CN108115143B - 一种过滤器件的制备方法 - Google Patents
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Abstract
本发明涉及金属材料的成型和表面处理领域。本发明要求保护一种过滤器件的制备方法，采用低熔点、轻质金属粉末为原料，通过粉末冶金技术制备多孔轻金属制件；再对其进行浸没式氧化，将多孔纯金属制件的所有开放孔洞表面（能与液体或气体接触的部分）均匀氧化成耐腐蚀的金属氧化物，实现金属表面陶瓷化，形成一种高强度、轻质、耐腐蚀、无异味、低成本的新型过滤器件。
Description
技术领域
本发明涉及金属材料的成型和表面处理领域。
背景技术
目前市场上常见的过滤材料包括陶瓷材质、金属材质、高分子材质。其中，纯陶瓷过滤材料为市场上广泛应用的过滤材料，具有化学性能稳定、耐磨性能好、用于食品行业过滤无异味、易清洗等特点，但也有脆性大，耐冲击能力低，加工成型难度大，比重大等缺点。纯金属过滤材料多用合金钢、钛合金等高熔点金属，一般具有重量大，成本高，不耐腐蚀等缺点。高分子过滤材料机械强度不高，耐磨性差，化学稳定性差。市场急需一种成本更低、效能更高的过滤材料。为解决上述技术问题，本发明由此而来。
发明内容
为解决上述问题，本发明提供了一种超细过滤器件及其制备方法。本发明采用低熔点、轻质金属粉末为原料，通过粉末冶金技术制备多孔轻金属制件；再对其进行浸没式氧化，将多孔纯金属制件的所有开放孔洞表面（能与液体或气体接触的部分）均匀氧化成耐腐蚀的金属氧化物，实现金属表面陶瓷化，形成一种高强度、轻质、耐腐蚀、无异味、低成本的新型超细过滤器件。根据实际需求，可以选择在上述超细过滤器件制件表面喷涂一定粒径的陶瓷粉，达到进一步精准控制表面过滤孔径的效果。本发明提供的超细过滤器件的工艺简单，成本低，易于产业化。
本发明提供的一种超细过滤器件的制备方法，具体步骤如下：
（1）以D1粒径的M金属粉末为原料，通过模压成型和烧结，得到多孔纯金属材料，作为内层；
（2）以D2粒径的M金属粉末为原料，在上述多孔纯金属材料外侧表面模压成型和烧结，得到多孔纯金属制件，作为过渡层；
（3）对上述多孔纯金属制件进行浸没式氧化处理，使所有开放孔洞的内腔表面（与氧化液接触的部分）均匀地原位形成一层致密的氧化膜，实现金属表面陶瓷化，得到包含两层多孔材料的超细过滤器件；
（4）为了精准控制过滤器件的表面过滤孔径，采用喷涂技术，将D3粒径的M金属的氧化物粉末，喷涂在（3）述超细过滤器件的过渡层表面，得到纳米陶瓷过滤层，作为外层，即得到由内层向外层孔径梯度分布的超細过滤器件。
优选地，所述M金属粉选自具有低熔点、低比重的纯金属材料或其合金，包括但不限于纯铝、纯镁、铝合金或镁合金。
优选地，所述金属粉末的粒径为20 nm~500 μm。
优选地，所述多孔纯金属制件的外形可以为盘式、管式、板式等。
优选地，所述多孔纯金属制件的多层结构中，同一层的孔径均匀一致，由内层到外层孔径梯度变小，即D3<D2<D1，其中D1为 750nm ~ 500μm，D2为120nm ~ 80μm，D3为20nm ~15μm。
优选地，所述超细过滤器件的纳米陶瓷过滤层的厚度为10~20 μm，过滤孔径为100~2000 nm。
优选地，所述浸没式氧化处理（金属表面陶瓷化）的方法，包括但不限于化学氧化、阳极氧化、微弧氧化等。
优选地，所述纳米陶瓷过滤层的厚度为1 ~ 20 μm，过滤孔径为5 ~ 200 nm。
优选地，所述喷涂技术，包括但不限于热喷涂、等离子喷涂等。
与现有技术相比，本发明的优点在于：
相对于传统以高熔点金属为原料的金属过滤材料生产工艺，本发明采用低熔点、轻质金属粉末为原料，可以较低温度下、通过粉末冶金成型、低成本制备轻质、高强度、高韧性多孔纯金属制件。
其次，利用不同粒径的金属粉层压复合，通过粉末冶金、在金属熔点温度以下烧结成型，形成由内到外孔径梯度减小的多孔纯金属制件。
第三，通过对多孔纯金属制件进行浸没式氧化，使所有开放孔洞的内腔表面（与氧化液接触的部分）均匀地原位形成一层致密的氧化膜，实现金属表面陶瓷化，赋予多孔纯金属制件与陶瓷制件同等的化学稳定性，耐酸、碱、盐、热的腐蚀；同时，解决了纯陶瓷过滤材料的脆性大，抗冲击能力低，加工成型难度大，比重大等应用难点。
第四，为了精准控制超细过滤器件的表面过滤孔径，可选择在上述超细过滤器件表面采用喷涂技术、再涂覆一层与基体材料相同材质的纳米陶瓷过滤层。
附图说明
图1 多孔纯金属制件多层结构示意图；
图2 多孔金属表面陶瓷化示意图；
图3A 超细过滤器件剖面微观结构；
图3B 超细过滤器件剖面微观结构（示意图）;
其中1为金属颗粒内层，2为金属颗粒外层；10为铝合金，20为表面氧化铝；3为纳米陶瓷过滤层。
具体实施方式
以下结合具体实施例对上述方案做进一步说明。应理解，这些实施例是用于说明本发明而不限于限制本发明的范围。实施例中采用的实施条件可以根据具体厂家的条件做进一步调整，未注明的实施条件通常为常规实验中的条件。
实施例1
采用LY12铝合金：粉体P1、平均粒径为500 nm，和粉体P2、平均粒径150 nm，将上述铝合金分别与PEG、硬脂酸，按98.4：0.6：1的质量比混合均匀，得到P1复合粉和P2复合粉。
二次模压成型制成型，得到内径100mm，内层由P1复合粉组成、厚度5mm；外层由P2复合粉组成、厚度20 μm的多孔铝合金制件，如图1所示。
将上述多孔铝合金过滤管，经除油处理，再以亚硫酸钠和氢氧化钾的硼酸溶液作为电解液，将上述铝合金过滤管全部浸入电解液作为正极，金属铅浸入电解液作为负极，电流密度为60A/dm2，通电时间20min，在多孔铝合金过滤管的所有开放孔洞的内腔表面（与氧化液接触的部分）原位均匀形成致密的氧化膜，即得到铝合金表面陶瓷化的超细过滤器件（图2）。
经检测，所得多孔铝合金过滤管内层孔径约130nm，表面过滤层孔径约40nm。阳极氧化处理后的多孔铝表面形成Al2O3陶瓷层，具有硬度高（HV>1200），耐蚀性强（CASS盐雾试验>480h），绝缘性好（膜阻>100MΩ）等优点，广泛适合于纳米粉体浆料的过滤。
实施例2
按照氧化铝粉与碳酸氢铵的比例为80：20称取原料，其中氧化铝粉为球状，平均粒径为60nm，碳酸氢铵平均粒径为15nm。将氧化铝粉和碳酸氢铵粉在氩气气氛中进行球磨，得到氧化铝粉与碳酸氢铵粉均匀分散的复合粉体。然后在氩气保护下，采用等离子喷涂技术，将上述复合粉体反复喷涂于实施例1得到的超细过滤器件制件表面，然后在沸水中静置1h，碳酸氢铵溶解脱离后，在实施例1制件表面即得到一层均匀致密的氧化铝纳米陶瓷过滤层（图3），其过滤孔直径约10 nm，孔隙率约为38%。
述实例只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人是能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡根据本发明精神实质所做的等效变换或修饰，都应涵盖在本发明的保护范围之内。
Claims (2)
1.一种过滤器件的制备方法，其特征在于，其包括如下制备步骤：
采用平均粒径500 nm和平均粒径150 nm的LY12铝合金，将上述两种粒径铝合金分别与PEG、硬脂酸，按98.4：0.6：1的质量比混合均匀，得到P1复合粉和P2复合粉；
进行二次模压成型制成型，即以P1复合粉为原料，通过模压成型和烧结，得到内径100mm多孔铝合金材料，作为内层，该内层厚度为5mm；以P2复合粉为原料，在上述多孔铝合金材料外侧表面模压成型和烧结，得到多孔铝合金制件，作为过渡层，过渡层厚度为20μm，即得到双层的多孔铝合金制件；
对上述多孔铝合金制件进行浸没式氧化处理，使所有开放孔洞的内腔表面与氧化液接触的部分均匀地原位形成一层致密的氧化膜，再以亚硫酸钠和氢氧化钾的硼酸溶液作为电解液，将上述多孔铝合金制件全部浸入电解液作为正极，金属铅浸入电解液作为负极，电流密度为60A/dm2，通电时间20min，在多孔铝合金制件的所有开放孔洞的内腔表面原位均匀形成致密的氧化膜，即得到铝合金表面陶瓷化的多孔铝合金制件；
按照氧化铝粉与碳酸氢铵的比例为80：20称取原料，其中氧化铝粉为球状，平均粒径为60nm，碳酸氢铵平均粒径为15nm；将氧化铝粉和碳酸氢铵粉在氩气气氛中进行球磨，得到氧化铝粉与碳酸氢铵粉均匀分散的复合粉体；然后在氩气保护下，采用等离子喷涂技术，将上述复合粉体反复喷涂于前述的铝合金表面陶瓷化的多孔铝合金制件表面，然后在沸水中静置1h，碳酸氢铵溶解脱离后，在制件表面得到一层均匀致密的氧化铝纳米陶瓷过滤层，最终得到由内层向外层孔径梯度分布的过滤器件，过滤孔直径10 nm。
2.根据权利要求1所述的一种过滤器件的制备方法，其特征在于，所述多孔铝合金制件的外形为盘式、管式、板式。
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Denomination of invention: A Preparation Method for Filter Devices Granted publication date: 20210309 Pledgee: Bank of China Limited Changshu branch Pledgor: SUZHOU FIRST ELEMENT NANO TECHNOLOGY CO.,LTD. Registration number: Y2024980011877 |