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How to improve the strength and wear resistance of wear-resistant castables
Detailed description of raw material selection
Aggregates:
It is key to select aggregates with high hardness and good wear resistance. For example, aggregates such as corundum and silicon carbide have excellent wear resistance and can effectively resist wear.
Control the particle size distribution of aggregates and reasonably match aggregates of different particle sizes. Through reasonable matching, the particles can be stacked more tightly, thereby improving the density and strength of the castable.
Binder:
Choose binders with excellent performance, such as calcium aluminate cement. These binders have good bonding properties and can firmly bind aggregates together to form a stable structure.
Introduce binders such as silica sol and aluminum sol, which can improve the high temperature performance and wear resistance of castables. Under high temperature environment, these binders can form stable chemical bonds, thereby enhancing the overall performance of castables.
Additives:
Add active micropowders such as silicon micropowder and alumina micropowder. These micropowders can fill the gaps between particles and further improve the density of castables.
Adding water reducer can reduce water consumption without reducing fluidity. Reducing water consumption can reduce the porosity in the castable, thereby improving strength and wear resistance.
Detailed description of mix design
Optimize the ratio of aggregate to powder:
Find the best ratio of aggregate to powder according to the use requirements and material properties. Generally, the aggregate accounts for 60%75% and the powder accounts for 25%40%. This ratio can ensure that the castable has good mechanical properties and wear resistance.
Too high an aggregate ratio may cause the castable to be too loose, while too high a powder ratio may cause the castable to be too dense and brittle. Therefore, it is necessary to find the best balance.
Determine the amount of binder:
The amount of binder should be moderate, generally 5%~10%. Too much or too little will affect the performance of the castable.
Too much binder may cause the castable to be too viscous and difficult to construct; while too little may cause the castable to have insufficient bonding and reduced strength. Therefore, it is necessary to accurately control the amount of binder.
Detailed description of construction process control
Mixing
Use a forced mixer to mix to ensure that the materials are evenly mixed. The mixing time is generally 3 to 5 minutes, and the specific time can be adjusted according to the actual situation.
During the mixing process, the amount of water added needs to be strictly controlled. Too much or too little water will affect the performance of the castable. Too much water may cause the to be too diluted and difficult to construct; while too little water may cause the castable to be too viscous and difficult to mix evenly.
Pouring and vibrating
Ensure that the mold is well sealed during pouring to prevent leakage and separation of aggregates and powders.
Vibrate fully to expel internal air and increase density. During the vibration process, attention should be paid to the vibration intensity and vibration time to avoid excessive vibration causing castable stratification or rupture.
Demolding and finishing
Demolding at the right time, generally 12 to 24 hours after pouring. Demolding too early may cause insufficient strength of the castable and difficulty in demolding; while demolding too late may cause the castable to adhere to the mold, affecting the appearance quality.
After demoulding, the surface should be trimmed in time to ensure that the appearance of the castable is smooth and defect-free. During the trimming process, attention should be paid to the strength and method to avoid damage to the castable.
Detailed description of curing and heat treatment
Curing
Reasonable curing should be carried out after pouring, such as curing in a humid environment for 3 to 7 days. During the curing process, the ambient humidity and temperature should be kept appropriate to avoid cracking of the castable due to drying or temperature changes.
Curing can promote the cement hydration reaction and improve the strength of the castable. At the same time, curing can also reduce the residual stress inside the castable and improve wear resistance.
Heat treatment
According to the type and use requirements of the castable, appropriate heat treatment should be carried out. Heat treatment can eliminate internal stress and further improve strength and wear resistance.
During the heat treatment process, attention should be paid to the control of temperature and time to avoid excessive temperature or long time causing castable performance degradation or cracking.
In summary, improving the strength and wear resistance of wear-resistant castables requires starting from raw material selection, mix design, construction process control, maintenance and heat treatment, etc. By taking these measures, the performance of wear-resistant castables can be significantly improved to meet the use requirements in various harsh environments.
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