CN1027239C - 用耐火材料涂覆氧化铝颗粒的方法及其所得磨料颗粒和含该颗粒的磨料产品 - Google Patents
用耐火材料涂覆氧化铝颗粒的方法及其所得磨料颗粒和含该颗粒的磨料产品 Download PDFInfo
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Abstract
公开了一种磨料颗粒,该颗粒含有一个氧化铝基矿芯,上面用阴极电弧淀积的方法涂覆一层金属硼化物、碳化物或氮化物耐火材料,其中芯(层)可以是熔融氧化铝或氧化铝基陶瓷。还公开了改进的磨料产品,其中至少一部分传统的磨料颗粒用上述涂覆的磨料颗粒所代替。
Description
本发明涉及一种通过在氧化铝基芯粒上阴极电弧淀积耐火材料制备磨料颗粒的方法;用该方法制得的磨料颗粒;以及用这种磨料颗粒制得的磨料制品。
氧化铝(或钒土)在各种磨料产品中用作磨料颗粒(或磨粒)已有很长时间。使用氧化铝磨料颗粒的主要原因是其在自然界资源丰富。天然存在的氧化铝以后通过熔融工艺、热处理和添加各种添加剂而被改性。尽管这样的技术会显著改善含这类磨料颗粒的磨料制品的功效,但仍急切需要进一步改进氧化铝磨料,以使其能抵抗因与金属工件接触造成的反应和磨蚀。
稍有点技术知识、但不是磨料技术领域或陶瓷 割具技术领域的普通技术人员可能指望着从陶瓷割具技术中得知如何改进磨料颗粒以使其反应性更低而耐久性更高。例如,美国专利4,366,254介绍了一种由氧化铝、氧化锆和选含的一种耐火金属化合物(例如周期表IVB和VB族金属的碳化物、氮化物或碳氮化物,和VIB族金属的碳化物)构成的切削工具,这种切削工具不易磨碎,但不如纯氧化铝那样耐磨。美国专利4,534,343介绍了一种切削工具,它含有一种由氧化铝、硼化钛、碳化钛和氧化锆
制成的高度导热的陶恣材料。美国专利4,776,863介绍了一种硬金属切削工具,这种切削工具涂覆了碳化钛、碳氮化钛和/或氮化钛的硬质层,最外层是氮化锆薄层。碳氧化钛连续层是用化学汽相淀积法(CVD)涂覆的,正如该专利所述的那样,氮化锆层也可借助于物理气相淀积法(PVD)得到。PVD法包括溅射蒸发法或电弧蒸发法。
美国专利4,746,563公开了一种多层涂覆的渗碳切削工具。该专利还叙述了用CVD法在渗碳基料上形成氧化铝和金属氮化物或碳化物的连续层。总厚度为5-20微米的氧化铝层被诸夹层分成若干层,各层厚度为0.01-2微米(10-2000纳米),各夹层厚为0.01-2微米且由选自TiC、TiN、TiCN、TiCNO、TiCO、TiNO、Ti氧化物、Ti(B,N)、Ti(B,N,C)、SiC、AlN和AlON的至少一种成分构成。
已经采用用一种涂覆的金属(如钼)溅射的方法,用附着金属层包覆金刚石来提高金刚石颗粒制成压制品时其间的粘接力(见美国专利3,351,543)。所谈到的优点是能使尺寸不同的小的人造金刚石粘合到一起制成可使用的切削工具。采用溅射法清理金刚石的表面,然后涂覆钼。据报道,涂层厚约为58-200纳米。
尽管上述某些参考文献提到用耐火金属化合物涂覆这类陶瓷切削工具的方法可改善其物理特性,但它们都不是引导磨料领域普通技术人员对氧化铝磨料颗粒(或磨粒)做类似改进。
有几个原因不能把切削工具看成是磨粒(磨削)。曾经有人把磨消看作是完全与切削工具相同的、纯属切除金属的机械效应。这得到了以下事实的支持,即:两种常用的磨料-氧化铝和碳化硅(SiC)对不同材料的行为各异。据认为是较硬矿物的氧化铝对高拉伸钢有效,而SiC对低拉伸材料更有效,对这些物质的进一步研究后发现,SiC实际上是这两种矿物中更硬的。随着对B4C(远硬于氧化铝或SiC)的开发发现,对磨削钢材来说,这种新矿物比氧化铝或SiC要差,所以,磨削总的来说是机械方法的理论早已过时。
通过比较用切削工具和磨削切除金属用的能量分布,可以找出为什么磨削总的来说不是机械方法的原因。在切削工具中,估计用于切削的总能量中有高达90%的能量随碎片一起被除掉,只有约5%的能量以热的形式通向金属表面。因此,对正常切削速度来说,切削工具温度保持在较低水平-约700℃-~800℃。对磨削来说,投入作业的总能量比切削工具高达10倍。在输入的总能量当中,与切削工具5%相比,在磨面上约80%以热的形式进入工件。因此,以热的形式进入工件中的能量,磨削比切削工具高出160倍。这种差别的原因可在铁屑形成的不同机理和刀面角值中发现。在切削工具中,刀面角接近零,使铁屑能几乎完全自由地向上移动而除掉。在磨削中,刀面角具有很大的负值,对铁屑向上移动的阻力相当大。因此,大量能量花费在使磨削面变形,仅有少量能量用于磨掉铁屑。由此使磨削界面的温度达到非常高的值,甚至可达到金属的熔点,这已通过在磨屑中常见到固化的铁屑得到
证明。高温的另一征兆是在磨削中观察到“火花雨”,它是由加热到红热或白热的铁屑组成。
由于磨削界面的高温的结果,必须考虑金属、磨粒和气氛之间的相互作用。例如,为什么对多数钢材来说氧化铝是比碳化硅更好的磨料的最佳解释,是在碳化硅和钢材之间磨削造成的高温下发生化学反应,这种反应的结果是“熔化”了磨料并造成过度磨损。已发现,碳化硼、碳化钨和碳化钛也是很坚硬的材料的例子,是优良的切削工具的材料,但因其与各种金属之间发生反应,所以几乎不能用作磨粒。
因此,在改善用于磨料产品的磨粒磨削功效方面(如采用涂覆的磨料),不是针对将用于切削工具的疏松材料代替磨粒,而且集中考虑改变磨粒的组成或将磨粒涂上薄的耐火材料层。
美国专利4,788,167就是前面的一个例子。在该专利中,公开了一种含氮化铝、氧氮化铝和元素周期表IVB金属氮化物的磨粒。所谈到的组合物对磨削冷轧钢材来说比公知的组合物有所改进。
日本公开末决专利公开号1-113485(公开日:1989年5月2日)介绍了各类磨料构造,其中谈到通过化学汽相淀积法涂覆了金刚石或立方晶系的氮化硼的氧化铝、氧化锆或碳化硅磨粒用于磨轮、切削刀具片和精饰工件。这专利针对将磨粒转变为“超硬”颗粒,方法是将磨粒涂覆上厚度为0.5-10微米(500-10000纳米)的金刚石或氮化硼。
日本专利文献JP-1-317111(A)的摘要公开了据说具有优良的研磨性能的磨料颗粒。该磨料颗粒具有金刚石、CBN、SiC,Al2O3、WC、TiC或W的粉状芯和通过汽相合成工艺沉积在上面的多晶金刚石覆层。
美国专利4,505,720(已转让给本申请人)介绍了一
种改进的颗粒状磨粒矿物,其制备方法是将硬质耐火材料涂覆到碳化硅磨粒上。涂层是在流化床中用化学汽相淀积到碳化硅上的方法涂覆的。所得涂覆过的磨粒用于磨削钢材料显著提高了磨粒功效。
但是,在本技术领域中仍缺乏的是,用于涂覆的磨料产品的氧化铝基磨粒对磨削金属的磨削特性的改进。
氧化铝基涂覆过的磨料一般以低速除掉金属,一个原因可能是由于磨粒的“金属包覆”造成的。这里所用的术语“金属包覆”指的是在磨蚀过程中由工件掉下来的金属包覆住磨料颗粒。金属包覆显著降低了涂覆的磨料产品的功效。特别令人头痛的问题是采用细级配的磨料颗粒(平均粒径小于100目或150微米)。据认为,消除或减少金属覆盖物可改善磨削速率和提高磨料矿物的使用寿命。
本发明的目的是提供具有改进的磨料性能的氧化铝基磨料颗粒、磨料产品及制备磨料颗粒的方法。
本发明提供了涂覆有金属硼化物、碳化物或氮化物耐火材料薄附着层(<0.1微米)的氧化铝基磨料颗粒,当这种颗粒掺入到磨料产品(如涂覆的磨盘)时,对磨料的功效提供了显著改进。
尽管不受理论的束缚,据信这种改进的磨料功效归因于形成了界面层或隔层,这种层防止了金属工件与磨料颗粒的表面发生反应,同时保持了其磨料特性。这种隔层是通过用耐火金属氮化物、碳化物和硼化物借助于阴极电弧沉积涂覆氧化铝基磨料颗粒而提供的。
概括地讲,本发明的磨料颗粒的特征在于,各颗粒包含一个氧化铝基芯,芯上涂有一层平均层厚小于100纳米的均匀的耐火材料层。所述涂层最好是一种选自金属硼化物、碳化物和氮化物的耐
火材料。优选的金属硼化物、碳化物和氮化物中,其金属选自钪、镧、铯、钕、钇、钛、锆、铪、钒、铌、钽、铬、钼、钨以及它们的混合物。硼的碳化物和氮化物也有用。
优选的涂层厚在1-100纳米左右,最好5-25纳米。
本发明磨料颗粒的氧化铝基芯最好是熔融氧化铝,熔融的氧化铝:氧化锆,或氧化铝基陶瓷材料,例如由溶胶-凝胶法得到的氧化铝基陶瓷材料。优选的陶瓷材料是由溶胶-凝胶法得到的α-氧化铝基陶瓷材料,该材料可以被接种,以提供较细小区域结构;也可以用一种改性剂(如氧化镁改进,以提供更耐用的磨粒,在陶瓷烧成之后得到一种氧化铝:氧化镁尖晶石。
按照以下方法制备本发明的磨料颗粒,该方法包括以下步骤:
a)向一金属阴极通入足够的电流,以形成一种构成阴极的金属等离子体;
b)使该等离子体处于一种气氛下,以形成该等离子体的金属硼化物、碳化物或氮化物;
c)使等离子体对准通往阳极的一个通道;
d)在所述通道内,使氮化铝颗粒保持在被涂覆状态;
e)旋转各氧化铝基颗粒,以使各颗粒的整个表面基本上暴露上等离子体通道内;
f)连续进行步骤a-e,直至在每个氧化铝颗粒上基本上涂覆一层基本均匀的耐火材料层,以及
g)在氧化铝颗粒上耐火材料的平均层厚达到100纳米之前中止步骤a-f。
所述气氛可含有一种惰性气体,如氩、氪、氙、氦,或元素周期表8族中的一种元素,或仅由反应气构成。合适的反应气有氧,氮,氨,烃或含硼气体。
本发明还提供了磨料制品,这类磨料制品中所含的磨粒可部分或全部由本发明的磨料颗粒所取代。这种磨料制品是涂覆的磨料产品(通称作砂纸),粘合的磨料产品(如砂轮或镗磨油石)或无纺磨料产品。除了传统的磨料颗粒全部或部分地用本发明的磨料颗粒替代之外,这类产品是常用的。
用本发明磨粒制成的涂覆的磨盘与含有传统的氧化铝基磨料颗粒、但无耐火材料层的同样磨盘相比,对各种金属工件(如不锈钢和软钢)的磨削功效得到改进。由于在磨料颗粒上存在耐火材料层,本发明磨盘的使用寿命要长的多。据认为,长的使用寿命代表了金属包覆问题得以降低。预计使用含本发明的磨料颗粒的磨料产品,同样可以改善对其它金属工件(如钛,硬钢,金属合金)的磨削功效。
用本发明耐火材料涂覆的、优选的氧化铝基颗粒包括熔融氧化铝,熔融氧化铝-氧化锆,和有和无接种材料或改性剂的溶胶-凝胶法得到的陶瓷的α-氧化铝基磨料颗粒。氧化铝基磨料颗粒最好用溶胶-凝胶法制备。这类磨粒的例子可参见美国专利4,314,827;4,744,802;4,770,671和4,881,951。
为了制备本发明磨料颗粒,采用阴极电弧淀积法,以在氧化铝基磨料颗粒上涂覆耐火材料。氧化铝基磨料颗粒置于阴极电弧淀积
装置的室内,或能摇动或振动颗粒的装置上,以沿等离子场方向得到均匀的面层。
摇动磨料颗粒的方法的代表例有抖动、振动或转动反应器,搅拌这些颗粒,或将它们悬浮在一流化床中。优选的反应室由一个配有折流板(baffles)的圆筒构成,所述折流板在涂覆过程中搅动颗粒。在这类反应室中,颗粒可以不同方式被抖动,从而使各颗粒的整个表面基本上暴露在涂料通量物下。抖动颗粒往往还能防止颗粒聚集,达到混合均匀的目的,从而得到更均匀的涂层。
将反应室抽真空,然后再充入惰性气体和/或反应气达到所需操作压力。在淀积过程中,在源阴极施加并维持高电流。在阴极电弧涂覆中,将反应气单独加入涂覆室能反应性分解化合物。
提供一个阳极和阴极并以如下方向设置:
当激发电弧放电,和提供给阴极足够大小的电流时,阴阳极之间发生电弧放电。形成的电弧是小的发光区,这些发光区活动性很强,迅速移向阴极表面。由于在各发光点中电流密度很高,电流刚一提供给阴极,就发生阴极物质的迅速沸腾。所得等离子体或粒子束由源(阴极)物质的原子和离子构成,各粒子的动能约为10-100电子伏特。磁螺线管将离子和原子束射向基料表面。一般认为,在涂覆室内原子和离子在基料表面上与反应气反应成薄膜。
涂覆过程一般需要约5小时操作时间,尽管也可采用1-10小时。在操作时间结束后,从真空室中取出涂覆了耐火材料的磨粒,然后用于制备磨料制品。
在真空淀积法中,常用一种惰性气体再充入真空室。但在本发
明的涂覆工艺中,更典型地是不使用惰性气体。有时需要再充入惰性气体,因为它有助于从阴极稳定放电。如果在涂覆工艺中使用一种惰性气体,则该惰性气体可选自氮、氪、氙、氦和在等离子体环境下呈化学惰性的任一种其它气体。一般优选氩,因其成本低和利用率高。
按照本发明能用于形成化合物的反应气包括氧气,氮气,氨气,烃类气体和含硼气体(例如乙硼烷和环硼氮烷)。
在本发明中用于形成氮化物、碳化物或硼化物涂层的金属的例子有钪、镧、铯、钕、钇、钛、锆、铪、钒、铌、钽、铬、钼、钨以及它们的混合物。涂层厚约为1-100纳米。
来自阴极电弧工艺的高能等离子体往往有助于形成化学计量量的涂覆层。由于在涂覆过程中采用了高能量,至使涂层通常牢固地附着在基料上。
本发明涂覆的磨料颗粒可以用于传统的磨料产品,在某些情况下,它们最好以和廉价的常用磨料(如熔融氧化铝,碳化硅,石榴石,熔融氧化铝-氧化锆等等)构成的混合物形式使用。这些涂覆的磨料颗粒还可以和未注明为磨料的矿物或物质(如碳酸钙,玻璃等等)掺混。
由于用耐火材料涂覆磨料颗粒成本相当高,所以优选选择将本发明的磨料颗粒与廉价的磨料矿物进行掺混。这样混合磨料颗粒是已知的。一种优选的混合方法参见受让人的美国专利4,734,104。该方法称作选择性矿物替代法。在该方法中,粗磨料矿物从待用于磨料产品(如涂覆的磨料产品)的廉价磨料粒料中被除
掉,代之以本发明的粗矿物。该专利承认,在任何涂覆的磨料中,磨粒大体上是用于磨掉工件的主要部分。通过这种替代,本发明改进的磨料颗粒可在磨料产品中嵌入传统的磨料矿物的较小磨料颗粒之间,从而用这种产品可使改进的粗磨料颗粒能进行大部分磨削。
本发明涂覆的磨料颗粒可方便地处置,并可按照公知技术掺入到不同磨料产品中,例如制成涂覆的磨料产品、粘合的磨料产品和膨松的无纺磨料产品。本领域专业人员都知道制备这类磨料产品的方法。涂覆的磨料产品包括一种背材,例如由织物制成的背材(例如,机织织物或无纺织物如纸),而且其织物可用填充的粘合物质浸透;聚合物薄膜,例如取向热固性聚邻苯二甲酸丙酯或聚邻苯二甲酸乙酯制得的薄膜,需要的话,可以用底层物质先涂底;或任何其它常用的背材材料。涂覆的磨料还包括粘合剂物质,一般来说,在包括织物结构层、胶浆层以及可能的优质上胶涂层(supersize coat)在内的诸层中。常用的粘合剂物质有酚醛树脂。
研磨助剂也可以加到胶浆涂料中,或作为颗粒物料加入。优选的研磨助剂是KBF4,虽然据信其它研磨助剂也有用。其它可使用的研磨助剂有Nacl,硫,K2TiF6,聚氯乙烯,聚偏氯乙烯,冰晶石,以及它们的组合物或混合物。优选的研磨助剂用量为每平方米涂覆的磨料产品约50-300克,最好80-160克。
无纺磨料产品一般包含膨松多孔的聚合物丝状结构,在整个结构上分布了涂有耐火材料的氧化铝磨料粗砂,并用粘合剂物质牢固地粘结起来,制备这种无纺磨料产品的方法是公知的。
粘合的磨料产品一般由有机或陶瓷粘合剂物质粘合到一起的磨料粗砂成型块材构成。成型块材最好呈砂轮形式。用于本发明涂有耐火材料的氧化铝磨料粗砂的优选粘合剂物质是有机粘合剂。如果陶瓷或玻璃化粘合剂在不影响本发明的磨料粗砂的温度和条件下能固化的话,那么也可以使用这样的粘合剂。
以下实施例旨在说明本发明,所有份数和百分率均以重量计,除非另外注明。
普通阴极电弧淀积法
为进行阴极电弧淀积,将氧化铝基磨料颗粒称重,并置于一真空系统中的夹具上。将夹具安置在使用Model 100的氮化硼约束型阴极电弧设备(由Rerkin Elmer公司的Metco Cat Arc部门出售)时能接收最大涂料通量物(flux)处。该设备与美国专利3,836,451(Snaper)介绍的设备类似,还装有Gilmore等人的“Pulsed Metallic-Plasma Generators”(Proceed of the IEEE,V.60,NO.8,PP.977-991)中介绍的磁螺旋管。夹具安置在距阴极约7.6cm处。所用的锆和钛阴极是市售品,可由Phoenix Metallurgical Corporation,Houston,Texas买到,其直径为7.62cm,厚度为2.5cm。
阴极装在一水冷阴极电极夹上,并一起安置在该设备的真空室内。在真空室抽真空到5×10-6乇之内,关闭高真空扩散泵,
并将氩气和反应气,或仅将反应气以足以维持该室内压力为10-20毫托的流速下通入该室。在整个操作中气体流速一般要调节到使压力保持恒定。电弧在阴极表面上被激发,并以恒定的电流供应量调节到150安(对于400克磨粒加料试验)和180安(对于2000克加料试验)。提供约50高斯磁强的螺线管用于将钛或锆等离子体通到磨粒上,同时在配有拆流板(在涂覆过程中用于抖动磨粒)的圆筒内振动磨粒。典型涂覆试验时间约为5小时。
试验方法
为了测定涂覆的磨粒功效的改进情况,先将磨粒按传统方法涂布到背材上,然后改造成7.6cm×335cm的磨带。在恒定载荷的平面磨床上进行研磨试验。将装在夹具上的预先称重的软钢工件(约2.5×5×18cm)垂直放置,其2.5×18cm面对着约36cm直径的85肖氏硬度A硬度计的据齿型橡胶接触轮,其上一个个的齿丑压在涂覆的磨带上并将其夹带走。然后,将工件以20次循环/分钟的速率通过18cm路径往复垂直运行,同时承受弹簧压力的柱塞使工件以11.36kg负荷顶住磨带(磨带是以约2050米/分钟运行)。
通过将预先称重的工件研磨1分钟,重新称重工件以得到被除掉的金属重量,然后冷却该工件来进行试验。一系列工件按同样方式进行处理,直至工件组加工完毕,然后重复循环到达到所需终点为止。将各工件每分钟磨掉的金属量相加得到除掉的金属总量,由此计算出磨掉的材料量。
实施例1
将一种热处理过的熔融氧化铝(HTA)样品(牌号150,平均粒径约95微米,Treibacker Chemishe Werke Aklungesellschaft,Treibach,Austria产)在以下条件下,通过上述阴极电弧淀积的方法涂覆碳化钛:
磨粒加料重:400克
室压和气氛:甲烷,15毫乇
阴极电流:150安
将磨料暴露在涂料通量物下5小时,以根据计算足以得到层厚约10纳米的镀层。根据涂料重量百分数(按照分析化学法测定)、磨粒的平均表面积和涂料的密度(如氮化钛的密度为5.22g/cc),采用以下方程式计算平均层厚:
t= (10W)/(SD)
其中t=涂层厚
W=涂料重量百分数
D=密度(以g/cc表示)
S=表面积(以m2/克表示)
采用传统技术,将涂覆的磨粒制成涂覆的磨料产品。涂覆的磨料产品再改造成磨带。用未涂覆的HTA制作对照涂覆的磨料产品(也再改造成磨带)。
在每一种情况下,背材是Y重缎纹布聚酯,带尺寸为7.6cm×335.3cm。背材上涂有一层传统的CaCO填充的苯酚甲醛的酚醛树脂织物结构涂层,固化后它含有45.2%CaCO3和54.8%树脂。然后,用静电淀积法涂覆磨料矿物。将织物结构涂层于80℃预固化2小时,然后涂覆胶浆涂料。胶浆涂料是传统的CaCO3填充的酚醛树脂,固化后含59.6%CaCO3和40.4%树脂。在涂覆胶浆涂料之后,涂覆的磨料于100℃固化12小时。
在上述平面磨床上,将4个4150软钢于11.36kg压力下研磨共20分钟以检测磨带。按同样方式制备和测定对照物,结果如下:
用对照磨带磨掉的金属总量:352.3克
用实施例1的磨带磨掉金属的总量:382.96克
改进百分率:8.7%
实施例2
在以下条件下,用阴极电弧淀积法将实施例1所述的热处理地过的熔融氧化铝(HTA)样品涂覆氮化钛:
磨粒加料量:400克
室压和气氛:氮气,15毫托
阴极电流:150安
将磨粒暴露在涂料通量物下5小时,以足以得到约10纳米的涂层厚。用所得涂覆的磨粒制作涂覆的磨料,再改造成磨带,并按
照实施例1的方法进行测定,结果如下:
用对照磨带磨掉金属的总量:352.3克
用实施例2磨带磨掉金属的总量:390.6克
改进百分数:10.8%
实施例3
将按照美国专利4,964,883实施例18制得的陶瓷溶胶-凝胶的氧化铝基磨粒(牌号150)样品(只是含0.5%氧化镁)利用阴极电弧淀积法在以下条件下涂覆氮化钛:
磨粒加料量:400克
室压和气氛:氮气,15毫托
阴极电流:150安
将磨粒暴露在涂料通量物下5小时,以足以得到计算的涂层厚约10纳米。用所得涂覆的磨粒制作涂覆的磨料产品,再改造成磨带,并按照实施例1的方法进行测定,结果如下:
用对照磨带磨掉金属的总量:248.3克
用实施例2磨带磨掉金属的总量:268.26克
改进百分数:8.2%
实施例4
在以下条件下,借助于阴极电弧淀积法,将α-氧化铝、氧化镁改性的氧化铁接种的陶瓷磨粒(由Minnesota Mining和Manufacturing公司出售,商标为
“Cubitron”,牌号150)涂覆碳化锆:
磨粒加料量:2000克
室压和气氛:甲烷气,15毫托
阴极电流:180安
将磨粒暴露在涂料量物下5小时,以足以得到计算的涂层厚约10纳米。
用所得涂覆的磨粒按传统的技术制成涂覆的磨料产品,再改造成磨带。用未涂覆的磨粒制成涂覆的磨料产品,再改造成对照磨带。
涂覆的磨料背材是一种处理过的棉J重斜纹布(由Gustav Ernstmeier Gmbh和Co.KG,West Germany得到),带尺寸为7.6cm×335.3cm。
将该布涂覆一种传统的CaCO3填充的酚醛树脂,固化后,得到固含量42%CaCO3和58%树脂。然后,通过静电淀积法涂覆磨料矿物,使之密度为0.0151克/cm2。
按照以下加热程序制备织物结构涂层:
4分钟 于71℃
20分钟 于96℃
74分钟 于104℃
织物结构涂料是一种传统的CaCO3填充的酚醛树脂,固化后,固含量为80%CaCO3和20%树脂。涂覆之后,按照以下加热程序固化磨带:
20分钟 于57℃
40分钟 于71℃
20分钟 于81℃
80分钟 于89℃
90分钟 于58℃
最终固化后,在上述平面磨床上,将4个4150软钢工件于4.5kg压力下共研磨20分钟,由此对磨带进行测定,结果如下:
用对照磨带磨掉的金属总量:346.46克
用实施例4磨带磨掉的金属总量:427.86克
改进百分数:23.5%
实施例5
在以下条件下,借助于阴极电弧淀积法,将实施例4介绍的Cubitron磨粒(牌号150)涂覆碳化锆:
磨粒加料量:2000克
室压和气氛:甲烷气,15毫托
阴极电流:180安
将磨料暴露在涂料通量约下5小时,以充分得到计算的涂层厚约10给米,用涂覆的磨粒制作涂覆的磨料产品,再改造成磨带,并按照实施例4介绍的方法进行测定,结果如下:
用对照磨带磨掉的金属总量:304.9克
用实施例5磨带磨掉的金属总量:395.1克
改进百分数:29.6%
尽管根据具体实施例已说明了本发明,但不用说本发明有许多变型,所附权利要求旨在包括这些变种。
Claims (10)
1、磨料颗粒,其各颗粒包含一个氧化铝基芯,所述磨料颗粒的特征在于:各芯上涂有基本上均匀的耐火材料层,且其平均层厚低于100nm。
2、根据权利要求1所述的磨料颗粒,其特征在于所述耐火材料是一种选自钪、镧、钯、钇、钛、锆、铪、钒、铌、钽、铬、钼、钨的金属及其混合物的硼化物、碳化物或氮化物。
3、根据权利要求1所述的磨料颗粒,其特征在于所述的涂层厚度高于1nm。
4、根据权利要求1所述的磨料颗粒,其特征在于所述的涂层厚为5-25nm。
5、一种呈涂覆的磨产品、粘合的磨料产品或无纺的磨料产品形式的磨料制品,该制品包含磨料颗粒,其特征在于至少一部分所述磨料颗粒是权利要求1的磨料颗粒。
6、一种制备磨料颗粒的方法,其中各颗粒具有一个氧化铝基芯,各芯上涂有基本上均匀的金属硼化物、碳化物或氮化物耐火材料层,所述方法的特征在于包括以下步骤:
a)向一金属阴极施加足够的电流以形成构成阴极的金属等离子体;
b)使所述等离子体处于一种气氛下,以形成所述等离子体的金属硼化物、碳化物或氮化物;
c)使所述等离子体对准通往阳极的通路;
d)在所述通路内,使氧化铝颗粒维持在被涂覆状态;
e)旋转各氧化铝基颗粒,以使所述各颗粒的整个表面基本上暴露在所述等离子体通道内;
f)连续进行a-e步骤,直至基本上在各个氧化铝基颗粒上涂覆一层基本上均匀的涂层为止,以及
g)在氧化铝在颗粒上耐火材料的平均厚超过100mm之前中止步骤a-f。
7、根据权利要求6所述的方法,其特征在于所述气氛包括一种惰性气体。
8、根据权利要求7所述的方法,其特征在于所述惰性气体选自氩、氪、氙,或元素周期表8族元素。
9、根据权利要求6所述的方法,其特征在于所述气氛包括一种还原气。
10、根据权利要求8所述的方法,其特征在于所述还原气包括氧、氮、氨、烃或含硼气体。
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- 1990-05-02 US US07/517,931 patent/US5085671A/en not_active Expired - Fee Related
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1991
- 1991-03-26 BR BR919106401A patent/BR9106401A/pt not_active IP Right Cessation
- 1991-03-26 WO PCT/US1991/002035 patent/WO1991017225A1/en active IP Right Grant
- 1991-03-26 JP JP91506665A patent/JPH05506678A/ja active Pending
- 1991-03-26 RU RU9192016414A patent/RU2092514C1/ru active
- 1991-03-26 EP EP91907376A patent/EP0527143B1/en not_active Expired - Lifetime
- 1991-03-26 CA CA002080598A patent/CA2080598A1/en not_active Abandoned
- 1991-03-26 AU AU75533/91A patent/AU639555B2/en not_active Ceased
- 1991-03-26 KR KR1019920702727A patent/KR0179636B1/ko not_active IP Right Cessation
- 1991-03-26 AT AT91907376T patent/ATE111501T1/de not_active IP Right Cessation
- 1991-03-26 DE DE69104039T patent/DE69104039T2/de not_active Expired - Fee Related
- 1991-04-10 TW TW080102730A patent/TW201789B/zh active
- 1991-04-12 ZA ZA912765A patent/ZA912765B/xx unknown
- 1991-04-23 MX MX025479A patent/MX167416B/es unknown
- 1991-04-30 CN CN91102779A patent/CN1027239C/zh not_active Expired - Fee Related
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1992
- 1992-01-31 US US07/828,514 patent/US5163975A/en not_active Expired - Lifetime
- 1992-10-30 NO NO92924189A patent/NO924189L/no unknown
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MX167416B (es) | 1993-03-22 |
EP0527143B1 (en) | 1994-09-14 |
NO924189L (no) | 1992-12-30 |
CN1056078A (zh) | 1991-11-13 |
DE69104039D1 (de) | 1994-10-20 |
ZA912765B (en) | 1992-01-29 |
US5163975A (en) | 1992-11-17 |
AU639555B2 (en) | 1993-07-29 |
KR0179636B1 (ko) | 1999-05-01 |
TW201789B (zh) | 1993-03-11 |
WO1991017225A1 (en) | 1991-11-14 |
US5085671A (en) | 1992-02-04 |
RU2092514C1 (ru) | 1997-10-10 |
BR9106401A (pt) | 1993-05-04 |
JPH05506678A (ja) | 1993-09-30 |
DE69104039T2 (de) | 1995-03-30 |
CA2080598A1 (en) | 1991-11-03 |
AU7553391A (en) | 1991-11-27 |
NO924189D0 (no) | 1992-10-30 |
ATE111501T1 (de) | 1994-09-15 |
EP0527143A1 (en) | 1993-02-17 |
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