JP3754271B2 - Butterfly valve and manufacturing method thereof - Google Patents
Butterfly valve and manufacturing method thereof Download PDFInfo
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- JP3754271B2 JP3754271B2 JP2000131650A JP2000131650A JP3754271B2 JP 3754271 B2 JP3754271 B2 JP 3754271B2 JP 2000131650 A JP2000131650 A JP 2000131650A JP 2000131650 A JP2000131650 A JP 2000131650A JP 3754271 B2 JP3754271 B2 JP 3754271B2
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- butterfly valve
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K1/00—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces
- F16K1/16—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces with pivoted closure-members
- F16K1/18—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces with pivoted closure-members with pivoted discs or flaps
- F16K1/22—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces with pivoted closure-members with pivoted discs or flaps with axis of rotation crossing the valve member, e.g. butterfly valves
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Description
【0001】
【発明の属する技術分野】
本発明は、高温の熱風の流量を制御するためのバタフライ弁に関する。
【0002】
【従来の技術】
従来から、1200℃以上の高温に熱せられた製鉄用高炉の羽口から吹き込む熱風ガスの流量調整等の弁として、バタフライ弁が使用されている。このバタフライ弁は、一般的には円板状の弁板とこの円周部に対向するように配置された2 本の回転軸からなる弁体であり、耐火断熱材で構成されるケーシングの流体流路内において弁板を回転軸により回動自在に支持し、弁板の回動により流路の開放度を調節して流量制御を行うものである。このような構造となっているため、バタフライ弁は、高温に加え、高圧・高速のガス流体に常時曝されると共に、風量調整のために弁体を回転させる際には回転負荷が掛かる。さらには熱風の流路と回転軸の軸受部との温度差が大きい上に、不規則な振動を常時受けるという様に、その使用環境は極めて厳しいものである。このため、バタフライ弁の材質としては、金属では実用に耐えないため、セラミックスの適用が検討されている。
【0003】
実公平2-32944 号公報には、窒化珪素質、サイアロン質、炭化珪素質、ジルコニア質、アルミナ質又はムライト質のセラミックスで弁板と軸とを一体に成形したバタフライ弁の弁体が提案されている。また、特開平9-42472 号公報には、1200℃における曲げ強度が294N/mm2(30kg/mm2)以上のセラミックスで弁板と軸部を一体的に形成し、軸部の端部に金属軸を焼き嵌めにより嵌着したバタフライ弁が提案され、セラミックスとして窒化珪素系又は炭化珪素系の緻密質セラミックスが開示されている。このように耐熱性、抗折強度に優れたセラミックスを適用することが試みられているが、製鉄用高炉羽口のバタフライ弁に使用するにあたり、寿命が短く、短期間の内に破損するという耐久性に関して基本的な問題が解決されていない。
【0004】
これまで、窒化珪素質焼結体は破壊靭性に優れるものの、高温強度、耐熱衝撃性、耐熱疲労性や硬度が低かった。例えば、酸化イットリウムと酸化アルミニウムを添加した系では、耐熱衝撃性においては優れたものが得られているが、耐熱性、靭性、高温での機械的強度に劣っている場合があった。そこで、高温下での特性改善を図る目的で、特開昭56-59674号公報に開示されている焼結体中にメリライト鉱物相(Y2O3 ・Si3N4 化合物) を生成させた窒化珪素焼結体、および特開昭62-202864 号公報に開示されている酸化ジルコニウム+酸化イットリウム+酸化珪素を添加し、焼結体中に酸化ジルコニウムを析出させた窒化珪素焼結体が試みられており、高温強度の向上等に効果が認められることが知られている。また、特開昭62-246865 号公報に開示されている希土類酸化物、酸化ジルコニウムを含む焼結体で粒界相にJ 相(Si2N2O ・2Y2O3)固溶体が存在する窒化珪素焼結体が試みられており、耐熱性、耐酸化性、静的疲労特性の向上に効果が認められることが知られている。また、特開平3-153574号公報では、より高温強度特性を向上させる目的で、サイアロンの焼結助剤としてHfO2を添加し、粒界相としてY2Hf2O7 を生成させたα'-β' サイアロンを開示している。
【0005】
ところが、上記材料では、高温即時破断強度は優れるものの、高温強度を維持したまま靭性および耐酸化性を飛躍的に改善するには至っていないため、より厳しい使用環境下、特に高温燃焼炎中において粒子の衝突等の生じる構造部材へ適用するに当たっては信頼性に欠ける等の問題点があり、実用化を阻害している。従って、高温強度の向上に加えて耐酸化性、耐熱衝撃性および靭性の向上した材料が要望されている。
【0006】
【発明が解決しようとする課題】
このようにバタフライ弁の使用環境では、単なる耐熱性や高温強度のみならず、ガス流体中に含まれる塵埃や耐火物の剥離粒子等の粉粒体による粒子衝突損傷や耐酸化性、熱的疲労特性、回転駆動時の捻りや風量変動時の振動に対する機械的耐久性、ハンドリング時の耐欠損性等の物理・化学的安定性や機械的安定性にも優れている必要があり、このような特性に優れている材質を有するバタフライ弁の提供が望まれていた。
【0007】
そこで、本発明は、上述の従来のセラミックス製バタフライ弁の問題点を解決し、物理・化学的安定性、熱的安定性、機械的安定性に優れ、長期耐久性を有するバタフライ弁及びその製造方法を提供することを目的とする。
【0008】
【課題を解決するための手段】
本発明者等は、上記問題点を解決するために、窒化珪素質セラミックス焼結体を構成する結晶相に関する検討を鋭意行った結果、前記β-Si3N4相、Si2N2O相およびY2Si2O7 相の3 種の結晶相から構成される場合にバタフライ弁として優れた特性を有する焼結体が得られることを見出し、本発明を完成させるに至った。
【0009】
即ち、本発明は、
(1)実質的にβ−Si3N4相、Si2N2O相及びY2Si2O7相からなる窒化珪素焼結体であって、粒界相としてSi 2 N 2 O相及びY 2 Si 2 O 7 相から構成され、β−Si 3 N 4 の平均結晶粒径が1〜3μm、アスペクト比が1.5〜10で、かつβ−Si 3 N 4 の柱状結晶粒が絡み合った組織であるものを成形加工してなることを特徴とするバタフライ弁、
(2)前記窒化珪素質焼結体の組成が0.1〜3質量%のSi2N2O相、4.9〜12質量%のY2Si2O7相及び残部がβ−Si3N4相からなる(1)記載のバタフライ弁、
(3)前記窒化珪素質焼結体の相対密度が95%以上である(1)又は(2)に記載のバタフライ弁、
(4)酸化イットリウム(Y2O3)3〜10質量%、酸化珪素(SiO2)1〜5質量%及び残部が窒化珪素(Si3N4)からなる混合粉末を成形し、該成形体を窒素ガス雰囲気中にて1700〜2000℃の温度範囲で焼結し、
(a)焼結の降温過程における降温速度を5℃/分以下とすること、
(b)の降温過程において、1350〜1650℃の温度範囲で2時間以上保持すること、
(c)焼結後、窒素雰囲気中、1350〜1650℃の温度範囲で2時間以上保持の再加熱処理を行うこと、
の少なくとも一つにより粒界相としてSi2N2O相及びY2Si2O7相を生成させた窒化珪素質焼結体を成形加工することを特徴とする(1)〜(3)のいずれかに記載のバタフライ弁の製造方法、
である。
【0010】
【発明の実施の形態】
以下に、本発明を詳細に説明する。
本発明者等は、従来使用されていたセラミックス製バタフライ弁について、その損耗状況を鋭意解析した結果、高温高圧のガス流体が高速で流通される場合、耐酸化性に劣る材料では、表面に耐摩耗性に劣る酸化層を形成し、その酸化層が容易に摩耗し、消耗していくことを見出した。また、摩耗部周囲には、チッピングや割れ等の欠損が認められることが多く、この欠損は熱疲労や流体中の粒子の衝突に伴う機械的衝撃により生成、進展し、バタフライ弁の破損に至ることも見出した。これらの摩耗と欠損は、バタフライ弁の材質が耐酸化性に劣り、靭性や耐熱衝撃性の特性が低い場合に特に顕著に認められた。したがって、バタフライ弁を長期間安定して使用するためには、耐摩耗性と耐欠損性を同時に向上させることが必要で、そのためには耐酸化性や耐熱衝撃性に優れ、高靭性な材質のセラミックスを用いることが必要不可欠である。窒化珪素質焼結体は、アルミナやジルコニア等を主成分とするセラミックス焼結体と異なり、耐熱性に優れると共に、高温下における機械強度も保持できることから、高温高圧環境下で使用されるバタフライ弁の材質として最適である。
【0011】
そこで、これらの特性を同時に向上させるために、各種結晶相より構成される窒化珪素質焼結体を作製し、その特性を評価した。従来の低融点ガラス相を有する窒化珪素焼結体では、高温下における耐酸化性、耐熱衝撃性に劣る。特性評価の結果、β-Si3N4相および粒界相としてSi2N2O相、Y2Si2O7 相から構成される緻密なセラミックス焼結体が優れた特性を有することを見出した。特に、β- Si3N4 相、 Si2N2O 相およびY2Si2O7 相からなる窒化珪素質焼結体を成形加工したバタフライ弁は、耐酸化性、耐熱衝撃性に優れ、使用環境下で弁体中に生じる温度勾配に起因する静疲労特性、また休風時の急冷に伴う熱応力破壊抵抗特性を高めるなどの特徴を有する。粒界相としてSi2N2O相及びY2Si2O7 相を結晶化させるためには、焼結の降温過程で5 ℃/ 分以下の降温速度で冷却するか、降温過程で1350〜1650℃、2 時間以上保持の熱処理するか、あるいは焼結後窒素雰囲気中にて1350〜1650℃、2 時間以上保持の再加熱処理の少なくとも一つを行うようにする。降温過程でSi2N2O相及びY2Si2O7 相を析出させる場合の降温速度は5 ℃/ 分以下が好ましいが、より望ましくは2 ℃/ 分以下である。降温速度が5 ℃/ 分より速い場合はSi2N2O相及びY2Si2O7 相が十分生成しない。また、降温過程の際の保持温度、および、再加熱処理の際の保持温度が1350℃未満、1650℃超の場合も同様にSi2N2O相及びY2Si2O7 相が十分に生成しない。また、各々の保持時間が2 時間未満の場合もSi2N2O相及びY2Si2O7 相は生成しない。 Si2N2O 相とY2Si2O7 相がそれぞれ質量比で0.1%、4.9%未満では焼結体中の気孔率が高くなり好ましくなく、それぞれ3%、12% を越えるとβ- Si3N4 結晶粒が十分に絡み合わず強度や靭性が低下し好ましくない。また、 Si2N2O 相とY2Si2O7 相に関し、 Si2N2O 相の質量比が全体の0.1%未満では機械的強度に寄与する効果が少なく、3%を越えるとβ- Si3N4 結晶粒が十分に絡み合わず強度や靭性が低下するため好ましくない。同様にY2Si2O7 相の質量比が全体の4.9%未満ではSi3N4 のα→β転移時の液相が少なく相転移を円滑に進行させず、12% を越えるとβ- Si3N4 結晶粒が十分に絡み合わず強度や靭性が低下するため好ましくない。本発明により得られる窒化珪素質焼結体は、β- Si3N4 の平均結晶粒径が1 〜3 μm 程度、アスペクト比が1.5 〜10程度と大きく、かつβ- Si3N4 の柱状結晶粒が絡み合った組織を呈し、また粒界に高融点のSi2N2O相及びY2Si2O7 相が析出しているため、高温まで高い強度を維持したまま高い靭性を有し、抗折強さが大気中1400℃にて500MPa以上の高強度でかつ靭性値K ICが5MPam1/2の高靭性を有するため、高温環境下での特性を要求されるバタフライ弁に好適に用いることができる。ここで、 Si2N2O 相は粉末X 線回折法により同定されるSi2N2O結晶と同じ型のX 線回折パターンを持ち、 Si3N4とSiO2とからなる化合物の中で高温酸化雰囲気中にて最も安定な化合物である。同様に、 Y2Si2O7結晶相は粉末X 線回折法により同定されるY2Si2O7 結晶と同じ型のX 線回折パターンを持ち、 Y2O3 とSiO2とからなる化合物の中で高温酸化雰囲気中にて最も安定な化合物である。また、β- Si3N4 結晶相は、JCPDS カード333-1160で示されるβ- Si3N4 結晶と同じ型のX 線回折パターンを持つ。さらに、前記β- Si3N4 相、 Si2N2O 相及びY2Si2O7 相により構成される窒化珪素質焼結体の相対密度は理論密度に対して95% 以上であることが望ましい。相対密度が95% 未満では、熱的安定性、機械的安定性が不充分になり易く、長期耐久性の向上効果が見られない恐れが高くなる。
【0012】
本発明において使用される窒化珪素粉末は、α型の結晶構造をもつSi3N4 粉末が焼結性の点から好適であるが、β型あるいは非晶質Si3N4 粉末が含まれていても構わない。焼結時に十分に高い密度とするためには、平均粒径1 μm 以下の微粒子であることが望ましい。窒化珪素は共有結合性の強い物質であり、単独では焼結が困難であることが多いため、一般に緻密化するために焼結助剤を添加する。本発明においては、焼結助剤としては、酸化珪素、酸化イットリウムを用いる。ここで、酸化イットリウムはSi3N4 の焼結時にα- Si3N4 相からβ- Si3N4 相への結晶相転移をその融液中で促進させる機能を持ち、さらにβ- Si3N4 の柱状相の成長を助長することにより、高温強度および靭性を向上させることが知られている。それぞれの添加量は、酸化珪素が1 〜5 質量% 、酸化イットリウムが3 〜10質量% が好ましい。酸化珪素が1 質量% 未満の場合、焼結昇温時の液相生成温度が高くなり十分緻密な焼結体が得られず、またSi2N2O相及びY2Si2O7 相が形成されない。5 質量% を越えるとY2Si2O7 相が形成されず比較的低融点のSiO2相が形成され高温での機械的強度が低下するため好ましくない。酸化イットリウムの添加量が3 質量% より少ないと融液形成が不十分で相対密度が95%未満となり緻密化が進行しない。酸化イットリウムの添加量が10質量% を超えるとY2Si2O7 相が形成されず比較的低融点のY2SiO5相が形成され、得られた焼結体の高温での機械的強度および耐酸化性が低下する。酸化珪素も酸化イットリウムも均質かつ高密度の焼結体を得るためには平均粒径が2 μm 以下の微粒子であることが好ましい。焼結助剤として用いるこれら原料粉末は比較的安価であり、水中での混合工程でも変質せず安定なセラミックス粉末である。焼結方法としては、窒素ガスを含む雰囲気にて、例えば無加圧焼結法、ガス圧焼結法、熱間静水圧プレス焼結法、ホットプレス焼結法、等の各種焼結法を用いることができ、さらにこれらの焼結法を複数組合せても良い。窒素ガスを含む雰囲気で焼結するのは、焼結中でのSi3N4 の分解を抑制するためである。 Si3N4は、窒素ガス1 気圧下では約1850℃以上で分解が生じるため、1850℃以上にて焼結を行う場合は、窒素ガス圧を焼結温度におけるSi3N4 の臨界分解圧力以上に設定するようにする。また、大型厚肉形状のバタフライ弁を製造する場合には、十分な緻密化を図るために、無加圧焼結後に、さらに窒素ガス雰囲気中での熱間静水圧プレス焼結を行うことがより好ましい。無加圧及び熱間静水圧プレス焼結条件としては、焼結温度が1700〜2000℃であることが望ましい。1700℃未満では、緻密な焼結体が得られず、固溶体粒子近傍に残留応力を十分に発生させることが困難となり、高靭性の焼結体とすることができない。一方、2000℃を越える高温では、β- Si3N4 結晶粒が粗大化し強度低下を起こし、高硬度と耐熱衝撃性が得られない。また、保持時間が8 時間未満では、成形体の肉厚にも依存するが緻密化が十分に進行しない。
【0013】
【実施例】
次に、本発明の実施例を比較例と共に説明する。
( 実施例1 〜3)
窒化珪素(Si3N4) 粉末( α化率97% 以上、純度99.7% 、平均粒径0.3 μm)に酸化イットリウム(Y2O3)粉末( 平均粒径1.5 μm)、酸化珪素(SiO2)粉末( 平均粒径0.3 μm)を表1 に示す所定量( 質量%)添加し、分散媒として精製水またはアセトンを用い、炭化珪素セラミックスを内貼りしたボールミルで24時間混練した。精製水またはアセトンの添加量は、セラミックス全粉末原料100gに対し120gとした。
【0014】
次いで得られた混合粉末を成形後、焼結した。成形条件としては冷間静水圧による加圧150MPaとし、250mm ×700mm ×厚さ65mmの平板を成形した。これを素地加工し、弁体径φ220mm ×厚さ28mmの外周部に対向するように配置された2 本の等長軸部径φ55mm×長さ220mm の形状を有する成形体を得た。焼結条件としては、窒素ガス流通中にて、表1 中に示す温度で8 時間保持の無加圧焼結を行い、降温時に1500℃で同じく表1 記載の時間だけ保持と降温速度にて炉冷を行った。実施例3 については、降温時放冷を行った後に1500℃まで再加熱し表1 記載の保持を行った。得られた焼結体から、図1 に示すように、径φ160mm ×厚さ20mmの弁板2 の外周部に対向するように配置された径φ40mm×長さ170mm の 2本の等長軸部1 を研削加工し、熱風ガスの通風中での耐久試験に供した。
【0015】
得られた焼結体から各種形状の試験片を切り出し、機械的特性を評価した。抗折強さは、JIS R1601 により、大気中室温および1400℃にて測定した。硬さは、押込荷重98N にてビッカース硬さとして測定した。靭性についてはJIS R1607 のSEPB法により室温にて破壊靭性値K ICを測定した。また、耐熱衝撃性としては、曲げ試験片を大気中にて所定の温度に加熱後、水中急冷し、抗折強さの劣化が始まる急冷温度差ΔTで評価した。焼結体密度は、アルキメデス法により相対密度として測定した。各種結晶相の比率に関して、予めX 線回折ピーク高さから求めた検量線に従って求め、表1 に示した。
【0016】
得られた各焼結体の諸特性を表2 に示す。熱風ガス通風試験としては、ガス成分は空気+酸素3%、ガス圧力0.3MPa、ガス温度1200℃、羽口通風速度120m/ 秒の条件にて行った。弁体は、図2 に示すように、通風方向に対して45°になるような向き( 弁= 半開) に固定し、2 ヶ月の通風後、弁体の外周部に発生した摩耗痕跡の深さh を投影型顕微鏡にて測定した。また、摩耗痕跡周囲の損傷有無、チッピング深さ、および割れ深さを蛍光探傷法および断面研磨面の光学顕微鏡観察により評価した。
【0017】
( 比較例4 〜5)
比較例4 〜5 は、実施例1 〜3 と同一原料を用い、同じく精製水またはアセトンで調製したが、それぞれ、降温時の焼結条件が不適で相対密度が95% を下回った場合( 比較例4)、焼結助剤(Y2O3)の添加割合が不適で相対密度が95% を下回った場合( 比較例5)の各比較例である。これらを併せて表1 に示す。また、これら比較例の材料も実施例1 〜3 と同様の条件で通風試験を行い、その結果を表2 に示した。
【0018】
【表1】
【0019】
【表2】
【0020】
表2 に示すように、本発明の実施例によるものは、摩耗痕跡深さが20μm以下と非常に少なく、かつ摩耗痕跡周囲には割れ・チッピングの欠損が何れの場合も認められず、耐摩耗性、耐欠損性共に優れるが、比較例の各弁体は本発明の実施例に比べて、破損や破断が発生するまでの短期間の摩耗痕跡深さ80μm以上と大きく、その上、ヒビ等の欠損が発生しており、耐摩耗性、耐欠損性が不充分であることが確認された。
【0021】
【発明の効果】
以上述べたように、本発明のβ- Si3 N4 相、Si2 N2 O相及びY2 Si2 O7 相により構成される窒化珪素質セラミックス焼結体を成形加工してなるバタフライ弁は、熱的安定性、機械的安定性に優れ、長期耐久性を有することから、高温高圧環境下での長期信頼性の非常に優れたバタフライ弁である。そして、例えば製鉄用高炉羽口から吹き込む熱風ガスの流量調整等の弁として、本発明のバタフライ弁を使用すれば、長期間熱風流量調整に供することができ、高炉等の安定操業による生産性向上と共に製造コスト低減に寄与すること大である。
【図面の簡単な説明】
【図1】実施例の高炉熱風ガスの支管風量調節用バタフライ弁( 全長500mm)の模式図。
【図2】実施例におけるバタフライ弁の設置状況を示す模式図。
【符号の説明】
1 …バタフライ弁の軸部
2 …バタフライ弁の弁板[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a butterfly valve for controlling the flow rate of hot hot air.
[0002]
[Prior art]
Conventionally, butterfly valves have been used as valves for adjusting the flow rate of hot air gas blown from the tuyere of an iron blast furnace heated to a high temperature of 1200 ° C. or higher. This butterfly valve is generally a valve body composed of a disc-shaped valve plate and two rotating shafts arranged so as to face the circumferential portion, and is a casing fluid made of a refractory heat insulating material. The valve plate is rotatably supported by a rotating shaft in the flow path, and the flow rate is controlled by adjusting the degree of opening of the flow path by the rotation of the valve plate. Because of this structure, the butterfly valve is constantly exposed to high-pressure and high-speed gas fluid in addition to high temperature, and a rotational load is applied when the valve body is rotated for air volume adjustment. Furthermore, the operating environment is extremely harsh, such that the temperature difference between the hot air flow path and the bearing portion of the rotating shaft is large and irregular vibrations are always received. For this reason, as a material of the butterfly valve, application of ceramics has been studied because metal cannot withstand practical use.
[0003]
Japanese Utility Model Publication No. 2-332944 proposes a valve body of a butterfly valve in which a valve plate and a shaft are integrally formed of silicon nitride, sialon, silicon carbide, zirconia, alumina or mullite ceramics. ing. Japanese Patent Laid-Open No. 9-42472 discloses that a valve plate and a shaft portion are integrally formed of ceramics having a bending strength at 1200 ° C. of 294 N / mm 2 (30 kg / mm 2 ) or more, and the end portion of the shaft portion is formed. A butterfly valve in which a metal shaft is fitted by shrink fitting is proposed, and silicon nitride-based or silicon carbide-based dense ceramics are disclosed as ceramics. Attempts have been made to apply ceramics with excellent heat resistance and bending strength in this way. However, when used for butterfly valves of blast furnace tuyeres for iron making, the durability is short and it will break within a short period of time. Basic problems regarding gender are not solved.
[0004]
So far, silicon nitride-based sintered bodies have excellent fracture toughness but have low high temperature strength, thermal shock resistance, thermal fatigue resistance and hardness. For example, in a system in which yttrium oxide and aluminum oxide are added, excellent thermal shock resistance is obtained, but there are cases where heat resistance, toughness, and mechanical strength at high temperatures are inferior. Therefore, a melilite mineral phase (Y 2 O 3 · Si 3 N 4 compound) was generated in the sintered body disclosed in JP-A-56-59674 for the purpose of improving the characteristics at high temperatures. Trial of silicon nitride sintered body and silicon nitride sintered body in which zirconium oxide + yttrium oxide + silicon oxide is added and zirconium oxide is precipitated in the sintered body disclosed in JP-A-62-202864 It is known that it is effective for improving high-temperature strength. Further, a nitridation in which a J-phase (Si 2 N 2 O 2Y 2 O 3 ) solid solution exists in a grain boundary phase in a sintered body containing rare earth oxide and zirconium oxide disclosed in JP-A-62-246865. Silicon sintered bodies have been tried and are known to be effective in improving heat resistance, oxidation resistance, and static fatigue characteristics. Further, in JP-A-3-155574, for the purpose of improving the high temperature strength characteristics, HfO 2 was added as a sintering aid for sialon, and Y 2 Hf 2 O 7 was produced as a grain boundary phase. -β 'Sialon is disclosed.
[0005]
However, although the above material has excellent high-temperature immediate breaking strength, it has not yet dramatically improved toughness and oxidation resistance while maintaining high-temperature strength, so particles in a severer use environment, particularly in high-temperature combustion flames. When applied to a structural member in which such a collision occurs, there are problems such as lack of reliability, which impedes practical application. Accordingly, there is a demand for materials that have improved oxidation resistance, thermal shock resistance and toughness in addition to improved high-temperature strength.
[0006]
[Problems to be solved by the invention]
In this way, in the environment where the butterfly valve is used, not only mere heat resistance and high temperature strength, but also particle collision damage, oxidation resistance, thermal fatigue caused by dust particles such as dust and refractory particles contained in the gas fluid It is necessary to have excellent physical and chemical stability and mechanical stability such as characteristics, mechanical durability against vibration during torsion during rotation and air flow fluctuation, and fracture resistance during handling. It has been desired to provide a butterfly valve having a material with excellent characteristics.
[0007]
Accordingly, the present invention solves the problems of the above-mentioned conventional ceramic butterfly valve, and has excellent physical and chemical stability, thermal stability, mechanical stability, and has a long-term durability, and its manufacture It aims to provide a method.
[0008]
[Means for Solving the Problems]
In order to solve the above problems, the present inventors have intensively studied the crystal phase constituting the silicon nitride ceramic sintered body, and as a result, the β-Si 3 N 4 phase, the Si 2 N 2 O phase The inventors have found that a sintered body having excellent characteristics as a butterfly valve can be obtained when it is composed of three types of crystal phases of Y 2 Si 2 O 7 phase, and has completed the present invention.
[0009]
That is, the present invention
(1) substantially β-Si 3 N 4 phase, a Si 2 N 2 O phase and Y 2 Si silicon nitride sintered body consisting of 2 O 7 phase, Si 2 N 2 O phase and a grain boundary phase It is composed of Y 2 Si 2 O 7 phase, β-Si 3 N 4 average crystal grain size is 1 to 3 μm, aspect ratio is 1.5 to 10, and β-Si 3 N 4 columnar crystal grains are entangled A butterfly valve characterized by being formed by processing what is an
(2) The composition of the silicon nitride-based sintered body is an Si 2 N 2 O phase having a composition of 0.1 to 3% by mass, a Y 2 Si 2 O 7 phase of 4.9 to 12% by mass and the balance being β-Si 3. The butterfly valve according to (1), comprising N 4 phases,
(3) The butterfly valve according to (1) or (2), wherein the relative density of the silicon nitride sintered body is 95% or more,
(4) A molded powder comprising 3 to 10% by mass of yttrium oxide (Y 2 O 3 ), 1 to 5% by mass of silicon oxide (SiO 2 ), and the balance being silicon nitride (Si 3 N 4 ), and the molded product Is sintered in a temperature range of 1700 to 2000 ° C. in a nitrogen gas atmosphere,
(A) The temperature lowering rate in the temperature lowering process of sintering is 5 ° C./min or less,
In the temperature lowering process of (b), holding at a temperature range of 1350 to 1650 ° C. for 2 hours or more,
(C) performing a reheating treatment for 2 hours or more in a temperature range of 1350 to 1650 ° C. in a nitrogen atmosphere after sintering;
(1) to (3), wherein a silicon nitride sintered body in which a Si 2 N 2 O phase and a Y 2 Si 2 O 7 phase are formed as grain boundary phases by at least one of A method for manufacturing the butterfly valve according to any one of the above ,
It is.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described in detail below.
As a result of intensive analysis of the wear state of ceramic butterfly valves that have been used in the past, the present inventors have found that when high-temperature and high-pressure gas fluids are circulated at high speed, materials with poor oxidation resistance are resistant to the surface. It was found that an oxide layer having poor wear properties was formed, and that the oxide layer was easily worn and consumed. In addition, chipping and cracking defects are often found around the worn part, and these defects are generated and propagated due to thermal fatigue and mechanical impacts associated with particle collisions in the fluid, leading to damage to the butterfly valve. I also found out. These wear and defects were particularly noticeable when the butterfly valve material was inferior in oxidation resistance and had low toughness and thermal shock resistance characteristics. Therefore, in order to use the butterfly valve stably for a long period of time, it is necessary to improve the wear resistance and fracture resistance at the same time. To that end, it is excellent in oxidation resistance and thermal shock resistance and is made of a tough material. It is essential to use ceramics. Unlike ceramic sintered bodies mainly composed of alumina, zirconia, etc., silicon nitride sintered bodies have excellent heat resistance and can maintain mechanical strength at high temperatures. It is most suitable as a material.
[0011]
Therefore, in order to improve these characteristics at the same time, silicon nitride-based sintered bodies composed of various crystal phases were produced, and the characteristics were evaluated. A conventional silicon nitride sintered body having a low melting point glass phase is inferior in oxidation resistance and thermal shock resistance at high temperatures. As a result of characteristic evaluation, it was found that a dense ceramic sintered body composed of β-Si 3 N 4 phase and Si 2 N 2 O phase and Y 2 Si 2 O 7 phase as grain boundary phases has excellent characteristics. It was. In particular, a butterfly valve formed by processing a silicon nitride sintered body composed of β-Si 3 N 4 phase, Si 2 N 2 O phase and Y 2 Si 2 O 7 phase has excellent oxidation resistance and thermal shock resistance, It has the characteristics of enhancing the static fatigue characteristics due to the temperature gradient generated in the valve body under the usage environment and the thermal stress fracture resistance characteristics associated with the rapid cooling during resting. In order to crystallize the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase as the grain boundary phase, cooling is performed at a temperature lowering rate of 5 ° C / min or lower during the temperature lowering process of sintering, or 1350 ~ Either heat treatment at 1650 ° C. for 2 hours or more, or at least one of reheating treatment at 1350-1650 ° C. for 2 hours or more in a nitrogen atmosphere after sintering. When the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase are precipitated in the temperature lowering process, the temperature decreasing rate is preferably 5 ° C./min or less, more preferably 2 ° C./min or less. When the cooling rate is faster than 5 ° C / min, the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase are not sufficiently formed. In addition, when the holding temperature during the temperature lowering process and the holding temperature during the reheating process are less than 1350 ° C and higher than 1650 ° C, the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase are also sufficient. Do not generate. Further, even when each holding time is less than 2 hours, the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase are not generated. If the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase are less than 0.1% and less than 4.9% in mass ratio, respectively, the porosity in the sintered body will be undesirably high, and if it exceeds 3% and 12%, β- The Si 3 N 4 crystal grains are not sufficiently entangled and the strength and toughness are lowered, which is not preferable. In addition, regarding the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase, if the mass ratio of the Si 2 N 2 O phase is less than 0.1% of the total, the effect of contributing to mechanical strength is small, and if it exceeds 3%, β -It is not preferable because Si 3 N 4 crystal grains are not sufficiently entangled and strength and toughness are lowered. Similarly, if the mass ratio of the Y 2 Si 2 O 7 phase is less than 4.9% of the total, the liquid phase at the α → β transition of Si 3 N 4 is small and the phase transition does not proceed smoothly, and if it exceeds 12%, β- This is not preferable because Si 3 N 4 crystal grains are not sufficiently entangled and strength and toughness are lowered. The silicon nitride sintered body obtained by the present invention has a β-Si 3 N 4 average crystal grain size of about 1 to 3 μm, an aspect ratio of about 1.5 to 10 and a β-Si 3 N 4 columnar shape. It has a structure in which crystal grains are intertwined, and high melting point Si 2 N 2 O phase and Y 2 Si 2 O 7 phase are precipitated at the grain boundary, so it has high toughness while maintaining high strength up to high temperature. With a bending strength of 500MPa or higher at 1400 ° C in the atmosphere and a toughness value K IC of 5MPam 1/2 , it is suitable for butterfly valves that require characteristics in high-temperature environments. Can be used. Here, the Si 2 N 2 O phase has the same type of X-ray diffraction pattern as the Si 2 N 2 O crystal identified by the powder X-ray diffraction method, and is a compound composed of Si 3 N 4 and SiO 2. It is the most stable compound in a high-temperature oxidizing atmosphere. Similarly, the Y 2 Si 2 O 7 crystal phase has the same type of X-ray diffraction pattern as the Y 2 Si 2 O 7 crystal identified by the powder X-ray diffraction method, and is a compound composed of Y 2 O 3 and SiO 2 Among them, it is the most stable compound in a high-temperature oxidizing atmosphere. The β-Si 3 N 4 crystal phase has the same type of X-ray diffraction pattern as the β-Si 3 N 4 crystal shown by the JCPDS card 333-1160. Furthermore, the relative density of the silicon nitride sintered body composed of the β-Si 3 N 4 phase, Si 2 N 2 O phase and Y 2 Si 2 O 7 phase should be 95% or more of the theoretical density. Is desirable. If the relative density is less than 95%, the thermal stability and mechanical stability tend to be insufficient, and there is a high possibility that the effect of improving long-term durability is not observed.
[0012]
As the silicon nitride powder used in the present invention, Si 3 N 4 powder having an α-type crystal structure is preferable from the viewpoint of sinterability, but β-type or amorphous Si 3 N 4 powder is included. It doesn't matter. In order to obtain a sufficiently high density during sintering, fine particles having an average particle diameter of 1 μm or less are desirable. Since silicon nitride is a substance having strong covalent bonding and is often difficult to sinter alone, generally a sintering aid is added for densification. In the present invention, silicon oxide and yttrium oxide are used as the sintering aid. Here, yttrium oxide has a function of accelerating the crystal phase transition during the sintering of Si 3 N 4 alpha-Si 3 from N 4 phase to the beta-Si 3 N 4 phase in its molten in further beta-Si It is known to improve high temperature strength and toughness by promoting the growth of 3 N 4 columnar phase. The addition amounts of silicon oxide are preferably 1 to 5% by mass and yttrium oxide is preferably 3 to 10% by mass. When silicon oxide is less than 1% by mass, the liquid phase generation temperature at the time of sintering temperature rises and a sufficiently dense sintered body cannot be obtained, and the Si 2 N 2 O phase and the Y 2 Si 2 O 7 phase Not formed. If it exceeds 5% by mass, the Y 2 Si 2 O 7 phase is not formed, and a relatively low melting point SiO 2 phase is formed, resulting in a decrease in mechanical strength at high temperatures. If the amount of yttrium oxide added is less than 3% by mass, melt formation is insufficient and the relative density is less than 95%, and densification does not proceed. When the added amount of yttrium oxide exceeds 10% by mass, the Y 2 Si 2 O 7 phase is not formed, and a relatively low melting point Y 2 SiO 5 phase is formed. The mechanical strength of the obtained sintered body at high temperature And the oxidation resistance decreases. Both silicon oxide and yttrium oxide are preferably fine particles having an average particle size of 2 μm or less in order to obtain a homogeneous and high-density sintered body. These raw material powders used as sintering aids are relatively inexpensive, and are stable ceramic powders that do not change even during the mixing process in water. As a sintering method, various sintering methods such as a pressureless sintering method, a gas pressure sintering method, a hot isostatic pressing sintering method, a hot pressing sintering method, etc. are performed in an atmosphere containing nitrogen gas. A plurality of these sintering methods may be combined. The reason why sintering is performed in an atmosphere containing nitrogen gas is to suppress decomposition of Si 3 N 4 during sintering. Si 3 N 4 decomposes at about 1850 ° C or higher under 1 atmosphere of nitrogen gas, so when sintering at 1850 ° C or higher, the nitrogen gas pressure is the critical decomposition pressure of Si 3 N 4 at the sintering temperature. Set as above. In addition, when manufacturing a large butterfly-shaped butterfly valve, it is possible to perform hot isostatic pressing in a nitrogen gas atmosphere after pressureless sintering in order to achieve sufficient densification. More preferred. As pressureless and hot isostatic pressing sintering conditions, the sintering temperature is desirably 1700 to 2000 ° C. When the temperature is less than 1700 ° C., a dense sintered body cannot be obtained, and it becomes difficult to generate sufficient residual stress in the vicinity of solid solution particles, so that a high toughness sintered body cannot be obtained. On the other hand, at a high temperature exceeding 2000 ° C., the β-Si 3 N 4 crystal grains become coarse and the strength is lowered, and high hardness and thermal shock resistance cannot be obtained. Further, if the holding time is less than 8 hours, the densification does not proceed sufficiently although it depends on the thickness of the molded body.
[0013]
【Example】
Next, examples of the present invention will be described together with comparative examples.
(Examples 1 to 3)
Silicon nitride (Si 3 N 4 ) powder (α conversion 97% or more, purity 99.7%, average particle size 0.3 μm), yttrium oxide (Y 2 O 3 ) powder (average particle size 1.5 μm), silicon oxide (SiO 2 ) Powder (average particle size: 0.3 μm) was added in a predetermined amount (mass%) shown in Table 1, and purified water or acetone was used as a dispersion medium and kneaded for 24 hours in a ball mill with silicon carbide ceramics attached thereto. The amount of purified water or acetone added was 120 g with respect to 100 g of all ceramic powder raw materials.
[0014]
Next, the obtained mixed powder was molded and then sintered. The molding conditions were a pressure of 150 MPa by cold isostatic pressure, and a flat plate of 250 mm × 700 mm × 65 mm thick was molded. This was processed to obtain a molded body having a shape of two isometric shaft diameters of φ55 mm × length of 220 mm arranged so as to face the outer peripheral portion of the valve body diameter of φ220 mm × thickness of 28 mm. As sintering conditions, non-pressure sintering was carried out for 8 hours at the temperature shown in Table 1 in the flow of nitrogen gas. Furnace cooling was performed. For Example 3, after allowing to cool, the temperature was reheated to 1500 ° C. and held as shown in Table 1. From the obtained sintered body, as shown in FIG. 1, two isometric shaft portions of diameter φ40 mm × length 170 mm arranged so as to face the outer peripheral portion of the
[0015]
Test pieces of various shapes were cut out from the obtained sintered body, and mechanical properties were evaluated. The bending strength was measured according to JIS R1601 at room temperature in the atmosphere and 1400 ° C. The hardness was measured as Vickers hardness with an indentation load of 98N. As for toughness, the fracture toughness value K IC was measured at room temperature by the SEPB method of JIS R1607. In addition, the thermal shock resistance was evaluated by a rapid cooling temperature difference ΔT at which a bending test piece was heated to a predetermined temperature in the air and then rapidly cooled in water and the bending strength began to deteriorate. The sintered body density was measured as a relative density by the Archimedes method. The ratio of various crystal phases was determined according to a calibration curve obtained in advance from the X-ray diffraction peak height, and is shown in Table 1.
[0016]
Table 2 shows the various characteristics of the obtained sintered bodies. In the hot air gas ventilation test, the gas components were air + oxygen 3%, gas pressure 0.3 MPa, gas temperature 1200 ° C., tuyere ventilation speed 120 m / sec. As shown in Fig. 2, the valve body is fixed at an angle of 45 ° to the ventilation direction (valve = half-open), and after two months of ventilation, the depth of wear marks generated on the outer periphery of the valve body The height h was measured with a projection microscope. In addition, the presence or absence of damage around the wear trace, the chipping depth, and the crack depth were evaluated by fluorescent flaw detection and observation of the cross-section polished surface with an optical microscope.
[0017]
(Comparative Examples 4 to 5)
In Comparative Examples 4 to 5, the same raw materials as in Examples 1 to 3 were used and prepared in the same manner with purified water or acetone. However, when the sintering conditions at the time of cooling were inappropriate and the relative density was less than 95% (Comparison Example 4) is a comparative example in which the addition ratio of the sintering aid (Y 2 O 3 ) is inappropriate and the relative density is less than 95% (Comparative Example 5). These are shown together in Table 1. The materials of these comparative examples were also subjected to a ventilation test under the same conditions as in Examples 1 to 3, and the results are shown in Table 2.
[0018]
[Table 1]
[0019]
[Table 2]
[0020]
As shown in Table 2, according to the embodiment of the present invention, the wear trace depth is very small as 20 μm or less, and no cracks or chipping defects are observed around the wear trace. In comparison with the examples of the present invention, each valve body of the comparative example is large with a short wear mark depth of 80 μm or more until breakage or fracture occurs, and cracks etc. It was confirmed that there was insufficient wear resistance and chipping resistance.
[0021]
【The invention's effect】
As described above, the butterfly valve formed by molding the silicon nitride ceramic sintered body composed of the β-Si 3 N 4 phase, Si 2 N 2 O phase and Y 2 Si 2 O 7 phase of the present invention. Is a butterfly valve with excellent long-term reliability in a high-temperature and high-pressure environment because of excellent thermal stability and mechanical stability and long-term durability. And, for example, if the butterfly valve of the present invention is used as a valve for adjusting the flow rate of hot air gas blown from the blast furnace tuyere for iron making, etc., it can be used for long-term hot air flow rate adjustment, and productivity improvement by stable operation of the blast furnace etc. At the same time, it greatly contributes to the reduction of manufacturing costs.
[Brief description of the drawings]
FIG. 1 is a schematic view of a butterfly valve (total length: 500 mm) for adjusting branch air volume of blast furnace hot air gas according to an embodiment.
FIG. 2 is a schematic diagram showing an installation situation of a butterfly valve in the embodiment.
[Explanation of symbols]
1… Butterfly valve shaft
2… butterfly valve plate
Claims (4)
(a)焼結の降温過程における降温速度を5℃/分以下とすること、
(b)の降温過程において、1350〜1650℃の温度範囲で2時間以上保持すること、
(c)焼結後、窒素雰囲気中、1350〜1650℃の温度範囲で2時間以上保持の再加熱処理を行うこと、
の少なくとも一つにより粒界相としてSi2N2O相及びY2Si2O7相を生成させた窒化珪素質焼結体を成形加工することを特徴とする請求項1〜3のいずれかに記載のバタフライ弁の製造方法。A mixed powder composed of 3 to 10% by mass of yttrium oxide (Y 2 O 3 ), 1 to 5% by mass of silicon oxide (SiO 2 ) and the balance of silicon nitride (Si 3 N 4 ) is molded, and the molded product is converted into nitrogen gas. Sintered in the temperature range of 1700-2000 ° C in the atmosphere,
(A) The temperature lowering rate in the temperature lowering process of sintering is 5 ° C./min or less,
In the temperature lowering process of (b), holding at a temperature range of 1350 to 1650 ° C. for 2 hours or more,
(C) performing a reheating treatment for 2 hours or more in a temperature range of 1350 to 1650 ° C. in a nitrogen atmosphere after sintering;
4. The silicon nitride sintered body in which a Si 2 N 2 O phase and a Y 2 Si 2 O 7 phase are formed as grain boundary phases by at least one of the above, is formed and processed . A method for producing a butterfly valve according to claim 1.
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000131650A JP3754271B2 (en) | 2000-04-28 | 2000-04-28 | Butterfly valve and manufacturing method thereof |
| CNB018237630A CN1281550C (en) | 2000-04-28 | 2001-10-29 | Valve body for adjusting flow rate of hot gas and method for preparing the same |
| KR1020047006242A KR100615107B1 (en) | 2000-04-28 | 2001-10-29 | Hot air flow control valve body and its manufacturing method |
| PCT/JP2001/009485 WO2003037821A1 (en) | 2000-04-28 | 2001-10-29 | Body of valve for adjusting flow rate of hot gas and method for preparing the same |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000131650A JP3754271B2 (en) | 2000-04-28 | 2000-04-28 | Butterfly valve and manufacturing method thereof |
| PCT/JP2001/009485 WO2003037821A1 (en) | 2000-04-28 | 2001-10-29 | Body of valve for adjusting flow rate of hot gas and method for preparing the same |
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| JP2001311474A JP2001311474A (en) | 2001-11-09 |
| JP3754271B2 true JP3754271B2 (en) | 2006-03-08 |
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| JP (1) | JP3754271B2 (en) |
| KR (1) | KR100615107B1 (en) |
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| JP3754271B2 (en) * | 2000-04-28 | 2006-03-08 | 新日本製鐵株式会社 | Butterfly valve and manufacturing method thereof |
| JP4603410B2 (en) * | 2005-04-22 | 2010-12-22 | 新日本製鐵株式会社 | Ceramic member and high temperature reactor |
| CN101747028B (en) * | 2008-11-28 | 2012-08-01 | 中国科学院金属研究所 | Preparation method of Y2Si2O7/ZrO2 ceramic composite material with precise and controllable bulk density ratio |
| CN105776824A (en) * | 2011-11-17 | 2016-07-20 | 旭硝子株式会社 | Molding method for plate glass |
| JP6094670B2 (en) * | 2013-05-16 | 2017-03-15 | 旭硝子株式会社 | Support roll, glass plate forming method, glass plate manufacturing apparatus, and glass plate manufacturing method |
| KR102153288B1 (en) * | 2013-05-16 | 2020-09-08 | 에이지씨 가부시키가이샤 | Support roller, method for molding glass plate, method for manufacturing glass plate, and device for manufacturing glass plate |
| JP6354621B2 (en) * | 2015-02-27 | 2018-07-11 | 新日鐵住金株式会社 | Silicon nitride ceramic sintered body and method for producing the same |
| CN108439995B (en) * | 2018-05-24 | 2020-12-22 | 中南大学 | A kind of composite ceramic and preparation method thereof |
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| JP3754271B2 (en) * | 2000-04-28 | 2006-03-08 | 新日本製鐵株式会社 | Butterfly valve and manufacturing method thereof |
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| JP2001311474A (en) | 2001-11-09 |
| CN1558880A (en) | 2004-12-29 |
| KR100615107B1 (en) | 2006-08-25 |
| CN1281550C (en) | 2006-10-25 |
| KR20040062592A (en) | 2004-07-07 |
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