A method for manufacturing a high-temperature refractory member and a high-temperature refractory member

Abstract

The application discloses a preparation method of a high-temperature refractory component and the high-temperature refractory component, and comprises the following steps: mixing refractory aggregate, cementitious material, binder, refractory powder and water to form a slurry; laying a reinforcing framework in a mold; pouring the slurry into the mold; curing the slurry to solidify; and demolding to obtain the high-temperature refractory component with the reinforcing framework embedded in the inside. The application mixes the refractory aggregate, the cementitious material, the binder, the refractory powder and water into the slurry, cooperates with the pouring forming and embeds the reinforcing framework in the inside of the component, so that the component is integrally formed, has good integrity, no brick joints, high refractoriness and thermal shock stability, and is not easy to melt and burst under the laser high-temperature roasting; meanwhile, the reinforcing framework significantly improves the breaking strength and the crack resistance of the component, overcomes the defects that the traditional refractory bricks are easy to break and crack, and enables the component to continuously and effectively insulate high temperature, prevent the thermal deformation of a laser cutting machine body, and guarantee the cutting precision and stability.

Description

Technical Field

[0001] This application relates to the field of high-temperature refractory components technology, and in particular to a method for preparing high-temperature refractory components and high-temperature refractory components. Background Technology

[0002] Currently, the internal structure of most laser cutting machine beds is protected with clay refractory bricks. These bricks are primarily composed of silicon dioxide, which has limited refractoriness and is prone to softening and melting at high temperatures. This makes them unable to effectively resist the high-temperature thermal erosion of the laser, leading to thermal deformation of the machine bed structure and affecting cutting accuracy. Furthermore, refractory bricks are brittle materials with poor thermal shock resistance, making them susceptible to cracking or even bursting under rapid heating conditions due to internal thermal stress concentration. Summary of the Invention

[0003] In view of the shortcomings of the prior art, this application provides a method for preparing high-temperature refractory components and high-temperature refractory components, which effectively solves the problems of existing refractory bricks being not resistant to high temperatures and being prone to cracking.

[0004] To address the aforementioned technical problems, this application discloses, in a first aspect, a method for preparing high-temperature refractory components, comprising the following steps: Refractory aggregates, cementitious materials, binders, refractory powders and water are mixed to form a slurry; A reinforcing skeleton is laid inside the mold; The mud slurry is poured into the mold; The slurry material is cured and solidified. Demolding yields a high-temperature refractory component with an internally embedded reinforcing skeleton.

[0005] As an optional implementation, in this embodiment of the application, the refractory aggregate is high-alumina bauxite aggregate, the cementing material is silicate cement, the binder is clay, the refractory powder is refractory sand, and the water is purified water.

[0006] As an optional implementation, in this embodiment of the application, by weight: 55-60 parts of the refractory aggregate, 10-15 parts of the cementitious material, 5-10 parts of the binder, 20-25 parts of the refractory powder, and 10-15 parts of the water.

[0007] As an optional implementation, in this embodiment of the application, the reinforcing skeleton is a metal mesh.

[0008] As an optional implementation method, in this embodiment of the application, the curing is high-temperature steam curing, and the high-temperature steam curing time is 5 to 6 hours.

[0009] As an optional implementation, in this embodiment of the application, the demolding is performed within 1 hour after the curing is completed.

[0010] As an optional implementation, in this embodiment of the application, after the step of "mixing refractory aggregate, cementitious material, binder, refractory powder and water to form slurry" and before the step of "laying the reinforcing skeleton in the mold", the following step is also included: Apply a release agent to the inner surface of the mold.

[0011] As an optional implementation, in this embodiment of the application, after the step of "pouring the slurry into the mold" and before the step of "curing the slurry to solidify", the following step is further included: The poured mud slurry is then vibrated and compacted.

[0012] As an optional implementation, in this embodiment of the application, after the step of "demolding to obtain a high-temperature refractory component with an internally embedded reinforcing skeleton", the following steps are also included: After demolding, let it stand for three days to cure, with water sprayed evenly once on the first day.

[0013] On the other hand, embodiments of this application disclose a high-temperature refractory component, which is prepared by the method described in any one of claims 1 to 9.

[0014] This application provides a method for preparing a high-temperature refractory component and the high-temperature refractory component itself. The component is a castable made of refractory aggregate, cementitious material, binder, and refractory powder, with an internally embedded reinforcing skeleton. When applied to a laser cutting machine tool, the castable system, composed of refractory aggregate, cementitious material, binder, and refractory powder, exhibits high refractoriness and thermal shock resistance. It is not easily melted or cracked under the high temperature of laser treatment. Combined with excellent resistance to sulfate corrosion, this effectively extends the service life and replacement cycle of the component, ensuring safe equipment operation. Simultaneously, the reinforcing skeleton embedded within the component significantly improves its flexural strength and crack resistance, overcoming the defects of traditional refractory bricks, such as fragility, cracking, and inconvenience in transportation and installation. Even if microcracks develop in the component under extreme high temperatures, the reinforcing skeleton can act as a bridge to prevent crack propagation, maintaining the structural integrity of the component. It can continuously and effectively insulate against high temperatures, preventing thermal deformation of the hollow beam structure inside the laser cutting machine tool, thereby ensuring the long-term processing accuracy and stability of laser cutting. Attached Figure Description

[0015] Figure 1 This is a schematic flowchart of an embodiment of the method for preparing high-temperature refractory components provided in this application.

[0016] Figure 2 This is a schematic flowchart of Example 2 of the method for preparing high-temperature refractory components provided in this application.

[0017] Figure 3 This is a schematic flowchart of Example 3 of the method for preparing high-temperature refractory components provided in this application.

[0018] Figure 4 This is a schematic flowchart of Example 4 of the method for preparing high-temperature refractory components provided in this application. Detailed Implementation

[0019] To make the objectives, technical solutions, and effects of this application clearer and more explicit, the following detailed description of this application is provided with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining this application and are not intended to limit this application. Unless further described, elements, structures, and features in one embodiment may be advantageously combined with other embodiments.

[0020] It should be noted that when a metastructure is referred to as "fixed to" or "set on" another metastructure, it can be directly on or indirectly on that other metastructure. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated.

[0021] The terms "length," "width," "upper," "lower," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are used only for the convenience of describing this application and simplifying the description, and are not intended to constitute an infringement. The instruction or implication refers to a device or component that must have a specific orientation, be constructed and operated in a specific orientation.

[0022] Example 1 Please see Figure 1 This embodiment discloses a method for preparing high-temperature refractory components, including the following steps: Step 10: Mix refractory aggregate, cementitious material, binder, refractory powder and water to form slurry.

[0023] Preferably, the refractory aggregate is high-alumina bauxite aggregate, the cementing material is silicate cement, the binder is clay, and the refractory powder is refractory sand. High-alumina bauxite aggregate, silicate cement, clay, refractory sand, and purified water are all widely available and cost-effective bulk industrial raw materials. Compared to traditional refractory bricks, which require the purchase of various sizes of finished bricks, this raw material system offers convenient procurement and low cost, saving more than half the material cost. Simultaneously, high-alumina bauxite aggregate and refractory sand possess high refractoriness, able to withstand the high temperatures generated by laser cutting without easily melting. Clay, as a binder, imparts good plasticity and adhesion to the slurry, making casting and molding smoother and the component structure more compact. Silicate cement provides early hydraulic strength, allowing the component to be quickly demolded after steam curing and obtain sufficient green strength, thereby shortening the production cycle. The use of purified water avoids the adverse effects of impurity ions on material properties and high-temperature performance, ensuring the structural stability and durability of the component during long-term high-temperature service.

[0024] It is understood that in other embodiments, the refractory aggregate may also be any one or more combinations of corundum aggregate, mullite aggregate, zircon aggregate, silicon carbide aggregate, or magnesium aluminate spinel aggregate; the cementing material may also be any one of aluminate cement, sulfoaluminate cement, phosphate binder, or water glass; the binder may also be any one of bentonite, kaolin, wood-knot clay, ball clay, or Suzhou clay; and the refractory powder may also be any one of high-alumina fine powder, corundum fine powder, mullite fine powder, silica powder, or kyanite powder. No limitations are imposed here.

[0025] In some embodiments, the composition includes 55-60 parts refractory aggregate, 10-15 parts cementitious material, 5-10 parts binder, 20-25 parts refractory powder, and 10-15 parts water. This design ensures that the refractory aggregate, within the range of 55-60 parts, forms a stable skeleton structure, providing sufficient compressive strength and volume stability for the component. Below this range, the skeleton strength is insufficient; above this range, the aggregate gaps are too large, and the density decreases. The cementitious material, within the range of 10-15 parts, ensures the slurry obtains sufficient early strength for smooth demolding; below this range, the early strength is insufficient; above this range, high-temperature performance decreases and costs increase. The binder, within the range of 5-10 parts, imparts good plasticity and adhesion to the slurry; below this range, the molding performance is poor and the component is prone to cracking; above this range, drying shrinkage increases. High temperatures can easily lead to cracking. A refractory powder ratio of 20-25 parts can fully fill the aggregate gaps, improving density and resistance to slag penetration. Below this range, porosity is high; above this range, the skeleton is relatively reduced, and strength decreases. A water ratio of 10-15 parts ensures the slurry has suitable fluidity for casting and compaction. Below this range, fluidity is poor, making it difficult to cast densely; above this range, segregation and shrinkage cracks are likely to occur. Through the synergistic effect of the above proportions, the component achieves an optimal balance between molding performance, early strength, high-temperature heat resistance, and crack resistance, effectively solving the technical problems of traditional refractory bricks being brittle, having poor heat resistance, and short lifespan. Specifically, first, the weighed grade I high-alumina bauxite aggregate, silicate cement, clay, and refractory sand are put into a mixer and dry-mixed at a speed of 60-80 r / min for 2-3 minutes to ensure that the powders are fully mixed. Then, 10 parts of purified water are added to the mixed powder, and the mixture is stirred for another 3-5 minutes to form a slurry.

[0026] Step 20: Lay the reinforcing skeleton inside the mold.

[0027] In some embodiments, depending on the shape of the required component, the mold can be a flat casting mold or a roof-type slope casting mold. The flat mold is used to form flat components and is laid on the bottom blanking plate inside the laser cutting machine bed. The roof-type slope mold is used to form components with a sloped surface and uses its slope structure to guide high-temperature molten slag and waste to slide into the waste collection device.

[0028] It is understood that the mold can be made of steel or wood, and there are no restrictions on the material. Steel molds have high strength, good dimensional accuracy, and can be reused, making them suitable for mass production; wooden molds are lower in cost and easier to process, making them suitable for small-batch customization or single-piece trial production.

[0029] In some embodiments, the reinforcing skeleton is a metal mesh. The metal mesh, embedded within the component as a reinforcing skeleton, significantly improves the overall flexural strength and crack resistance of the component, preventing cracking or even breakage due to thermal stress or mechanical impact during transportation, hoisting, and high-temperature service. This overcomes the shortcomings of traditional refractory bricks, such as fragility, cracking, and inconvenience in transportation and installation. Simultaneously, the metal mesh forms a three-dimensional network structure within the component. Even if microcracks develop under extreme temperatures, the mesh can act as a "bridging" element, preventing further crack propagation and effectively extending the component's service life. This ensures the continuous and effective protection of the hollow beam structure inside the laser cutting machine bed, preventing thermal deformation of the bed due to component breakage and guaranteeing the long-term accuracy and stability of laser cutting.

[0030] It is understood that in other embodiments, the reinforcing skeleton may also be any one of stainless steel mesh, carbon fiber mesh, glass fiber mesh, corrugated steel bars, or V-shaped steel bars. No limitation is imposed herein.

[0031] The metal mesh can be laid parallel to the component surface within the mold, located in the middle layer along the component's thickness; alternatively, the metal mesh can be distributed in a three-dimensional mesh structure inside the component, arranged in two staggered layers along the component's thickness; or, the metal mesh can have a corrugated structure, with peaks and troughs extending undulating along the component's thickness. Metal meshes arranged in these ways can effectively improve the component's flexural strength and crack resistance, while eliminating thermal expansion stress and preventing cracking due to thermal stress during high-temperature service.

[0032] Step 30: Pour the mud slurry into the mold.

[0033] The pouring operation should be carried out within 30 minutes after the mud slurry is mixed. If the mud slurry has already begun to set or has clumped, it should not be used. During pouring, the mud slurry should be continuously poured into the mold through the pouring port. The pouring should be completed in one continuous pour. If it is interrupted for any reason and the interval exceeds the initial setting time of the mud slurry, the interface should be treated according to the requirements of the construction joint. Specifically, roughening or leaving grooves can be used to ensure a firm bond between the old and new interfaces.

[0034] Step 40: The mud material is cured and solidified.

[0035] In this embodiment, the curing method is high-temperature steam curing, which lasts for 5-6 hours. Compared to natural curing, which requires 7-14 days to reach demolding strength, high-temperature steam curing only requires 5-6 hours to solidify the slurry and achieve sufficient demolding strength. This significantly shortens the curing cycle, allowing components to be quickly demolded and proceed to the next process, thus significantly improving production efficiency and making it suitable for rapid customization and emergency repair projects. Simultaneously, high-temperature steam curing ensures a more complete and uniform hydration reaction of the cementitious material, effectively improving the early strength and internal structural density of the components. This avoids problems such as insufficient strength or surface cracking caused by inadequate curing, thereby ensuring the structural integrity of the components during subsequent demolding, transportation, and high-temperature service. This effectively solves the technical problems of traditional refractory bricks being fragile and having poor heat resistance.

[0036] It is understood that in other embodiments, curing can also be either natural curing or dry heat curing. Natural curing involves covering the material with a damp cloth or plastic film for 7 to 14 days at an ambient temperature not lower than 15°C, and is suitable for small-scale production scenarios where high-temperature steam curing is not available. Dry heat curing involves heating the material in a drying kiln at 60 to 80°C, which can also solidify the slurry, and is not limited to this method.

[0037] Step 50: Demolding yields a high-temperature refractory component with an internally embedded reinforcing skeleton.

[0038] In some embodiments, demolding is performed within one hour after curing. After steam curing, the component has sufficient demolding strength. Demolding within one hour avoids excessive adhesion between the component and the mold due to prolonged cooling time inside the mold, thereby reducing demolding difficulty, minimizing the risk of surface damage or cracking during demolding, and ensuring the appearance quality and structural integrity of the component. At the same time, timely demolding allows the mold to be quickly put into the next production cycle, improving mold turnover efficiency and production efficiency, which is beneficial for meeting the needs of rapid customization and emergency repair projects.

[0039] The high-temperature refractory component prepared in this embodiment is cast from a refractory material composed of refractory aggregate, cementitious material, binder, and refractory powder, with an internal reinforcing skeleton. When applied to a laser cutting machine tool, the refractory material system, composed of refractory aggregate, cementitious material, binder, and refractory powder, has high refractoriness and thermal shock resistance. It is not easily melted or cracked under the high temperature of laser. Combined with excellent resistance to sulfate corrosion, it effectively extends the service life and replacement cycle of the component, ensuring the safe operation of the equipment. At the same time, the reinforcing skeleton embedded in the component significantly improves the flexural strength and crack resistance of the component, overcoming the defects of traditional refractory bricks that are fragile, prone to cracking, and inconvenient to transport and lay. Even if the component develops microcracks under extreme high temperatures, the reinforcing skeleton can act as a bridge to prevent crack propagation, keeping the component structurally intact. It can continuously and effectively insulate against high temperatures, preventing thermal deformation of the hollow beam structure inside the laser cutting machine tool body, thereby ensuring the long-term processing accuracy and stability of laser cutting. In addition, the mud material prepared in this method sets and hardens quickly, can be quickly customized and used for emergency repair projects, has a large heat of hydration and concentrated heat release, and can also set and harden quickly in sub-zero low temperature environments, making it suitable for winter construction.

[0040] The high-temperature refractory component of this embodiment can be matched with a suitable mold according to the actual needs of the laser cutting machine tool, so as to prepare an integral seamless structure suitable for the laser cutting machine tool, completely eliminating the brick joints present in the traditional refractory brick assembly, and the high-temperature molten slag cannot seep into the machine bed from the brick joints; compared with the traditional refractory bricks that require the purchase of various specifications of finished bricks, the raw materials of this application are widely available and inexpensive, saving more than half of the material cost, thus achieving cost reduction and efficiency improvement.

[0041] Example 2 Please see Figure 2 The difference between this embodiment and Embodiment 1 is that, after the step of "mixing refractory aggregate, cementitious material, binder, refractory powder and water to form slurry" and before the step of "laying the reinforcing skeleton in the mold", the following steps are also included: Step 60: Apply release agent to the inner surface of the mold.

[0042] Specifically, depending on the desired shape of the finished product, a flat steel mold or a roof-type sloped steel mold is selected. A layer of release agent is evenly applied to the inner surface of the mold to facilitate subsequent demolding operations, prevent the component from sticking to the mold, which could lead to demolding difficulties or damage to the component surface, and ensure the appearance quality and structural integrity of the component. At the same time, the use of release agent can also protect the inner surface of the mold from corrosion by alkaline components in the slurry, extend the service life of the mold, and facilitate the cleaning and maintenance of the mold, thereby improving the turnover efficiency and production efficiency of the mold.

[0043] It should be noted that the release agent can be any of the following: engine oil, waste engine oil, paraffin emulsion, or conventional commercially available release agents; there are no restrictions on which one is used.

[0044] The remaining steps are the same as in Example 1, and will not be described in detail here.

[0045] Example 3 Please see Figure 3 The difference between this embodiment and Embodiment 1 or 2 is that, after the step of "pouring the slurry into the mold" and before the step of "curing the slurry to solidify", the following step is also included: Step 70: Vibrate and compact the poured mud.

[0046] Specifically, the slurry is poured into the mold through the pouring port. After pouring, the slurry in the mold is vibrated for 2-3 minutes with a vibrator to remove air bubbles that were trapped inside the slurry during the pouring process. This also makes the slurry more evenly distributed and densely packed inside the mold, ensuring that there are no air holes or defects inside the cast component. This improves the structural density and overall strength of the component, and further enhances its resistance to slag penetration and its high-temperature service performance.

[0047] The remaining steps are the same as in Embodiment 1 or 2, and will not be described in detail here.

[0048] Example 4 Please see Figure 4 The difference between this embodiment and embodiments one, two, or three is that after the step of "demolding to obtain a high-temperature refractory component with an internally embedded reinforcing skeleton", the following steps are also included: Step 80: Let it stand for three days to cure, with watering once evenly on the first day.

[0049] Specifically, the demolded components are left to cure at room temperature for 3 days. On the first day, water is sprayed evenly once to allow the moisture to fully penetrate the surface of the components, replenishing the moisture lost during the hardening process due to hydration and surface evaporation. This prevents the surface of the components from drying out too quickly and causing cracks, ensuring the surface quality and overall structural integrity of the components. No watering is required for the next two days, allowing the components to continue the hydration reaction in a stable humidity environment and gradually reach the design strength. This ensures the structural reliability and service life of the components during subsequent transportation, installation, and high-temperature service.

[0050] The remaining steps are the same as in Examples 1, 2, or 3, and will not be repeated here.

[0051] Example 5 This embodiment discloses a high-temperature refractory component, which is prepared by any one of the preparation methods in Embodiments 1 to 4.

[0052] Specifically, the high-temperature refractory component is a monolithically cast plate-shaped component with embedded metal mesh as a reinforcing skeleton. The metal mesh is distributed in a three-dimensional mesh structure inside the component. The main matrix of the component is formed by mixing refractory aggregate, cementitious material, binder, and refractory powder with water and then curing it.

[0053] The high-temperature refractory components are either flat plate structures or roof-type sloping structures. The flat plate structure is laid on the bottom blanking plate inside the laser cutting machine bed to withstand the direct impact of the high-temperature molten slag generated during laser cutting. The roof-type sloping structure is located on the waste guide plate, using its sloping surface to guide the high-temperature molten slag and waste to slide into the waste collection device. Both types of components provide effective thermal protection for the hollow beam structure inside the machine bed, preventing thermal deformation of the machine bed structure due to high-temperature erosion.

[0054] The high-temperature refractory component provided in this embodiment is integrally cast using the above-mentioned preparation method. It has a metal mesh embedded inside as a reinforcing skeleton, which has good integrity and no brick joints. It has high fire resistance and thermal shock resistance. It is not easy to melt or crack under the high temperature of laser baking. At the same time, it has excellent flexural strength and crack resistance, and is not easy to break or crack. It is suitable for high-temperature protection inside the laser cutting machine bed and can replace traditional refractory bricks.

[0055] It is understood that those skilled in the art can make equivalent substitutions or changes based on the technical solution and concept of this application, and all such substitutions or changes should fall within the protection scope of the appended claims.

Claims

1. A method for preparing a high-temperature refractory component, characterized in that, Includes the following steps: Refractory aggregates, cementitious materials, binders, refractory powders and water are mixed to form a slurry; A reinforcing skeleton is laid inside the mold; The mud slurry is poured into the mold; The slurry material is cured and solidified. Demolding yields a high-temperature refractory component with an internally embedded reinforcing skeleton.

2. The method for preparing high-temperature refractory components according to claim 1, characterized in that, The refractory aggregate is high-alumina bauxite aggregate, the cementing material is silicate cement, the binder is clay, the refractory powder is refractory sand, and the water is purified water.

3. The method for preparing high-temperature refractory components according to claim 1, characterized in that, By weight: 55-60 parts of the refractory aggregate, 10-15 parts of the cementitious material, 5-10 parts of the binder, 20-25 parts of the refractory powder, and 10-15 parts of water.

4. The method for preparing high-temperature refractory components according to claim 1, characterized in that, The reinforcing skeleton is a metal mesh.

5. The method for preparing high-temperature refractory components according to claim 1, characterized in that, The curing process is high-temperature steam curing, and the high-temperature steam curing time is 5 to 6 hours.

6. The method for preparing high-temperature refractory components according to claim 1, characterized in that, The demolding is carried out within 1 hour after the curing is completed.

7. The method for preparing high-temperature refractory components according to any one of claims 1 to 6, characterized in that, After the step of "mixing refractory aggregate, cementitious material, binder, refractory powder and water to form slurry", and before the step of "laying the reinforcing skeleton in the mold", the following steps are also included: Apply a release agent to the inner surface of the mold.

8. The method for preparing high-temperature refractory components according to any one of claims 1 to 6, characterized in that, After the step "pouring the slurry into the mold" and before the step "curing the slurry to solidify", the following steps are also included: The poured mud slurry is then vibrated and compacted.

9. The method for preparing high-temperature refractory components according to any one of claims 1 to 6, characterized in that, After the step of "demolding to obtain a high-temperature refractory component with an internally embedded reinforcing skeleton", the following steps are also included: After demolding, let it stand for three days to cure, with water sprayed evenly once on the first day.

10. A high-temperature refractory component, characterized in that, It is prepared by any one of the preparation methods described in claims 1 to 9.

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