大型钢锭模涂料实验研究
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摘要
我国航空航天、船舶、电力、石化对大型铸锻件需求强烈,加强对大型铸锻件相关技术的开发研究,探索技术可靠、经济合理的工艺方法,具有重要的科学价值和现实意义。大型铸锻件质量的好坏与钢锭的质量密切相关。钢锭模涂料在钢液浇注过程中,作为钢液和模壁的中间层,起着调控传热的作用,不仅仅可以减少钢液对钢锭模模壁的热冲击,从而改善钢锭凝固质量和提高钢锭模使用寿命,还有利于钢锭脱模,减少结疤等缺陷,增加钢锭的成材率。
本文以大型钢锭模涂料为研究对象,对不同组成条件下的涂料基本配方进行实验,通过考察涂料的熔点、悬浮性、涂层厚度、涂层低温强度和高温强度等性能,并借助差热分析和物相分析,得到综合性能较好的涂料配方,在此基础上对涂料进行正交优化,得到涂料的最佳比例,并进行成本的估算。通过实验室浇注实验观察涂料的应用效果,并对大型钢锭的热环境进行了模拟,弄清楚涂料在此环境下的变化情况。主要的研究内容及结果如下:
(1)按骨料和粘接剂的结合方式把涂料分成水玻璃结合石英质涂料、水玻璃结合铝硅质涂料、硅溶胶结合铝硅质涂料、硅溶胶结合镁质涂料、水玻璃结合镁质涂料、磷酸盐结合铝硅质涂料六个涂料组成配方,通过考察六种涂料熔点、悬浮性、涂层厚度、涂层低温烘烤后的表面质量和高温烘烤后的表面质量,并借助热分析和物相分析实验,获得综合性能较好的涂料配方。研究表明:磷酸盐结合镁铝质涂料熔点达到1450℃以上,料浆比为2:1(涂料非水组成与外加水之比)时,涂料的粘度约20泊,涂料的悬浮性达到97%,涂层厚度在0.4mm左右,涂层经过低温和高温烘烤后表面平整、无掉粉,抗开裂性为1级;双无机粘接剂结合镁质涂料1450℃以上,料浆比为2:1(涂料非水组成与外加水之比)时,涂料的粘度约20泊,涂料的悬浮性达到85%,涂层厚度在0.4mm左右,涂层经过低温和高温烘烤后表面平整、无掉粉,抗开裂性为1级。
(2)以磷酸盐结合镁铝质涂和双无机粘接剂结合镁质涂料为实验对象,把涂料组成按五因素四水平进行正交实验优化配方,得到涂料的最佳组成,并对涂料成本进行估算。研究结果表明:磷酸盐结合镁硅质涂料组成配比为铝矾土:镁砂粉=1:6,CMC、六偏磷酸钠、硅微粉占10-30%;双无机粘接剂结合镁质涂料组成配比为镁砂粉:硅微粉=10:1,CMC、六偏磷酸钠、硅溶胶占10-25%具有较好的涂层抗开裂性、低温强度和高温强度等性能;通过涂料成本的估算,磷酸盐结合镁硅质涂料约850元/吨,双无机结合镁质涂料约730元/吨。
(3)将优化后的磷酸盐结合镁硅质涂料和双无机粘接剂结合镁质涂料进行了实验室浇注实验,在料浆比为2:1的条件下,考察了不同涂层厚度条件下涂料的应用效果,还考察了钢锭冷、热态脱模时的应用效果。并对大型钢锭浇注的热环境进行模拟,考察涂料高温强度的变化情况。研究结果表明:涂层厚度在0.3mm时,涂层表面质量较好,经过风干和烘烤,抗裂性为1级,涂层厚度在1mm时,涂层风干后,抗裂性为3级,经烘干后,抗裂性为4级,相比之下,涂层厚度为0.3mm时涂层的抗裂性更强;冷态和热态条件下钢锭均容易脱模,热态脱模时,钢锭表面附着涂层较少,降低了钢锭表面清理工作量,涂料均不熔,减小了钢锭模所受的热冲击,保护了钢锭模;研究涂层高温强度随时间和温度的变化情况来模拟大型钢锭浇注的热环境,结果表明磷酸盐结合镁硅质涂料和双无机粘接剂结合镁质涂料对大钢锭浇注基本能够适应。
China's aviation and aerospace, shipbuilding, electric power, petrochemical strong demand for large casting and forging, strengthening of the Forging research and development related technologies to explore the technology is reliable, economical process method, Juyou important to the scientific value and practical significance. Forging their quality, and is closely related to the quality of steel ingots. Paint in liquid steel ingot mold casting process, molten steel and the die wall as the middle layer, heat transfer plays a regulatory role, not only can reduce the liquid steel ingot mold die wall on the thermal shock, in order to improve quality and increase ingot solidification Ingot mold service life, but also help ingot mold release, reduce scarring and other defects, increase the rate of finished steel ingot.
In this paper, a large steel ingot mold coating for the study, under the conditions of the different composition of the basic formula of the coating experiments, the melting point by examining the paint, suspension, coating thickness, coating temperature strength and high temperature strength properties, and the help of differential thermal analysis and phase of analysis, good performance of paint formulations, coatings based on this orthogonal optimization to obtain the best ratio of paint, and make cost estimates. Laboratory experiments by pouring paint application effect observed, and a large steel ingot to simulate the thermal environment, clear coatings in this environment changes. The main research contents and the results are as follows:
(1) By a combination of aggregate and form the adhesive coating into water glass coating combined with the quality of quartz, sodium silicate combination of aluminosilicate coating, silica coating combined with aluminosilicate, colloidal silica combined with magnesia coating, sodium silicate and magnesium sulfate quality coating, phosphate coating combined with aluminosilicate coatings composed of six formula, melting point by examining the six paint, suspension, coating thickness, baking temperature after coating the surface quality and surface quality after high temperature baking, and with Thermal analysis and phase analysis of experiments, and good performance of coatings formulations. The results show that: the quality of phosphate coating combined with Mg to 1450℃above the melting point of the slurry ratio of 2:1 (non-aqueous coating composition and applied to water ratio), the viscosity of about 20 parked paint, coating suspension to 97% the coating thickness is about 0.4mm, coated and low and high temperature baking the surface smooth, no dropped powder, anti-cracking resistance is one; double inorganic adhesive bonded magnesia coating above 1450℃, the slurry ratio of 2 : 1 (non-aqueous coating composition and applied to water ratio), the coating viscosity of about 20 parked, coating suspension to 85%, coating thickness is about 0.4mm, low and high temperature baking after coating the surface smooth, No swap powder, resistance to cracking of the one.
(2) The combination of Mg, Al-quality phosphate coating and double coating inorganic adhesive bonded magnesia as the experimental object, the coating composition according to five factors, four levels Optimize the formula, get the best composition of paint, and paint cost estimates. The results show that: the quality of phosphate coating in the bauxite alumina combined 10-15%, 60-75% magnesite powder, the remaining materials account for 10-30% of the composition, the coating has good resistance to cracking, low strength and high temperature strength properties; pair of inorganic coating adhesive bonded magnesia magnesite powder in 60-75%, 0.7-1% sodium hexametaphosphate, and the remaining material composed of about 25-40%, the coating has a good Crack Resistance, low strength and high temperature strength properties; through the paint for the cost estimates, phosphate and magnesium silicon coating about 850 yuan / ton, double-inorganic bonded magnesia coating is about 730 yuan / ton.
(3) the optimized combination of magnesium phosphate inorganic silica coating and double coating adhesive bonded magnesia casting laboratory experiments carried out in slurry ratio of 2:1 were investigated under conditions of different coating thickness effect under the application of paint, also looked at the cold steel ingot, hot stripping effect when applied. And a large steel ingot casting simulation of the thermal environment to study the changes in coating high temperature strength. The results show that: the coating thickness of 0.3mm, the coating surface quality is better, after drying and curing, cracking resistance to a coating thickness of 1mm, the coating dried, the crack is 3, after drying, the crack was four, compared to when the coating thickness is 0.3mm greater crack resistance coatings; cold and hot conditions are easy ingot stripping, thermal stripping, the ingot surface coating less attached to reduce the workload of ingot surface cleaning, coating not melt, reduces the thermal shock suffered ingot mold to protect the ingot mold; of coated high temperature strength with time and temperature to simulate the change the thermal environment of large steel ingot casting, the results show that the combination of magnesium phosphate inorganic silica coating and double coating adhesive bonded magnesia casting of large ingots basic to adapt.
本文以大型钢锭模涂料为研究对象,对不同组成条件下的涂料基本配方进行实验,通过考察涂料的熔点、悬浮性、涂层厚度、涂层低温强度和高温强度等性能,并借助差热分析和物相分析,得到综合性能较好的涂料配方,在此基础上对涂料进行正交优化,得到涂料的最佳比例,并进行成本的估算。通过实验室浇注实验观察涂料的应用效果,并对大型钢锭的热环境进行了模拟,弄清楚涂料在此环境下的变化情况。主要的研究内容及结果如下:
(1)按骨料和粘接剂的结合方式把涂料分成水玻璃结合石英质涂料、水玻璃结合铝硅质涂料、硅溶胶结合铝硅质涂料、硅溶胶结合镁质涂料、水玻璃结合镁质涂料、磷酸盐结合铝硅质涂料六个涂料组成配方,通过考察六种涂料熔点、悬浮性、涂层厚度、涂层低温烘烤后的表面质量和高温烘烤后的表面质量,并借助热分析和物相分析实验,获得综合性能较好的涂料配方。研究表明:磷酸盐结合镁铝质涂料熔点达到1450℃以上,料浆比为2:1(涂料非水组成与外加水之比)时,涂料的粘度约20泊,涂料的悬浮性达到97%,涂层厚度在0.4mm左右,涂层经过低温和高温烘烤后表面平整、无掉粉,抗开裂性为1级;双无机粘接剂结合镁质涂料1450℃以上,料浆比为2:1(涂料非水组成与外加水之比)时,涂料的粘度约20泊,涂料的悬浮性达到85%,涂层厚度在0.4mm左右,涂层经过低温和高温烘烤后表面平整、无掉粉,抗开裂性为1级。
(2)以磷酸盐结合镁铝质涂和双无机粘接剂结合镁质涂料为实验对象,把涂料组成按五因素四水平进行正交实验优化配方,得到涂料的最佳组成,并对涂料成本进行估算。研究结果表明:磷酸盐结合镁硅质涂料组成配比为铝矾土:镁砂粉=1:6,CMC、六偏磷酸钠、硅微粉占10-30%;双无机粘接剂结合镁质涂料组成配比为镁砂粉:硅微粉=10:1,CMC、六偏磷酸钠、硅溶胶占10-25%具有较好的涂层抗开裂性、低温强度和高温强度等性能;通过涂料成本的估算,磷酸盐结合镁硅质涂料约850元/吨,双无机结合镁质涂料约730元/吨。
(3)将优化后的磷酸盐结合镁硅质涂料和双无机粘接剂结合镁质涂料进行了实验室浇注实验,在料浆比为2:1的条件下,考察了不同涂层厚度条件下涂料的应用效果,还考察了钢锭冷、热态脱模时的应用效果。并对大型钢锭浇注的热环境进行模拟,考察涂料高温强度的变化情况。研究结果表明:涂层厚度在0.3mm时,涂层表面质量较好,经过风干和烘烤,抗裂性为1级,涂层厚度在1mm时,涂层风干后,抗裂性为3级,经烘干后,抗裂性为4级,相比之下,涂层厚度为0.3mm时涂层的抗裂性更强;冷态和热态条件下钢锭均容易脱模,热态脱模时,钢锭表面附着涂层较少,降低了钢锭表面清理工作量,涂料均不熔,减小了钢锭模所受的热冲击,保护了钢锭模;研究涂层高温强度随时间和温度的变化情况来模拟大型钢锭浇注的热环境,结果表明磷酸盐结合镁硅质涂料和双无机粘接剂结合镁质涂料对大钢锭浇注基本能够适应。
China's aviation and aerospace, shipbuilding, electric power, petrochemical strong demand for large casting and forging, strengthening of the Forging research and development related technologies to explore the technology is reliable, economical process method, Juyou important to the scientific value and practical significance. Forging their quality, and is closely related to the quality of steel ingots. Paint in liquid steel ingot mold casting process, molten steel and the die wall as the middle layer, heat transfer plays a regulatory role, not only can reduce the liquid steel ingot mold die wall on the thermal shock, in order to improve quality and increase ingot solidification Ingot mold service life, but also help ingot mold release, reduce scarring and other defects, increase the rate of finished steel ingot.
In this paper, a large steel ingot mold coating for the study, under the conditions of the different composition of the basic formula of the coating experiments, the melting point by examining the paint, suspension, coating thickness, coating temperature strength and high temperature strength properties, and the help of differential thermal analysis and phase of analysis, good performance of paint formulations, coatings based on this orthogonal optimization to obtain the best ratio of paint, and make cost estimates. Laboratory experiments by pouring paint application effect observed, and a large steel ingot to simulate the thermal environment, clear coatings in this environment changes. The main research contents and the results are as follows:
(1) By a combination of aggregate and form the adhesive coating into water glass coating combined with the quality of quartz, sodium silicate combination of aluminosilicate coating, silica coating combined with aluminosilicate, colloidal silica combined with magnesia coating, sodium silicate and magnesium sulfate quality coating, phosphate coating combined with aluminosilicate coatings composed of six formula, melting point by examining the six paint, suspension, coating thickness, baking temperature after coating the surface quality and surface quality after high temperature baking, and with Thermal analysis and phase analysis of experiments, and good performance of coatings formulations. The results show that: the quality of phosphate coating combined with Mg to 1450℃above the melting point of the slurry ratio of 2:1 (non-aqueous coating composition and applied to water ratio), the viscosity of about 20 parked paint, coating suspension to 97% the coating thickness is about 0.4mm, coated and low and high temperature baking the surface smooth, no dropped powder, anti-cracking resistance is one; double inorganic adhesive bonded magnesia coating above 1450℃, the slurry ratio of 2 : 1 (non-aqueous coating composition and applied to water ratio), the coating viscosity of about 20 parked, coating suspension to 85%, coating thickness is about 0.4mm, low and high temperature baking after coating the surface smooth, No swap powder, resistance to cracking of the one.
(2) The combination of Mg, Al-quality phosphate coating and double coating inorganic adhesive bonded magnesia as the experimental object, the coating composition according to five factors, four levels Optimize the formula, get the best composition of paint, and paint cost estimates. The results show that: the quality of phosphate coating in the bauxite alumina combined 10-15%, 60-75% magnesite powder, the remaining materials account for 10-30% of the composition, the coating has good resistance to cracking, low strength and high temperature strength properties; pair of inorganic coating adhesive bonded magnesia magnesite powder in 60-75%, 0.7-1% sodium hexametaphosphate, and the remaining material composed of about 25-40%, the coating has a good Crack Resistance, low strength and high temperature strength properties; through the paint for the cost estimates, phosphate and magnesium silicon coating about 850 yuan / ton, double-inorganic bonded magnesia coating is about 730 yuan / ton.
(3) the optimized combination of magnesium phosphate inorganic silica coating and double coating adhesive bonded magnesia casting laboratory experiments carried out in slurry ratio of 2:1 were investigated under conditions of different coating thickness effect under the application of paint, also looked at the cold steel ingot, hot stripping effect when applied. And a large steel ingot casting simulation of the thermal environment to study the changes in coating high temperature strength. The results show that: the coating thickness of 0.3mm, the coating surface quality is better, after drying and curing, cracking resistance to a coating thickness of 1mm, the coating dried, the crack is 3, after drying, the crack was four, compared to when the coating thickness is 0.3mm greater crack resistance coatings; cold and hot conditions are easy ingot stripping, thermal stripping, the ingot surface coating less attached to reduce the workload of ingot surface cleaning, coating not melt, reduces the thermal shock suffered ingot mold to protect the ingot mold; of coated high temperature strength with time and temperature to simulate the change the thermal environment of large steel ingot casting, the results show that the combination of magnesium phosphate inorganic silica coating and double coating adhesive bonded magnesia casting of large ingots basic to adapt.
引文
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