莫来石刚玉喷涂料的核心性能优势 及施工要点Core performance advantages and key points of application for mullite-corundum spray coating

莫来石刚玉喷涂料的核心性能优势

Core performance advantages of mullite corundum gunning mass

莫来石刚玉喷涂料凭借其独特的材料组成与施工特性，在高炉热风炉应用中展现出显著的"性能-价值"双重优势。技术层面，该材料通过ZrO₂相变增韧机制与莫来石相低膨胀特性的协同作用，实现抗热震性的突破性提升。其中，ZrO₂在温度变化过程中发生的马氏体相变能够有效细化晶粒并释放内应力，而莫来石相5.6×10⁻⁶/℃的低膨胀系数则显著降低了热循环条件下的体积变化率，两者共同构建起材料在高温交替环境下的结构稳定性基础。

Mullite-corundum gunning mass, with its unique material composition and application characteristics, exhibits significant performance-value advantages in blast furnace hot blast stove applications. Technically, this material achieves a breakthrough improvement in thermal shock resistance through the synergistic effect of the ZrO₂ phase transformation toughening mechanism and the low expansion characteristics of the mullite phase. Specifically, the martensitic phase transformation of ZrO₂ during temperature changes effectively refines grains and releases internal stress, while the low expansion coefficient of the mullite phase (5.6 × 10⁻⁶/℃) significantly reduces the volume change rate under thermal cycling conditions. Together, these two factors form the foundation for the material's structural stability in alternating high-temperature environments.
施工效率的革新是其另一核心竞争力。采用免支模喷涂工艺可将热风炉内衬施工周期从传统耐火砖砌筑的21天压缩至7天，同时实现3天快速烘烤即可达到90%设计强度的硬化效果，大幅缩短了高炉停机维护时间。俄罗斯MMK钢铁公司的工业应用案例显示，该材料不仅使年维护成本降低40万元，其耐磨性能与抗侵蚀能力也较传统浇注料提升30%以上，形成"施工提速-成本下降-寿命延长"的良性循环。

Innovation in construction efficiency is another core competitive advantage. The use of a formwork-free spray coating process reduces the construction cycle of hot blast stove linings from 21 days for traditional refractory brickwork to 7 days. Simultaneously, it achieves 90% of the design strength through rapid baking in just 3 days, significantly shortening blast furnace downtime for maintenance. Industrial application cases at Russia's MMK Steel Company show that this material not only reduces annual maintenance costs by 400,000 yuan, but also improves wear resistance and corrosion resistance by more than 30% compared to traditional castables, creating a virtuous cycle of "accelerated construction - reduced costs - extended lifespan."
性能对比核心结论：莫来石刚玉喷涂料在抗热震性（≥ 30次循环）、施工效率（3倍提速）、维护成本（年降40万元）等关键指标上全面超越传统耐火材料，其"材料-施工-运维"的全周期优化特性，重新定义了热风炉内衬材料的技术标准。
从微观结构到工程应用的全链条优势，使莫来石刚玉喷涂料成为现代高炉热风炉长寿化、高效化改造的精选材料方案，尤其适用于大型高炉热风炉高温区（1200-1400℃）的内衬关键部位。

Key conclusions from the performance comparison: Mullite-corundum spray coating surpasses traditional refractory materials in key indicators such as thermal shock resistance (≥ 30 cycles), construction efficiency (3 times faster), and maintenance costs (annual reduction of 400,000 RMB). Its optimized full-cycle "material-construction-operation and maintenance" characteristics redefine the technical standards for hot blast stove lining materials.

The advantages across the entire chain, from microstructure to engineering applications, make mullite-corundum spray coating a preferred material solution for the long-life and high-efficiency retrofitting of modern blast furnace hot blast stoves, especially suitable for critical lining components in the high-temperature zone (1200-1400℃) of large blast furnace hot blast stoves.

与传统高铝喷涂料相比，莫来石刚玉喷涂料在抗热震性（50次循环 vs 35次）、施工效率（7天 vs 21天）、耐磨性（0.2mm/月 vs 0.5mm/月）等关键指标上均实现显著提升，形成全方位性能优势。

Compared with traditional high-alumina spray coatings, mullite-corundum spray coatings have achieved significant improvements in key indicators such as thermal shock resistance (50 cycles vs. 35 cycles), construction efficiency (7 days vs. 21 days), and abrasion resistance (0.2 mm/month vs. 0.5 mm/month), forming an all-round performance advantage.
施工工艺与质量控制要点
高炉热风炉莫来石刚玉喷涂料的施工需遵循以“施工全流程”为主线的系统性工艺规范，确保涂层性能达到设计要求。施工工艺主要采用半干法喷涂技术，结合Y型锚固钉焊接的锚固系统，形成完整的施工体系。

Construction Technology and Quality Control Key Points:

 The application of mullite-corundum spray coating for blast furnace hot blast stoves must follow a systematic process specification centered on the "entire construction process" to ensure that the coating performance meets design requirements. The main construction technology employed is semi-dry spraying, combined with an anchoring system using Y-type anchor bolts, forming a complete construction system.

施工流程分为四个关键步骤。首先是预处理阶段，采用压缩空气对基体表面进行彻底吹扫，去除浮尘、氧化皮等杂物，对于存在锈蚀的区域需进行机械打磨处理，确保表面粗糙度符合喷涂要求，为涂层附着提供良好基础。

The construction process consists of four key steps. The first step is the pretreatment stage, in which compressed air is used to thoroughly blow away the substrate surface to remove dust, scale, and other impurities. For areas with rust, mechanical grinding is required to ensure that the surface roughness meets the spraying requirements and provides a good foundation for coating adhesion.
其次是锚固系统施工，选用310S不锈钢Y型锚固钉，其焊接高度严格控制为设计喷涂厚度的2/3，以保证锚固强度与涂层整体性。焊接过程需确保钉体与基体连接牢固，避免出现虚焊、脱焊现象.

Secondly, the anchoring system is constructed using 310S stainless steel Y-type anchors. The welding height is strictly controlled to 2/3 of the designed coating thickness to ensure anchoring strength and coating integrity. During welding, it is crucial to ensure a firm connection between the anchor and the substrate, avoiding incomplete welds or detachment.
喷涂操作阶段，喷嘴与工作面的距离应保持在1 - 1.5 m，采用螺旋式移动轨迹进行喷涂，确保涂层厚度均匀。同时，喷涂压力需控制在0.4 - 0.6 MPa的合理范围内，以优化材料附着率和涂层致密度。

During the spraying operation, the distance between the nozzle and the working surface should be maintained at 1-1.5 m, and a spiral movement trajectory should be used for spraying to ensure uniform coating thickness. At the same time, the spraying pressure needs to be controlled within a reasonable range of 0.4-0.6 MPa to optimize material adhesion and coating density.

养护烘烤是施工的最后关键环节，需严格控制升温速率，在150 - 500 ℃区间内缓慢升温，避免因热应力集中导致涂层开裂。Curing and baking is the final and crucial step in the construction process. The heating rate must be strictly controlled, and the temperature should be increased slowly within the range of 150-500 ℃ to avoid cracking of the coating due to concentrated thermal stress.
质量控制方面，需重点关注反弹料清理和厚度检测。反弹料清理应遵循“底部先喷，顶部后喷”的原则，避免顶部反弹料堆积影响涂层质量；厚度检测采用激光测厚仪进行实时监控，施工偏差需符合YB/T 4194 - 2018标准中±5 mm的要求，确保涂层厚度达到设计指标。

In terms of quality control, the focus should be on cleaning up rebound material and thickness testing. Rebound material cleaning should follow the principle of "spraying the bottom first, then the top" to avoid accumulation of rebound material on the top affecting coating quality. Thickness testing should be performed using a laser thickness gauge for real-time monitoring, and the construction deviation must meet the ±5 mm requirement in the YB/T 4194-2018 standard to ensure that the coating thickness meets the design specifications.
施工关键控制点
预处理：压缩空气吹扫压力≥0.5 MPa，锈蚀打磨至Sa2.5级
锚固系统：310S不锈钢Y型钉间距≤200 mm，焊接后进行100%敲击检查
喷涂参数：喷嘴移动速度0.5 - 1 m/s，单次喷涂厚度≤50 mm
施工全过程需严格执行上述工艺要求，通过标准化操作与精细化控制，确保莫来石刚玉喷涂料在高炉热风炉上的应用效果，延长热风炉使用寿命。

Key Control Points for Construction

Pretreatment: Compressed air purging pressure ≥ 0.5 MPa, rust polishing to Sa2.5 grade

Anchoring System: 310S stainless steel Y-shaped nails spacing ≤ 200 mm, 100% hammer inspection after welding

Spraying Parameters: Nozzle movement speed 0.5 - 1 m/s, single spray thickness ≤ 50 mm

The above process requirements must be strictly followed throughout the construction process. Through standardized operation and meticulous control, the application effect of mullite-corundum spray coating on blast furnace hot blast stoves can be ensured, extending the service life of the hot blast stoves.