预应力金属微晶陶瓷复合衬板的研发与应用

Development and Application of Prestressed Metal Microcrystalline Ceramic Composite Lining Plate

微晶陶瓷是一种具有耐磨、耐腐和耐温的高性能材料,可在同时具有磨损、腐蚀和高温环境中使用,其性能优于金属和有机材料。但是微晶陶瓷的显著性不足在于抗冲击韧性差,属于脆性材料,是由于微晶陶瓷的烧结工艺所造成晶粒之间形成结构微裂纹,微晶陶瓷受到抗拉和冲击时易产生结构微裂纹“失稳”而断裂。尽管先进的陶瓷加工工艺有助于提高微晶陶瓷的冲击韧性,但因制作成本因素,致使其应用领域受限。发明了一种预应力金属微晶陶瓷复合材料,提高了微晶陶瓷抗冲击强度的20~80倍,急冷急热性能较好。对预应力金属微晶陶瓷复合衬板的研发原理进行了分析,并通过试验分析构建了预应力与微晶陶瓷衬板长度的数学模型,为生产各种性能指标的预应力金属微晶陶瓷复合衬板提供了一种设计参数的计算方法。将该型衬板应用于斜沟煤矿、陕西建新煤化有限公司、乌审旗蒙大矿业等矿山企业,详细阐述了衬板的安装技术流程,取得了理想成效。研究表明:预应力金属微晶陶瓷技术在矿山应用前景广阔,可以进一步推广应用于生产预应力金属微晶陶瓷复合衬板和管道,有助于解决微晶陶瓷由于冲击韧性差致使应用领域受限的不足。

Microcrystalline ceramics is a kind of high performance materials with wear resistance,corrosion resistance and temperature resistance.They can be used in the environment with wear,corrosion and high temperature at the same time,and their performance is better than that of metal and organic materials.However,the significant deficiency of microcrystalline ceramics lies in the poor impact toughness,which is a brittle material.It is due to the formation of structural microcracks between grains caused by the sintering process of microcrystalline ceramics.When the microcrystalline ceramics are subjected to tensile and impact,it is easy to produce structural microcracks"instability"and fracture.Although advanced ceramic processing technology helps to improve the impact toughness of microcrystalline ceramics,its application is limited due to manufacturing cost.A prestressed metal microcrystalline ceramic composite was invented,which increased the impact strength of microcrystalline ceramics by 20~80 times.The research and development principle of prestressed metal microcrystalline ceramic composite lining plate was analyzed,and the mathematical model of prestress and the length of microcrystalline ceramic lining plate was established through experimental analysis,so as to provide a method to calculate the design parameters of the prestressed metal microcrystalline ceramic composite lining plate.This type of ling plate is applied to Xigou Coal Mine,Shaanxi Jianxin Coal chemical Co.,Ltd.,Mengda Mining Co.,Ltd.,Wushen Banner and other mining enterprises,the installation technical process of lining plate is described in detail,and the ideal results is achieved.The study results show that prestressed metal microcrystalline ceramics technology has a broad application prospect in mines,and can be further popularized and applied in the production of prestressed metal microcrystalline cerami cs composite lining plate and pipe,which is helpful to solve the shortage of microcrystalline ceramics limited in application field due to poor impact toughness.