includes the following steps:

[0095] The alkali lignin, sodium hydroxide, and phenol were mixed and stirred evenly according to a mass ratio of 0.4:0.05:1. The mixture was then heated to 90°C and reacted for 1.2 hours. After the reaction was completed, the mixture was cooled to room temperature and then added to deionized water (the mass of deionized water was 15 times the mass of phenol) to precipitate the phenol. The precipitate was filtered and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of phenol, and each time the mass of deionized water was 15 times the mass of phenol). Finally, the mixture was vacuum dried at 65°C for 24 hours to obtain the lignin phenol prepolymer.

[0096] A2: Following a mass ratio of 0.005:20:1:0.4 for 2,2-dimethoxy-2-phenylacetophenone, isopropanol, lignin-based phenolic resin, and silanized reinforcing material, mix the 2,2-dimethoxy-2-phenylacetophenone, isopropanol, lignin-based phenolic resin from step A1, and silanized reinforcing material thoroughly. Then, stir and react for 23 hours at room temperature under ultraviolet light irradiation (UV wavelength 365 nm, light intensity 25 W / cm²). 2 After the reaction was completed, the mixture was centrifuged at 18,000 rpm for 4 min, washed 5 times with isopropanol (each time the mass of isopropanol was 50% of the mass of the above isopropanol), and finally vacuum dried at 50℃ for 24 h to obtain the composite material.

[0097] The preparation method of silanized reinforced materials includes the following steps:

[0098] The reinforcing material, ethanol, and 3-mercaptopropyltrimethoxysilane were mixed in a mass ratio of 0.7:35:4.5 and reacted at 90°C for 48 h. After the reaction was completed, the mixture was cooled to room temperature, centrifuged at 18,000 rpm for 8 min, washed three times with ethanol (each time the ethanol mass was 40% of the above ethanol mass), and finally dried under vacuum at 50°C for 24 h to obtain the silanized reinforcing material.

[0099] The preparation method of the reinforcing material includes the following steps:

[0100] The pretreated fiber material, toluene solution, and triethoxymethylsilane were mixed in a mass ratio of 1:90:9.5. The pretreated fiber material was added to the toluene solution, followed by the triethoxymethylsilane, and stirred until homogeneous. Then, 32 wt% hydrochloric acid solution was added to adjust the pH of the system to 3. The reaction was carried out under a nitrogen atmosphere at 75°C for 5 hours. After the reaction was completed, the mixture was cooled to room temperature, filtered, and washed three times each with deionized water and anhydrous ethanol (each time the mass of deionized water was 15% of the mass of the toluene solution, and each time the mass of anhydrous ethanol was 10% of the mass of the toluene solution). Finally, the mixture was dried at 65°C for 12 hours to obtain the reinforcing material.

[0101] The specific processing procedure for the pretreated fiber materials is as follows:

[0102] The fiber material, acetone, and piranha solution were mixed in a mass ratio of 1:30:30. The mixture was heated in an oil bath at 60°C for 8 hours. After heating, the fiber material was washed three times with deionized water (each time the deionized water mass was 40% of the acetone mass). Then, it was vacuum dried at 80°C for 1 hour. Next, it was immersed in the piranha solution (the piranha solution was composed of 98wt% concentrated sulfuric acid and 30wt% hydrogen peroxide solution in a volume ratio of 7:3) and stirred at 90°C for 30 minutes. The mixture was then washed three times with deionized water (each time the deionized water mass was 50% of the acetone mass). Finally, it was vacuum dried at 80°C for 2.5 hours to obtain the pretreated fiber material, which was composed of basalt fiber and chopped carbon fiber in a mass ratio of 0.85:0.65.

[0103] A3: According to the mass ratio of concentrated sulfuric acid, functional polymer, and composite material of 0.15:5:1, 98wt% concentrated sulfuric acid was added to the functional polymer, and then the composite material from step A2 was added and stirred evenly. The mixture was then reacted at 140℃ for 1.5h. After the reaction was completed, 0.2mol / L sodium hydroxide solution was added to adjust the pH of the system to 7.5. After filtration, the mixture was washed three times with deionized water (the mass of deionized water was 10 times the mass of concentrated sulfuric acid). The pH of the system was then adjusted to 5.3 with 5mol / L sulfuric acid solution. The mixture was centrifuged at 12000rpm for 8min and finally dried at 40℃ for 48h to obtain the modified adhesive. The functional polymer was composed of polypropylene glycol and hyperbranched polyester in a mass ratio of 1.1:0.75.

[0104] A high-performance wear-resistant ceramic material comprises the following raw materials in parts by weight: 23 parts potassium feldspar, 55 parts alumina, 4 parts sintering aid, 12 parts kaolin, 5 parts reinforcing phase, and 10 parts modified binder.

[0105] The sintering aid is composed of lanthanum oxide and molybdenum trioxide mixed in a mass ratio of 0.65:0.45; the reinforcing phase is composed of nano-silica and nano-zirconium oxide mixed in a mass ratio of 2:1.

[0106] The preparation method includes the following steps:

[0107] S1: Ball milling: Weigh the raw materials by mass, add potassium feldspar, alumina, sintering aid, kaolin and reinforcing phase into a ball mill for mixing and ball milling. The ball milling speed is 400 r / min and the ball milling time is 7 h. Zirconia balls are used as grinding balls. The mass of the grinding balls is 4 times the total mass of potassium feldspar, alumina, sintering aid, clay and reinforcing phase (i.e., the ball-to-material ratio is 4:1) to obtain a premix with a particle size of 0.8 μm.

[0108] S2: Granulation: The premix obtained in step S1 is mixed with the modified binder, and then spray granulation is performed. During spray drying, the inlet hot air temperature of the dryer is 320℃ and the outlet temperature is 100℃. After granulation, a loose density of 0.95 g / cm³ is obtained. 3 Ceramic powder;

[0109] S3: Compression molding: The ceramic powder obtained in step S2 is placed in a mold for compression molding to obtain a ceramic blank, wherein the compression molding pressure is 120MPa;

[0110] S4: Sintering: The ceramic blank obtained in step S3 is placed in a sintering furnace and sintered under the protection of an inert gas (argon). After cooling to room temperature with the furnace, a high-performance wear-resistant ceramic material is obtained. The sintering process is as follows: first, the temperature is raised to 900℃ at a rate of 5℃ / min, and then raised to 2100℃ at a rate of 8℃ / min. The sintering time is 1.5h.

[0111] Example 3

[0112] The specific steps for preparing the modified adhesive are as follows:

[0113] A1: The phenolic compound, lignin phenol prepolymer, formaldehyde solution, and sodium hydroxide were mixed evenly according to a mass ratio of 0.2:1.1:0.6:0.07. The mixture was then heated to 95°C and held for 50 min, followed by cooling to 65°C. 37 wt% formaldehyde solution and sodium hydroxide were added and stirred evenly. The mixture was reacted at 65°C for 20 min, then heated to 105°C and reacted for 2 h. After the reaction was completed, the mixture was cooled to room temperature and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of the lignin phenol prepolymer, and each time the mass of deionized water was 15 times the mass of the lignin phenol prepolymer). After filtration, the mixture was vacuum dried at 70°C for 48 h to obtain lignin-based phenolic resin. The phenolic compound was composed of resveratrol and cashew phenol in a mass ratio of 0.8:0.6.

[0114] The preparation method of lignin phenol prepolymer includes the following steps:

[0115] The alkali lignin, sodium hydroxide, and phenol were mixed and stirred evenly according to a mass ratio of 0.5:0.06:1.1. The mixture was then heated to 95°C and reacted for 1 hour. After the reaction was completed, the mixture was cooled to room temperature and then added to deionized water (the mass of deionized water was 15 times the mass of phenol) to precipitate the phenol. The precipitate was filtered and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of phenol, and each time the mass of deionized water was 15 times the mass of phenol). Finally, the mixture was vacuum dried at 70°C for 24 hours to obtain the lignin phenol prepolymer.

[0116] A2: Following a mass ratio of 0.006:25:1.1:0.5 for 2,2-dimethoxy-2-phenylacetophenone, isopropanol, lignin-based phenolic resin, and silanized reinforcing material, mix the 2,2-dimethoxy-2-phenylacetophenone, isopropanol, lignin-based phenolic resin from step A1, and silanized reinforcing material thoroughly. Then, stir and react for 24 hours at room temperature under ultraviolet light irradiation (UV wavelength 365 nm, light intensity 25 W / cm²). 2After the reaction was completed, the mixture was centrifuged at 20,000 rpm for 3 min, washed 5 times with isopropanol (each time the mass of isopropanol was 50% of the mass of the above isopropanol), and finally vacuum dried at 55℃ for 24 h to obtain the composite material.

[0117] The preparation method of silanized reinforced materials includes the following steps:

[0118] The reinforcing material, ethanol, and 3-mercaptopropyltrimethoxysilane were mixed in a mass ratio of 0.8:40:5 and reacted at 95°C for 46 h. After the reaction was completed, the mixture was cooled to room temperature, centrifuged at 20,000 rpm for 5 min, washed three times with ethanol (each time the ethanol mass was 40% of the above ethanol mass), and finally vacuum dried at 55°C for 24 h to obtain the silanized reinforcing material.

[0119] The preparation method of the reinforcing material includes the following steps:

[0120] The pretreated fiber material, toluene solution, and triethoxymethylsilane were mixed in a mass ratio of 1.1:100:10. The pretreated fiber material was added to the toluene solution, followed by the triethoxymethylsilane, and stirred until homogeneous. Then, 32 wt% hydrochloric acid solution was added to adjust the pH of the system to 3.5. The reaction was carried out under a nitrogen atmosphere at 80°C for 4 hours. After the reaction was completed, the mixture was cooled to room temperature, filtered, and washed three times each with deionized water and anhydrous ethanol (each time the mass of deionized water was 15% of the mass of the toluene solution, and each time the mass of anhydrous ethanol was 10% of the mass of the toluene solution). Finally, the mixture was dried at 70°C for 12 hours to obtain the reinforcing material.

[0121] The specific processing procedure for the pretreated fiber materials is as follows:

[0122] The fiber material, acetone, and piranha solution were mixed in a mass ratio of 1.2:35:35. The mixture was heated in an oil bath at 65°C for 7 hours. After heating, the fiber material was washed three times with deionized water (each time the deionized water mass was 40% of the acetone mass). Then, it was vacuum dried at 85°C for 0.5 hours and then immersed in the piranha solution (the piranha solution was composed of 98wt% concentrated sulfuric acid and 30wt% hydrogen peroxide solution in a volume ratio of 7:3). The mixture was stirred at 95°C for 25 minutes and then washed three times with deionized water (each time the deionized water mass was 50% of the acetone mass). Finally, it was vacuum dried at 85°C for 2 hours to obtain the pretreated fiber material, which was composed of basalt fiber and chopped carbon fiber in a mass ratio of 0.9:0.7.

[0123] A3: According to the mass ratio of concentrated sulfuric acid, functional polymer, and composite material of 0.2:5.1:1.1, 98wt% concentrated sulfuric acid was added to the functional polymer, followed by the composite material from step A2, and the mixture was stirred evenly. The mixture was then reacted at 145℃ for 1 hour. After the reaction was completed, 0.2mol / L sodium hydroxide solution was added to adjust the pH of the system to 8. The mixture was filtered, washed three times with deionized water (the mass of deionized water was 10 times the mass of concentrated sulfuric acid), and then the pH of the system was adjusted to 5.5 with 5mol / L sulfuric acid solution. The mixture was centrifuged at 15000rpm for 5 minutes and finally dried at 45℃ for 48 hours to obtain the modified adhesive. The functional polymer was composed of polypropylene glycol and hyperbranched polyester in a mass ratio of 1.2:0.8.

[0124] A high-performance wear-resistant ceramic material comprises the following raw materials in parts by weight: 25 parts potassium feldspar, 60 parts alumina, 5 parts sintering aid, 14 parts montmorillonite, 6 parts reinforcing phase, and 12 parts modified binder.

[0125] The sintering aid is composed of lanthanum oxide and molybdenum trioxide mixed in a mass ratio of 0.7:0.5; the reinforcing phase is composed of nano-silica and nano-zirconium oxide mixed in a mass ratio of 2:1.

[0126] The preparation method includes the following steps:

[0127] S1: Ball milling: Weigh the raw materials by mass, add potassium feldspar, alumina, sintering aid, montmorillonite and reinforcing phase into a ball mill for mixing and ball milling. The ball milling speed is 500 r / min and the ball milling time is 6 h. Zirconia balls are used as grinding balls. The mass of the grinding balls is 4 times the total mass of potassium feldspar, alumina, sintering aid, clay and reinforcing phase (i.e., the ball-to-material ratio is 4:1) to obtain a premix with a particle size of 1 μm.

[0128] S2: Granulation: The premix obtained in step S1 is mixed with the modified binder, and then spray granulation is performed. During spray drying, the inlet hot air temperature of the dryer is 330℃ and the outlet temperature is 110℃. After granulation, a loose density of 1g / cm³ is obtained. 3 Ceramic powder;

[0129] S3: Compression molding: The ceramic powder obtained in step S2 is placed in a mold for compression molding to obtain a ceramic blank, wherein the compression molding pressure is 130MPa;

[0130] S4: Sintering: The ceramic blank obtained in step S3 is placed in a sintering furnace and sintered under the protection of an inert gas (argon). After cooling to room temperature with the furnace, a high-performance wear-resistant ceramic material is obtained. The sintering process is as follows: first, the temperature is raised to 1000℃ at a rate of 6℃ / min, and then raised to 2200℃ at a rate of 10℃ / min. The sintering time is 1 hour.

[0131] Comparative Example 1

[0132] The difference between this comparative example and Example 3 is that, in preparing the modified binder, the phenolic compound in step A1 is replaced with resveratrol by an equal mass, while the remaining steps and raw materials are the same as in Example 3.

[0133] A1: Resveratrol, lignin prepolymer, formaldehyde solution, and sodium hydroxide were mixed evenly according to a mass ratio of 0.2:1.1:0.6:0.07. The mixture was then heated to 95°C and held for 50 min, followed by cooling to 65°C. 37 wt% formaldehyde solution and sodium hydroxide were added and stirred evenly. The mixture was reacted at 65°C for 20 min, then heated to 105°C and reacted for 2 h. After the reaction was completed, the mixture was cooled to room temperature and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of the lignin prepolymer, and each time the mass of deionized water was 15 times the mass of the lignin prepolymer). After filtration, the mixture was vacuum dried at 70°C for 48 h to obtain lignin-based phenolic resin.

[0134] Comparative Example 2

[0135] The difference between this comparative example and Example 3 is that, in preparing the modified binder, the phenolic compound in step A1 is replaced by cashew phenol by an equal mass, while the remaining steps and raw materials are the same as in Example 3.

[0136] A1: Cashew nut shell phenol, lignin phenol prepolymer, formaldehyde solution, and sodium hydroxide were mixed evenly according to a mass ratio of 0.2:1.1:0.6:0.07. The mixture was then heated to 95°C and held for 50 min, followed by cooling to 65°C. 37 wt% formaldehyde solution and sodium hydroxide were added and stirred evenly. The mixture was reacted at 65°C for 20 min, then heated to 105°C and reacted for 2 h. After the reaction was completed, the mixture was cooled to room temperature and washed three times each with anhydrous ethanol and deionized water (each time the mass of anhydrous ethanol was 10 times the mass of the lignin phenol prepolymer, and each time the mass of deionized water was 15 times the mass of the lignin phenol prepolymer). After filtration, the mixture was vacuum dried at 70°C for 48 h to obtain lignin-based phenolic resin.

[0137] Comparative Example 3

[0138] The difference between this comparative example and Example 3 is that, in preparing the modified binder, the fiber material in step A2 is replaced with basalt fiber by the same mass, while the remaining steps and raw materials are the same as in Example 3.

[0139] The specific processing procedure for pretreated fiber materials is as follows:

[0140] The basalt fiber was added to acetone in a mass ratio of 1.2:35:35 and heated in an oil bath at 65°C for 7 hours. After heating, the fiber was washed three times with deionized water (each time the mass of deionized water was 40% of the mass of acetone). Then, it was vacuum dried at 85°C for 0.5 hours and then immersed in the piranha solution (the piranha solution was composed of 98wt% concentrated sulfuric acid and 30wt% hydrogen peroxide solution in a volume ratio of 7:3). The solution was stirred at 95°C for 25 minutes and then washed three times with deionized water (each time the mass of deionized water was 50% of the mass of acetone). Finally, it was vacuum dried at 85°C for 2 hours to obtain the pretreated fiber material.

[0141] Comparative Example 4

[0142] The difference between this comparative example and Example 3 is that, in preparing the modified binder, the fiber material in step A2 is replaced with short-cut carbon fiber by the same mass, while the remaining steps and raw materials are the same as in Example 3.

[0143] The specific processing procedure for pretreated fiber materials is as follows:

[0144] The short-cut carbon fibers, acetone, and piranha solution were mixed in a mass ratio of 1.2:35:35. The mixture was heated in an oil bath at 65°C for 7 hours. After heating, the fibers were washed three times with deionized water (each time the deionized water mass was 40% of the acetone mass). The fibers were then vacuum dried at 85°C for 0.5 hours. The mixture was then immersed in the piranha solution (which was a mixture of 98wt% concentrated sulfuric acid and 30wt% hydrogen peroxide solution in a volume ratio of 7:3) and stirred at 95°C for 25 minutes. The fibers were then washed three times with deionized water (each time the deionized water mass was 50% of the acetone mass). Finally, the mixture was vacuum dried at 85°C for 2 hours to obtain the pretreated fiber material.

[0145] Comparative Example 5

[0146] The difference between this comparative example and Example 3 is that, in preparing the modified binder, the lignin-based phenolic resin and the silanized reinforcing material in step A2 are directly mixed, while the remaining steps and raw materials are the same as in Example 3.

[0147] A2: The isopropanol, lignin-based phenolic resin, and silanized reinforcing material are mixed evenly according to a mass ratio of 25:1.1:0.5. The mixture is then stirred at room temperature for 24 hours, centrifuged at 20,000 rpm for 3 minutes, washed 5 times with isopropanol (each time the mass of isopropanol is 50% of the mass of the above isopropanol), and finally vacuum dried at 55°C for 24 hours to obtain the composite material.

[0148] Comparative Example 6

[0149] The difference between this comparative example and Example 3 is that, in preparing the modified adhesive, the functional polymer in step A3 is replaced by polypropylene glycol in equal mass, while the remaining steps and raw materials are the same as in Example 3.

[0150] A3: According to the mass ratio of concentrated sulfuric acid, polypropylene glycol, and composite material of 0.2:5.1:1.1, 98wt% concentrated sulfuric acid was added to polypropylene glycol, and then the composite material from step A2 was added and stirred evenly. The mixture was then reacted at 145℃ for 1 hour. After the reaction was completed, 0.2mol / L sodium hydroxide solution was added to adjust the pH of the system to 8. After filtration, the mixture was washed three times with deionized water (the mass of deionized water was 10 times the mass of concentrated sulfuric acid). The pH of the system was then adjusted to 5.5 with 5mol / L sulfuric acid solution. The mixture was centrifuged at 15000rpm for 5 minutes and finally dried at 45℃ for 48 hours to obtain the modified binder.

[0151] Comparative Example 7

[0152] The difference between this comparative example and Example 3 is that, in preparing the modified adhesive, the functional polymer in step A3 is replaced by an equal mass of hyperbranched polyester, while the remaining steps and raw materials are the same as in Example 3.

[0153] A3: According to the mass ratio of concentrated sulfuric acid, hyperbranched polyester, and composite material of 0.2:5.1:1.1, 98wt% concentrated sulfuric acid was added to the hyperbranched polyester, and then the composite material from step A2 was added and stirred evenly. The mixture was then reacted at 145℃ for 1 hour. After the reaction was completed, 0.2mol / L sodium hydroxide solution was added to adjust the pH of the system to 8. After filtration, the mixture was washed three times with deionized water (the mass of deionized water was 10 times the mass of concentrated sulfuric acid). The pH of the system was then adjusted to 5.5 with 5mol / L sulfuric acid solution. The mixture was centrifuged at 15000rpm for 5 minutes and finally dried at 45℃ for 48 hours to obtain the modified binder.

[0154] Comparative Example 8

[0155] The difference between this comparative example and Example 3 is that, in preparing the modified binder, the functional polymer in step A3 is directly mixed with the composite material, while the remaining steps and raw materials are the same as in Example 3.

[0156] A3: The functional polymer and the composite material are mixed evenly according to a mass ratio of 5.1:1.1. The mixture is then stirred at 145°C for 1 hour, filtered, washed three times with deionized water (the mass of deionized water is 10 times the mass of concentrated sulfuric acid), centrifuged at 15000 rpm for 5 minutes, and finally dried at 45°C for 48 hours to obtain the modified binder. The functional polymer is composed of polypropylene glycol and hyperbranched polyester mixed in a mass ratio of 1.2:0.8.

[0157] The high-performance wear-resistant ceramic materials prepared in Examples 1-3 and Comparative Examples 1-8 were tested for flexural strength, fracture toughness, and wear resistance. Flexural strength was tested according to GB / T 4741-1999 "Test Method for Flexural Strength of Ceramic Materials". Fracture toughness was tested according to GB / T 23806-2009 three-point bending test. For wear resistance testing, the high-performance wear-resistant ceramic materials prepared in Examples 1-3 and Comparative Examples 1-8 were used as test specimens, with specimen dimensions set to 300mm × 300mm × 6mm. The wear resistance of the specimens was tested according to GB / T 12988-2009. The test results are shown in Table 1 below.

[0158] Table 1 Performance parameters of the high-performance wear-resistant ceramic materials prepared in Examples 1-3 and Comparative Examples 1-8

[0159]

[0160] As shown in Table 1 above, and comparing Comparative Examples 1-5 and Example 3, the test results of high-performance wear-resistant ceramic materials prepared by replacing the phenolic compounds in step A1 with resveratrol or cashew phenol by mass, or replacing the fiber materials in step A2 with basalt fibers or chopped carbon fibers by mass, or directly mixing the lignin-based phenolic resin and silanized reinforcing material in step A2, are worse than those of Example 3. This indicates that the phenolic compounds composed of resveratrol and cashew phenol have a synergistic effect, which can effectively improve the mechanical properties and wear resistance of ceramic materials; the fiber materials composed of basalt fibers and chopped carbon fibers have a good synergistic effect, which can improve the bending strength, fracture toughness and wear resistance of ceramic materials; and the combination of lignin-based phenolic resin and silanized reinforcing material through chemical reaction can enhance the bonding force between the two, improve the dispersibility and compatibility of the reinforcing material in the phenolic resin, and further improve the mechanical properties, thermal stability and wear resistance of ceramic materials.

[0161] A comparison of Comparative Examples 6-8 and Example 3 shows that replacing the functional polymer in step A3 with polypropylene glycol or hyperbranched polyester by the same mass, or directly mixing the functional polymer in step A3 with the composite material, results in a lower performance of the high-performance wear-resistant ceramic material compared to Example 3. This indicates that the functional polymer composed of polypropylene glycol and hyperbranched polyester can synergistically improve the mechanical properties of the ceramic material, significantly enhancing its fracture toughness and flexural strength, and also improving its wear resistance and thermal stability. Furthermore, combining the functional polymer with the composite material through a chemical reaction increases the bonding force between the two, further enhancing the mechanical properties, thermal stability, and wear resistance of the ceramic material.

[0162] As shown in Table 1 above, the high-performance wear-resistant ceramic materials prepared in Examples 1-3, compared to those prepared in Comparative Examples 1-8, achieved better overall performance by combining lignin phenol prepolymer and phenolic compounds, then combining them with silanized reinforcing materials, and finally combining them with functional polymers to obtain a modified binder. Potassium feldspar, alumina, sintering aids, clay, and reinforcing phases were ball-milled, then mixed with the modified binder, granulated, pressed, and sintered to obtain the final high-performance wear-resistant ceramic material, meeting the performance requirements. In contrast, the high-performance wear-resistant ceramic materials prepared in Comparative Examples 1-8 did not meet the performance requirements. This indicates that the high-performance wear-resistant ceramic material prepared in this invention not only possesses better mechanical properties, thermal stability, and wear resistance, but also improves the densification of the ceramic material.

[0163] In the description of this specification, the references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0164] The above description is merely an example and illustration of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the invention or exceed the scope defined by the present invention, they should all fall within the protection scope of the present invention.

Claims

1. A high-performance wear-resistant ceramic material, characterized in that, The raw materials include the following parts by weight: 20-25 parts potassium feldspar, 50-60 parts alumina, 3-5 parts sintering aid, 10-14 parts clay, 4-6 parts reinforcing phase, and 8-12 parts modified binder; The preparation method of the modified adhesive includes the following steps: A1: By combining lignin phenol prepolymer and phenolic compounds, lignin-based phenolic resin is obtained; A2: Combine the lignin-based phenolic resin from step S1 with the silanized reinforcing material to obtain a composite material; A3: Combine the composite material from step S2 with a functional polymer to obtain a modified adhesive; The lignin-based phenolic resin contains carbon-carbon double bonds, and the silanized reinforcing material contains thiol groups. Under the action of a photoinitiator, the carbon-carbon double bonds in the lignin-based phenolic resin can react and combine with the thiol groups in the silanized reinforcing material, thus combining the lignin-based phenolic resin and the silanized reinforcing material to obtain a composite material. The phenolic compound is composed of resveratrol and cashew nut alcohol in a mass ratio of 0.7-0.8:0.5-0.6; Step A2 is as follows: The photoinitiator, isopropanol, lignin-based phenolic resin from step A1, and silanized reinforcing material are mixed evenly, and then stirred and reacted at room temperature and under ultraviolet light for 22-24 hours. After the reaction is completed, the mixture is centrifuged for 3-5 minutes, washed with isopropanol, and finally vacuum dried at 45-55℃ to obtain the composite material. The method for preparing the silanized reinforced material includes the following steps: The reinforcing material, ethanol and silane coupling agent are mixed and reacted at 85-95℃ for 46-50h. After the reaction is completed, the mixture is cooled to room temperature, centrifuged for 5-10min, washed with ethanol, and finally vacuum dried at 45-55℃ to obtain the silanized reinforcing material. Silicon nanowires were grown in situ on the surface of the pretreated fiber material to obtain the final reinforcing material. Step A3 is as follows: Concentrated sulfuric acid was added to the functional polymer, followed by the composite material from step A2, and the mixture was stirred until homogeneous. The mixture was then reacted at 135-145℃ for 1-2 hours. After the reaction was completed, sodium hydroxide solution was added to adjust the pH of the system to 7-8. The mixture was then filtered, washed with deionized water, and the pH of the filtrate was adjusted to 5-5.5 with sulfuric acid solution. The filtrate was centrifuged for 5-10 minutes and finally dried at 35-45℃ to obtain the modified binder. The functional polymer is composed of polypropylene glycol and hyperbranched polyester in a mass ratio of 1-1.2:0.7-0.8; The fiber material is composed of basalt fiber and chopped carbon fiber in a mass ratio of 0.8-0.9:0.6-0.

7.

2. The high-performance wear-resistant ceramic material according to claim 1, characterized in that, Step A1 is as follows: Phenolic compounds are mixed evenly with lignin phenol prepolymer, then heated to 85-95℃ and held for 50-70 min, then cooled to 55-65℃, formaldehyde solution and sodium hydroxide are added and stirred evenly. After reacting at 55-65℃ for 20-40 min, the temperature is further increased to 95-105℃ and reacted for 2-3 h. After the reaction is completed, the mixture is cooled to room temperature, washed with anhydrous ethanol and deionized water, filtered, and finally vacuum dried at 60-70℃ to obtain lignin-based phenolic resin.

3. The high-performance wear-resistant ceramic material according to claim 2, characterized in that, The preparation method of the lignin phenol prepolymer includes the following steps: Alkali lignin, sodium hydroxide, and phenol are mixed and stirred evenly. The mixture is then heated to 85-95℃ and reacted for 1-1.5 hours. After the reaction is complete, the mixture is cooled to room temperature and then added to deionized water to precipitate the lignin. The precipitate is filtered, washed with anhydrous ethanol and deionized water, and finally dried under vacuum at 60-70℃ to obtain the lignin phenol prepolymer.

4. The high-performance wear-resistant ceramic material according to claim 1, characterized in that, The method for preparing the reinforcing material includes the following steps: The pretreated fiber material was added to a toluene solution, followed by triethoxymethylsilane, and stirred until homogeneous. Then, hydrochloric acid solution was added to adjust the pH of the system to 2.5-3.

5. The reaction was carried out under a nitrogen atmosphere at 70-80℃ for 4-6 hours. After the reaction was completed, the mixture was cooled to room temperature, filtered, washed with deionized water and anhydrous ethanol, and finally dried at 60-70℃ to obtain the reinforcing material.

5. A method for preparing a high-performance wear-resistant ceramic material as described in any one of claims 1-4, characterized in that, Includes the following steps: S1: Ball milling: Weigh the raw materials by mass, add potassium feldspar, alumina, sintering aid, clay and reinforcing phase into a ball mill for mixing and ball milling to obtain a premix; S2: Spray granulation: The premix obtained in step S1 is mixed with the modified binder and then spray granulated to obtain ceramic powder; S3: Press molding: The ceramic powder obtained in step S2 is placed in a mold for pressing molding to obtain a ceramic blank; S4: Sintering: The ceramic blank obtained in step S3 is placed in a sintering furnace and sintered under inert gas protection. After cooling to room temperature with the furnace, a high-performance wear-resistant ceramic material is obtained.

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