MC尼龙复合改性与梯度复合管制备
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摘要
为进一步提高MC尼龙管材强度和耐磨性,满足航道疏浚、火力发电、冶金矿山等行业特殊使用要求,采用玻璃纤维、粉煤灰和纳米Si02三种不同形态和尺度的增强体对MC尼龙进行复合改性,分析增强体表面处理对MC尼龙复合改性的影响,以及复合改性的增强效果与增强机理；结合材料综合性能和生产成本分析,实现两相协同增强尼龙复合材料的制备,并开展尼龙梯度复合管的制备与产业化生产。主要研究结论如下：
(1)增强体表面偶联预处理是MC尼龙复合改性的关键和前提,玻璃纤维、粉煤灰和纳米SiO2三种不同种类增强体,适用的偶联剂及其最佳用量不同。硅烷偶联剂KH-550所含氨基与聚合反应体系加入催化剂之后形成的酰亚胺结构中的羰基反应,使基体与增强体界面形成化学键结合；原状粉煤灰尺寸粗大、疏松多孔,只有在活化偶联处理后才能够均匀分散在尼龙基体中体现增强效果。
(2)增强体形态对MC尼龙的增强效果具有重要影响,不同形态增强体的强化机制不同。玻璃纤维在复合材料中承载基体通过界面传递的载荷,提高材料强度和模量；粉煤灰颗粒和纳米NiO2粒子在复合材料中改变基体应力场,阻碍裂纹扩展或使裂纹改变方向,提高材料强度和塑性；30%玻璃纤维对尼龙复合材料的增强效果最明显,其拉伸强度较纯尼龙提高46.6%。
(3)三种增强体都能够有效改善复合材料的摩擦性能。玻璃纤维通过刚度和硬度的增加降低材料的摩擦系数；粉煤灰在磨损表面形成摩擦膜,有效减轻磨损；纳米SiO2粒子在磨损表面微滚动,变滑动摩擦为滚动和滑动复合摩擦,降低摩擦系数和磨损量；1%纳米SiO2对复合材料摩擦性能的改善效果最明显。
(4)不同形态增强体之间对尼龙基体具有协同增强效果。玻璃纤维与粉煤灰协同增强尼龙复合材料力学性能优于单一组分改性的加和,30%玻璃纤维+10%粉煤灰协同增强尼龙复合材料拉伸强度较30%玻璃纤维复合材料强度提高7.5%,较10%粉煤灰复合材料强度提高47.4%。
(5)发明了尼龙梯度复合管及其制备技术,并成功实现了产业化。10%玻璃纤维+5%粉煤灰协同复合,利用离心力场使粉煤灰颗粒沿径向由内向外呈负梯度分布,玻璃纤维呈正梯度分布,实现了内壁抗磨、外壁高强度的理想性能组合,梯度复合管耐压强度比MC尼龙管提高1倍,成本降低20%以上,成功应用于航道疏浚、火力发电、冶金矿山等行业,取得了显著的经济效益和社会效益。
In order to further enhance the MC nylon pipe strength and wear resistance, to meet the special requirements of waterway dredging, thermal power, metallurgy, mining and other industries, glass fiber, fly ash and nano-silica particles were selected to modify MC nylon. The effect of different enhancement surface pretreatment and their reinforced mechanisms were respectively investigated. Analysising combined with the material properties and the production cost, two kinds of enhancements synergistic reinforced nylon composite material was prepared and the nylon gradient composite tube was produced, which realize industrial production. The main conclusions are as follows:
(1) The coupling surface pretreatment for enhancement is the key and prerequisite to composite modification MC nylon. Different enhancements needed different coupling agent with suitable dosage. The amido of silane coupling agent could attack carbonyl group of imido group to form a chemical bond matrix and reinforcement during polymerization reaction. Original fly ash grains were so crassitude and loose that machine milling activation and coupling surface pretreatment were needed before they were added into basement.
(2) The shape of enhancement has an important influence to strengthen nylon with different forms of reinforcement mechanism. Glass fiber endured most load transferred through interface and increased nylon strength and modulus. Fly ash particles and nanometer SiO2particles could change the stress field in the composite, hinder the crack or change the crack direction, and improve nylon strength and plasticity.30%glass fiber reinforced nylon composite material had the most obvious effect and its tensile strength was46.6%higher than that of pure nylon.
(3) Three kinds of reinforcement can effectively improve the performance of friction composites. Glass fiber could reduce the friction coefficient just by increasing the stiffness and hardness. Fly ash could form the friction film on the worn surface, which effectively reduce the wear and tear. Nano SiO2particles were micro rolling on the worn surface, so that sliding friction was changed into rolling and sliding friction and the friction coefficient and wear rate were reduced. The most obvious improvement effect was1%nano SiO2.
(4) Different kinds of enhancements have a synergetic reinforcement effect when they are simultaneously added into nylon composites. The mechanical properties of composites coexistent with fiber glass and fly ash were higher than sum of composites only with one kind of filler. When glass fiber was30%and fly ash10%, the tensile strength of synergetic reinforced composite was7.5%higher than that of30%glass fiber composite and47.4%higher than that of10%fly ash composite.
(5) Nylon composites pipe with functionally gradient were invented and its industrialization were realized. In the field of centrifugal force, fly ash particle could enrich in inner tube with negative grade distribution from inner to outer and glass fiber enriched in outer, which made ideal structure in nylon composites pipe with inlayer abrasion resistant and outer high strength. Compared with MC nylon, the compressive strength of nylon composites pipe was increased by1times and the costs reduced20%, which made nylon pipe successfully applied in waterway dredging, thermal power, metallurgy, mining and other industries, and achieved remarkable economic and social benefits.
(1)增强体表面偶联预处理是MC尼龙复合改性的关键和前提,玻璃纤维、粉煤灰和纳米SiO2三种不同种类增强体,适用的偶联剂及其最佳用量不同。硅烷偶联剂KH-550所含氨基与聚合反应体系加入催化剂之后形成的酰亚胺结构中的羰基反应,使基体与增强体界面形成化学键结合；原状粉煤灰尺寸粗大、疏松多孔,只有在活化偶联处理后才能够均匀分散在尼龙基体中体现增强效果。
(2)增强体形态对MC尼龙的增强效果具有重要影响,不同形态增强体的强化机制不同。玻璃纤维在复合材料中承载基体通过界面传递的载荷,提高材料强度和模量；粉煤灰颗粒和纳米NiO2粒子在复合材料中改变基体应力场,阻碍裂纹扩展或使裂纹改变方向,提高材料强度和塑性；30%玻璃纤维对尼龙复合材料的增强效果最明显,其拉伸强度较纯尼龙提高46.6%。
(3)三种增强体都能够有效改善复合材料的摩擦性能。玻璃纤维通过刚度和硬度的增加降低材料的摩擦系数；粉煤灰在磨损表面形成摩擦膜,有效减轻磨损；纳米SiO2粒子在磨损表面微滚动,变滑动摩擦为滚动和滑动复合摩擦,降低摩擦系数和磨损量；1%纳米SiO2对复合材料摩擦性能的改善效果最明显。
(4)不同形态增强体之间对尼龙基体具有协同增强效果。玻璃纤维与粉煤灰协同增强尼龙复合材料力学性能优于单一组分改性的加和,30%玻璃纤维+10%粉煤灰协同增强尼龙复合材料拉伸强度较30%玻璃纤维复合材料强度提高7.5%,较10%粉煤灰复合材料强度提高47.4%。
(5)发明了尼龙梯度复合管及其制备技术,并成功实现了产业化。10%玻璃纤维+5%粉煤灰协同复合,利用离心力场使粉煤灰颗粒沿径向由内向外呈负梯度分布,玻璃纤维呈正梯度分布,实现了内壁抗磨、外壁高强度的理想性能组合,梯度复合管耐压强度比MC尼龙管提高1倍,成本降低20%以上,成功应用于航道疏浚、火力发电、冶金矿山等行业,取得了显著的经济效益和社会效益。
In order to further enhance the MC nylon pipe strength and wear resistance, to meet the special requirements of waterway dredging, thermal power, metallurgy, mining and other industries, glass fiber, fly ash and nano-silica particles were selected to modify MC nylon. The effect of different enhancement surface pretreatment and their reinforced mechanisms were respectively investigated. Analysising combined with the material properties and the production cost, two kinds of enhancements synergistic reinforced nylon composite material was prepared and the nylon gradient composite tube was produced, which realize industrial production. The main conclusions are as follows:
(1) The coupling surface pretreatment for enhancement is the key and prerequisite to composite modification MC nylon. Different enhancements needed different coupling agent with suitable dosage. The amido of silane coupling agent could attack carbonyl group of imido group to form a chemical bond matrix and reinforcement during polymerization reaction. Original fly ash grains were so crassitude and loose that machine milling activation and coupling surface pretreatment were needed before they were added into basement.
(2) The shape of enhancement has an important influence to strengthen nylon with different forms of reinforcement mechanism. Glass fiber endured most load transferred through interface and increased nylon strength and modulus. Fly ash particles and nanometer SiO2particles could change the stress field in the composite, hinder the crack or change the crack direction, and improve nylon strength and plasticity.30%glass fiber reinforced nylon composite material had the most obvious effect and its tensile strength was46.6%higher than that of pure nylon.
(3) Three kinds of reinforcement can effectively improve the performance of friction composites. Glass fiber could reduce the friction coefficient just by increasing the stiffness and hardness. Fly ash could form the friction film on the worn surface, which effectively reduce the wear and tear. Nano SiO2particles were micro rolling on the worn surface, so that sliding friction was changed into rolling and sliding friction and the friction coefficient and wear rate were reduced. The most obvious improvement effect was1%nano SiO2.
(4) Different kinds of enhancements have a synergetic reinforcement effect when they are simultaneously added into nylon composites. The mechanical properties of composites coexistent with fiber glass and fly ash were higher than sum of composites only with one kind of filler. When glass fiber was30%and fly ash10%, the tensile strength of synergetic reinforced composite was7.5%higher than that of30%glass fiber composite and47.4%higher than that of10%fly ash composite.
(5) Nylon composites pipe with functionally gradient were invented and its industrialization were realized. In the field of centrifugal force, fly ash particle could enrich in inner tube with negative grade distribution from inner to outer and glass fiber enriched in outer, which made ideal structure in nylon composites pipe with inlayer abrasion resistant and outer high strength. Compared with MC nylon, the compressive strength of nylon composites pipe was increased by1times and the costs reduced20%, which made nylon pipe successfully applied in waterway dredging, thermal power, metallurgy, mining and other industries, and achieved remarkable economic and social benefits.
引文
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