Refractory member and method of producing the same

Patent metadata

Field	Value
Publication number	US-2024262758-A1
Application number	US-202218570254-A
Country	US
Kind code	A1
Filing date	Jun 7, 2022
Priority date	Jun 15, 2021
Publication date	Aug 8, 2024
Grant date	—

Abstract

Provided is a refractory member that is excellent in corrosion resistance and excellent in the adhesiveness of a carbide coating disposed on a surface of a graphite material base. The refractory member includes: a graphite material base; and a carbide layer disposed to coat at least a part of a surface of the graphite material base. In the refractory member, the graphite material base includes a graphite material phase and a pore, the carbide layer includes a composite region, and the composite region includes an alternating region in which a continuous graphite material phase of at least 50 μm or more and a continuous carbide phase of at least 50 μm or more alternately exist in a horizontal direction along an interface between the graphite material base and the carbide layer, as viewed in a cross section along the thickness direction of the carbide layer.

First claim

1 . A refractory member comprising:
a graphite material base; and a carbide layer disposed to coat at least a part of a surface of the graphite material base, wherein the graphite material base comprises a graphite material phase and a pore, the carbide layer comprises a composite region, and the composite region comprises an alternating region in which a continuous graphite material phase of at least 50 μm or more and a continuous carbide phase of at least 50 μm or more alternately exist in a horizontal direction along an interface between the graphite material base and the carbide layer, as viewed in a cross section along a thickness direction of the carbide layer.

2 . The refractory member according to claim 1 , wherein the composite region has a thickness of 50 to 1000 μm.

3 . The refractory member according to claim 1 , wherein a rate of the carbide phase in the composite region is 10 to 60 area %, as viewed in a cross section along the thickness direction of the carbide layer.

4 . The refractory member according to claim 2 , wherein a rate of the carbide phase in the composite region is 10 to 60 area %, as viewed in a cross section along the thickness direction of the carbide layer.

5 . The refractory member according to claim 1 , wherein a rate of the graphite material phase in the composite region is 40 to 90 area %, as viewed in a cross section along the thickness direction of the carbide layer.

6 . The refractory member according to claim 2 , wherein a rate of the graphite material phase in the composite region is 40 to 90 area %, as viewed in a cross section along the thickness direction of the carbide layer.

7 . The refractory member according to claim 1 , wherein
the carbide layer further comprises a carbide region on the composite region, and a continuous graphite material phase of less than 50 μm and a continuous carbide phase of at least 50 μm or more exist on the carbide region in a horizontal direction along an interface between the graphite material base and the carbide layer, as viewed in a cross section along the thickness direction of the carbide layer.

8 . The refractory member according to claim 2 , wherein
the carbide layer further comprises a carbide region on the composite region, and a continuous graphite material phase of less than 50 μm and a continuous carbide phase of at least 50 μm or more exist on the carbide region in a horizontal direction along an interface between the graphite material base and the carbide layer, as viewed in a cross section along the thickness direction of the carbide layer.

9 . The refractory member according to claim 7 , wherein the carbide region has a thickness of 10 to 300 μm.

10 . The refractory member according to claim 8 , wherein the carbide region has a thickness of 10 to 300 μm.

11 . The refractory member according to claim 7 , wherein a rate of the carbide phase in the carbide region is 50 to 99 area %, as viewed in a cross section along the thickness direction of the carbide layer.

12 . The refractory member according to claim 8 , wherein a rate of the carbide phase in the carbide region is 50 to 99 area %, as viewed in a cross section along the thickness direction of the carbide layer.

13 . The refractory member according to claim 7 , wherein a rate of the graphite material phase in the carbide region is 0 to 10 area %, as viewed in a cross section along the thickness direction of the carbide layer.

14 . The refractory member according to claim 8 , wherein a rate of the graphite material phase in the carbide region is 0 to 10 area %, as viewed in a cross section along the thickness direction of the carbide layer.

15 . The refractory member according to claim 1 , wherein the carbide is selected from a group consisting of niobium carbide and tantalum carbide.

16 . The refractory member according to claim 2 , wherein the carbide is selected from a group consisting of niobium carbide and tantalum carbide.

17 . A method of producing the refractory member according to claim 1 , the method comprising:
preparing a graphite material base comprising a graphite material phase and a pore; applying an oxide-containing liquid to at least a part of a surface of the graphite material base; performing heating of the graphite material base, to which the oxide-containing liquid has been applied, to melt the oxide; impregnating the pore of the graphite material base with the molted oxide; and performing carbonization of the oxide with the graphite material base as a carbon source to form a carbide.

18 . The method according to claim 17 , wherein the heating is performed at 1450 to 2000° C.

19 . The method according to claim 17 , wherein the carbonization is performed at 2000 to 2500° C.

20 . The method according to claim 17 , wherein the graphite material base has a porosity of 8 to 30% and a mean pore diameter of 50 to 300 μm.

Assignees

• Mitsui Mining & Smelting Co Ltd

Inventors

• Kajino Hitoshi
• Imaura Shoji

Classifications

• C04B2111/00405

  Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another · CPC title

• C04B41/89

  for obtaining at least two superposed coatings having different compositions · CPC title

• C04B41/5057

  Carbides · CPC title

• C04B41/5051

  Niobium oxides or niobates · CPC title

• C04B41/52

  Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation} · CPC title