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    助熔剂CaO及MgO对煤矸石基泡沫陶瓷性能及孔结构的影响

    Effects of flux CaO and MgO on the properties and pore structure of coal gangue based ceramic foams

    • 摘要: 以煤矸石为主要原料并添加助溶剂CaO和MgO制备了泡沫陶瓷,依据SiO2–Al2O3–CaO–MgO体系设计了不同的组分,研究了原料中的CaO/SiO2质量比、MgO/SiO2质量比及煅烧条件对泡沫陶瓷性能的影响规律。当原料中助熔剂CaO的添加量为1–2 wt.%时,制备的泡沫陶瓷样品具有均匀的孔隙结构,超过4 wt.%时高温发泡过程中液相黏度下降,形成连通孔。泡沫陶瓷的气孔率和气孔大小随煅烧温度的增加逐渐增大,过高的温度使气体从熔融基体中逸出,形成超大连通孔,当煅烧温度为1190 ℃时样品的发泡效果最好。对原料中MgO添加量为1–4 wt.%的研究发现,当MgO添加量为2 wt.%时,泡沫陶瓷样品的抗压强度和表观密度达到最大值,过量的MgO使液相黏度增大,发泡不充分,气孔结构变差;升温速率影响熔融基体熔化速率与发泡剂在高温下的反应时间,当升温速率为2 ℃/min时,样品具有均匀、细小的气孔结构。在添加1 wt.%的CaO时再添加适量MgO使单位面积上出现更多的颗粒,堇青石与钙长石相的紧密连接形成了颗粒间相互交织的连锁结构,改善了泡沫陶瓷的孔结构,提高了样品的综合性能。

       

      Abstract: Coal gangue was used as the main raw material and CaO and MgO were used as fluxes to prepare ceramic foams, and a reasonable SiO2-Al2O3-CaO-MgO component system was designed, and the effects of CaO/SiO2 mass ratio, MgO/SiO2 mass ratio and calcination conditions on the properties of foam ceramics were investigated. When the amount of added CaO was 1-2 wt%, the prepared foam ceramic samples showed uniform pore structure, while the sample with more than 4 wt.% CaO caused a decrease in the viscosity of the liquid phase during foaming, and thus forming interconnected pores. The porosity and pore size of the foam ceramics gradually increased with the increase of the calcination temperature, and the excessively high temperature caused the gas to escape from the molten matrix, forming oversized interconnecting pores. When the calcination temperature was 1190 ℃, the prepared sample possessed the best foaming effect. The study of the samples with 1-4 wt.% MgO shows that, when the amount of MgO reached 2 wt.%, the compressive strength and apparent density of the foam ceramic sample show the maximum value, the excessive MgO increased the viscosity of the liquid phase, resulting in insufficient foaming and poor pore structure. The heating rate affects the melting rate of the molten matrix melting and the reaction time of the foaming agent at high temperatures. When the heating rate was 2 ℃/min, the prepared sample has a uniform and fine pore structure. Under the condition of 1 wt.% CaO, the addition of a suitable amount of MgO presented more particles, and the close connection between cordierite and calcium feldspar phase formed the interwoven chain structure between the particles, which improved the pore structure of the foam ceramics and improved the overall comprehensive performance of the samples.

       

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