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WO2006005150A1 - Procedes de production de corps en aluminium mousse a partir de poudre d'aluminium enrobee - Google Patents

Procedes de production de corps en aluminium mousse a partir de poudre d'aluminium enrobee Download PDF

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Publication number
WO2006005150A1
WO2006005150A1 PCT/CA2004/001011 CA2004001011W WO2006005150A1 WO 2006005150 A1 WO2006005150 A1 WO 2006005150A1 CA 2004001011 W CA2004001011 W CA 2004001011W WO 2006005150 A1 WO2006005150 A1 WO 2006005150A1
Authority
WO
WIPO (PCT)
Prior art keywords
aluminum
powder
foamed
particles
foaming agent
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CA2004/001011
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English (en)
Inventor
Serguei Vatchiants
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Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to PCT/CA2004/001011 priority Critical patent/WO2006005150A1/fr
Publication of WO2006005150A1 publication Critical patent/WO2006005150A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention relates to the area of powder metallurgy I more specifically to the methods of manufacturing of foamed aluminum and products composed of it, which can be used in various sectors of industry, for example, transportation and construction industries, where there is a need for materials with such functional qualities as ability to absorb vibrations and impacts, ability to absorb sound, light weight and rigidity of structural elements, being at the same time inflammable and environmentally friendly.
  • the most promising material, for the purpose of creation of foam metal, is aluminum since it has low density ( ⁇ 2.7 g/cm 3 ) and low melting point (-660 0 C). These parameters reduce the energy requirements for its processing and facilitate the choice of foaming agents with the temperature of decomposition in the range of 500-700 0 C.
  • the metallurgical processes involving melt are marked by the simplicity of the technological approach (US5622542, US5112697).
  • the gas (air, CO 2 , N 2 or other) or the foaming agent (TiH 2 , CaCO3 or other) is introduced in the molten metal body and the foamed liquid metal is obtained through the bubbling.
  • the solid foam is obtained when the melt is allowed to crystallise. This constitutes the advantage of such process, which allows creating foamed metal directly from the molten phase, bypassing such labour intensive processes as compaction of the aluminum powder into precursors and their further foaming.
  • Powder metallurgical approach includes the following operations: mixing of the powders of metal and foaming agent, pre-compaction of the charge obtained, hot compaction, deforming, foaming and finishing solid foam into the final product.
  • the known methods (US5151246, US5393485, RU2139774, RU2154548) differ slightly. Some of them use hot pressing or extrusion of the powder, other use isostatic compression and rolling, yet some use a combination of several procedures. However, the production yield and product's quality still remains relatively low.
  • the process of formation of the structure of the foam depends greatly on the chemical composition of the metal and particle size of the metal and foaming agent powders.
  • the non-uniform distribution of the foaming agent in the precursor which is explained by the difficulty of preparing a homogenous charge composed of components that greatly differ by mass ratio (99.0-99.5% Al and 1.0-0.5 % TiH 2 ) and by density (-2.7 g/cm 3 and -3.9 g/cm 3 ), also reflect negatively on the outcome of the process.
  • the surface activation of the granules (particles) by plating them with metals other than aluminum and capable of creation of strong bond without high pressures would promote good sintering of the particles into a high quality aluminum foam material.
  • the primary object of the present invention is to create methods for production of foamed aluminum materials and products with regular structure of pores and stable functional properties.
  • the base of the proposed methods is activation and plating of the powders or particles (granules), provided by means of thermal-chemical treatment, i.e. brazing or plating.
  • the chlorinating processes can be represented as follows:
  • the products of thermal dissociation of NH 4 CI are the active pairs of HCI* (1), which, after being adsorbed by the surface of aluminum particles, react with oxide films AI 2 O 3 .
  • the intermediate product - aluminum oxychloride AIOCI, (2) is produced and at the second stage, the main product - aluminum chloride, AICI 3 , (3) is produced, the sublimation temperature of which is 180 0 C.
  • the aluminum powder is de-oxidised, in other words the oxide film AI 2 O 3 is removed.
  • the chlorination of the metallic titanium (4) presented in a form of disperse powder particles ( ⁇ 325 mesh), is performed at ⁇ 350 0 C.
  • the sublimation temperature of the titanium tetrachloride TiCI 4 is around 136 0 C.
  • the second stage of the thermal-chemical treatment is characterised by thermal- diffusion processes, i.e. plating of the particles of the "reduced" aluminum in accordance with following reactions:
  • the plating is produced due to creation of atomic titanium Ti* (5,6) and its diffusion into the surface layer of the aluminum particles (7), as well as through the process of displacement or exchange reactions as per (8).
  • the reactions of decomposition (6) are based on the process of thermal dissociation, and this is why all chlorides of titanium can participate in it.
  • the solubility of Al in Ti in the temperature interval of 400-600 0 C is 7.0-7.5% by mass, while Ti --> Al is about 0.1 % by mass.
  • This minuscule solubility of titanium in the aluminum allows to plate the particles with layers of micron thickness. This is sufficient to protect the aluminum powder from oxidation during the following stages of mixing with a foaming agent and hot compaction of the charge into the precursor (semi ⁇ finished product). If plating is applied to the aluminum particles already containing foaming agents, then preparing the charge, i.e. mixing stage, is no longer necessary.
  • the plating was done in the following manner.
  • the aluminum, titanium and ammonium chloride powders were mixed.
  • the prepared charge was loaded into a ceramic container, and placed into an oven preheated to the necessary temperature.
  • the container was rotated to ensure uniform plating and exclude the possibility of particle sintering.
  • the container was removed from the oven, cooled down and unloaded.
  • the physical properties of the initial and final powder were analysed, in particular to determine their ability to be pressed and sintered. Plated powder satisfied all requirements standard for metallic powders (deformability, fluidity.)
  • high pressure i.e. high level of deformation.
  • Sintered samples produced from plated powder are characterised as being very strong and having good impact resistance. This is explained by the increased activation of the sintering processes (due to the absence Of AbO 3 ) which usually hinders the agglomeration or diffusion of aluminum particles (creation of the metallic bond), as well as by the overall improvement of the properties of the alloy due to presence of titanium.
  • the first method consists of thermal-chemical treatment of the aluminum powder, after which the powder is mixed with the foaming agent, loaded into closed volume metallic containers and pre-compacted.
  • the container with powder is heated to the temperature 10-20 0 C below the solidus temperature T s of the aluminum alloy and compacted into billets (slabs) using a rolling mill.
  • the slabs are then transformed into sheets, strips and various profiles by means of hot rolling.
  • the precursors are prepared by cutting the sheets into pieces of desired configuration. They are then heated and deformed into semi-finished products, resembling by size and configuration the final products.
  • the semi-finished products are foamed inside forms (moulds) and the foamed products are finished to give them their final shape of commercial product.
  • the features of the process are: Thermal-chemical treatment of aluminum alloy powder in order to activate it, in other words to increase its reactivity, and which consists of elimination of the oxide film AbO 3 and plating aluminum particles with various metals, for example titanium;
  • the absence of these factors allows to provide the foaming process without overheating of the metal and therefore avoiding drainage of the aluminum.
  • the optimal temperatures for the phase transition ⁇ T S ⁇ --> T L > are those with gradient of no more than ⁇ 10 0 C. Under these conditions, the foaming process becomes controllable, which allows the production of foamed aluminum with uniform pores and stable properties;
  • lubricants for example alcohol/glycerine solutions to produce a uniform charge from the aluminum and foaming agent powder, as well as to improve environmental friendliness (dust removal and explosion hazard prevention).
  • the second method consists of producing materials and products using aluminum particles or granules that already contain the foaming agent inside eliminates the stages of mixing the powder with the foaming agent, preliminary compacting the charge and hot compaction of it into precursors.
  • Aluminum particles, granules or even powder containing the foaming agent are produced by the method of dispersion of the alloy in its liquid phase or by mechanically crushing the precursors. After that, it is loaded into closed forms (moulds) heated and foamed. Depending on the volumetric fill of the form with granules (particles) it is possible to control the structural porosity of the foamed aluminum to a great extent.
  • the process consists of the following steps:
  • the use of the thermal-chemical treatment substantially increases the surface activation energy of the aluminum powder (particles) and granules, which is due to the elimination of the oxide film of AI2O3 being replaced with the metal plating, in particular with titanium, as well as assures the particles' reactionary sintering into a strong foamed aluminum material;
  • the third method described herein consists of putting the aluminum alloy powder through:
  • the method is applicable even to producing dense non-porous aluminum based materials, if the foaming agent is excluded from the charge preparation, obviously eliminating the foaming process.
  • the thermal-chemical treatment i.e. de-oxidation and the plating of the aluminum alloy powder (or the granules/particles containing the foaming agent) and the discrete fibres, ensures the complete metallic compatibility of the matrix-fibre system. This greatly improves the functional properties of the foamed aluminum reinforced with fibres, in particular its strength (Sb) and impact elasticity (KCU);
  • Example 1 The initial materials included aluminum alloy ⁇ AI-Mg-Cu> (80-270 mesh), titanium (325 mesh) and ammonium chloride NH 4 CI, ( ⁇ 1.0% mass). The thermal-chemical treatment was done in a rotating container with rotation frequency of 30-35 s "1 , under 350-450 0 C and for 1.0-1.5 hours. The quantity of titanium was determined based on ensuring a plating layer of 2-4 ⁇ m thick. The activated aluminum powder was mixed with foaming agent T1H 2 (0.5-1.5% mass, with interval of 0.5% mass) using an alcohol/glycerine solution as a lubricant. The prepared charge was loaded into closed metallic containers made of sheet aluminum ⁇ AI-Mg-Cu>.
  • Example 2 The initial materials included aluminum alloy ⁇ AI-Si-Cu> granules (0.5-3.5 mm) containing the foaming agent, titanium and ammonium chloride (NH 4 CI, ⁇ 1.0% mass). The content of the foaming agent (TiH2) in the granules, produced by dispersion, was 0.8-1.0% mass.
  • the thermal-chemical treatment of the granules was done by the same method described in Example 1. The treated activated granules were loaded into moulds (filling different portions of the overall inner volume for a given test), heated to ⁇ Ts + 10 °C> and foamed. Then all the necessary experiments and analysis were performed on the products.
  • the well-sintered mass of foamed aluminum was produced with high mechanical strength and regular structural porosity.
  • the form and size of the pores, and as a result the density of the material, could be controlled within great accuracy.
  • the size of the pores varied within 0.5-3.5 mm range and the density lied within 0.5-1.3 g/cm 3 range.
  • Example 3 Production of the foamed aluminum reinforced with dispersed particles (1) and discrete fibres (2) consists of the following.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

L'invention concerne des procédés de production de matériaux en mousse d'aluminium et de produits métallurgiques en poudre, notamment le procédé consistant à mélanger des matériaux de base en poudre, à compacter au préalable le mélange obtenu et à compacter à chaud celui-ci par roulage dans des contenants métalliques fermés, soit dans un volume restreint. Un autre procédé permettant d'obtenir des produits denses de précurseur renfermant un agent de moussage (poudres, granulés) consiste en une dispersion du métal fondu par atomisation de celui-ci dans des injecteurs et en une introduction simultanée dans l'agent de moussage fondu (de la poudre TiH2, par exemple). Selon l'invention, les procédés consistent à désoxyder les particules ou granulés de poudre d'aluminium et à les électrodéposer au moyen d'autres métaux, le titane par exemple, mettant en oeuvre un procédé de réaction thermique-chimique. En raison de l'électrodéposition, le frittage réactif de la poudre ou des granulés est obtenu. Le procédé de moussage est également nettement amélioré du fait qu'il peut être mis en oeuvre sans surchauffe du précurseur et drainage excessif. Par conséquent, il est possible d'obtenir de la mousse d'aluminium présentant une structure normale des pores et possédant des propriétés fonctionnelles stables. Des matériaux de mousse obtenus au moyen du procédé selon l'invention peuvent être utilisés dans diverses industries, notamment, mais sans caractère restrictif l'industrie automobile, aérospatiale, des machines, du transport et de la construction.
PCT/CA2004/001011 2004-07-15 2004-07-15 Procedes de production de corps en aluminium mousse a partir de poudre d'aluminium enrobee Ceased WO2006005150A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
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Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007137681A1 (fr) * 2006-05-29 2007-12-06 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé de moussage métallique
RU2312913C1 (ru) * 2006-03-13 2007-12-20 Федеральное государственное унитарное предприятие "Российский Федеральный ядерный центр - Всероссийский научно-исследовательский институт экспериментальной физики" - ФГУП "РФЯЦ-ВНИИЭФ" Способ получения полуфабриката для изготовления пенометалла
RU2360020C2 (ru) * 2007-05-28 2009-06-27 Федеральное государственное унитарное предприятие "Российский Федеральный ядерный центр - Всероссийский научно-исследовательский институт экспериментальной физики" - ФГУП "РФЯЦ-ВНИИЭФ" Способ получения полуфабриката для изготовления изделий из пенометалла
EP2163330A2 (fr) 2008-08-27 2010-03-17 DePuy Products, Inc. Mélanges pour la formation de constructions poreuses
RU2412021C1 (ru) * 2009-07-30 2011-02-20 Открытое акционерное общество Акционерная холдинговая компания "Всероссийский научно-исследовательский и проектно-конструкторский институт металлургического машиностроения имени академика Целикова" (ОАО АХК "ВНИИМЕТМАШ") Способ и линия производства листов пеноалюминия
RU2430811C1 (ru) * 2010-03-03 2011-10-10 Открытое акционерное общество Акционерная холдинговая компания "Всероссийский научно-исследовательский и проектно-конструкторский институт металлургического машиностроения имени академика Целикова" (ОАО АХК "ВНИИМЕТМАШ") Способ и линия получения листов пеноалюминия
RU2444416C2 (ru) * 2010-05-21 2012-03-10 Владимир Сергеевич Колеров Способ получения изделия из слоистого композита на основе пеноалюминия
RU2450892C1 (ru) * 2010-11-11 2012-05-20 Владимир Сергеевич Колеров Способ получения пористых материалов на основе пеноалюминия (изделий) из алюминиевых сплавов
CN102796911A (zh) * 2012-08-10 2012-11-28 黑龙江科技学院 一种多孔泡沫铁镍金属抑爆材料及其应用
US9204967B2 (en) 2007-09-28 2015-12-08 Depuy (Ireland) Fixed-bearing knee prosthesis having interchangeable components
RU2582846C2 (ru) * 2014-07-25 2016-04-27 ООО "Электрический гранулятор пенометаллов" (ООО ЭГПМ) Способ получения гранул пенометаллов
US9398956B2 (en) 2007-09-25 2016-07-26 Depuy (Ireland) Fixed-bearing knee prosthesis having interchangeable components
EP3165307A1 (fr) * 2015-11-03 2017-05-10 Havel metal foam GmbH Procédé et dispositif de fabrication de corps composites en mousse métallique et corps composites en mousse métallique
RU2638608C1 (ru) * 2016-10-04 2017-12-14 Общество с ограниченной ответственностью "Электрический гранулятор пенометаллов" (ООО ЭГПМ) Способ получения металлических гранул с открытой пористостью
CN109719297A (zh) * 2019-01-31 2019-05-07 广东科技学院 一种多孔金属复合材料及其制备方法
CN110303158A (zh) * 2019-08-13 2019-10-08 广西大学 一种新型制备泡沫铝的方法
CN111579442A (zh) * 2020-06-11 2020-08-25 上海交通大学 精确测量铝基复合材料中原位自生TiB2颗粒尺寸分布的方法
CN112108652A (zh) * 2019-12-27 2020-12-22 航天特种材料及工艺技术研究所 一种轻质泡沫铝夹芯板的一体化制备方法及轻质泡沫铝夹芯板
CN112122611A (zh) * 2020-09-25 2020-12-25 航天特种材料及工艺技术研究所 一种夹心结构的泡沫铝及其制备方法
CN113773827A (zh) * 2021-08-31 2021-12-10 广汉市福客科技有限公司 一种自发泡延缓型固体泡沫排水剂及其制备方法

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WO2003009956A2 (fr) * 2001-07-26 2003-02-06 Dirk Schwingel Materiau composite et composant fabrique a partir de ce materiau, forme d'une ame metallique expansee et d'une tole de recouvrement massive, son utilisation et son procede de fabrication
US20030104147A1 (en) * 2000-01-25 2003-06-05 Frank Bretschneider Hollow balls and a method for producing hollow balls and for producing light-weight structural components by means of hollow balls
US20040081571A1 (en) * 2001-01-16 2004-04-29 Serguei Vatchiants Method for production of metal foam or metal-composite bodies with improved impact, thermal and sound absorption properties

Patent Citations (3)

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US20030104147A1 (en) * 2000-01-25 2003-06-05 Frank Bretschneider Hollow balls and a method for producing hollow balls and for producing light-weight structural components by means of hollow balls
US20040081571A1 (en) * 2001-01-16 2004-04-29 Serguei Vatchiants Method for production of metal foam or metal-composite bodies with improved impact, thermal and sound absorption properties
WO2003009956A2 (fr) * 2001-07-26 2003-02-06 Dirk Schwingel Materiau composite et composant fabrique a partir de ce materiau, forme d'une ame metallique expansee et d'une tole de recouvrement massive, son utilisation et son procede de fabrication

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2312913C1 (ru) * 2006-03-13 2007-12-20 Федеральное государственное унитарное предприятие "Российский Федеральный ядерный центр - Всероссийский научно-исследовательский институт экспериментальной физики" - ФГУП "РФЯЦ-ВНИИЭФ" Способ получения полуфабриката для изготовления пенометалла
WO2007137681A1 (fr) * 2006-05-29 2007-12-06 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé de moussage métallique
RU2360020C2 (ru) * 2007-05-28 2009-06-27 Федеральное государственное унитарное предприятие "Российский Федеральный ядерный центр - Всероссийский научно-исследовательский институт экспериментальной физики" - ФГУП "РФЯЦ-ВНИИЭФ" Способ получения полуфабриката для изготовления изделий из пенометалла
US9398956B2 (en) 2007-09-25 2016-07-26 Depuy (Ireland) Fixed-bearing knee prosthesis having interchangeable components
US9204967B2 (en) 2007-09-28 2015-12-08 Depuy (Ireland) Fixed-bearing knee prosthesis having interchangeable components
EP2163330A2 (fr) 2008-08-27 2010-03-17 DePuy Products, Inc. Mélanges pour la formation de constructions poreuses
EP2163330A3 (fr) * 2008-08-27 2010-04-21 DePuy Products, Inc. Mélanges pour la formation de constructions poreuses
CN101811189A (zh) * 2008-08-27 2010-08-25 德普伊产品公司 用于形成多孔构建体的混合物
RU2412021C1 (ru) * 2009-07-30 2011-02-20 Открытое акционерное общество Акционерная холдинговая компания "Всероссийский научно-исследовательский и проектно-конструкторский институт металлургического машиностроения имени академика Целикова" (ОАО АХК "ВНИИМЕТМАШ") Способ и линия производства листов пеноалюминия
RU2430811C1 (ru) * 2010-03-03 2011-10-10 Открытое акционерное общество Акционерная холдинговая компания "Всероссийский научно-исследовательский и проектно-конструкторский институт металлургического машиностроения имени академика Целикова" (ОАО АХК "ВНИИМЕТМАШ") Способ и линия получения листов пеноалюминия
RU2444416C2 (ru) * 2010-05-21 2012-03-10 Владимир Сергеевич Колеров Способ получения изделия из слоистого композита на основе пеноалюминия
RU2450892C1 (ru) * 2010-11-11 2012-05-20 Владимир Сергеевич Колеров Способ получения пористых материалов на основе пеноалюминия (изделий) из алюминиевых сплавов
CN102796911A (zh) * 2012-08-10 2012-11-28 黑龙江科技学院 一种多孔泡沫铁镍金属抑爆材料及其应用
CN102796911B (zh) * 2012-08-10 2013-09-25 黑龙江科技学院 一种多孔泡沫铁镍金属抑爆材料及其应用
RU2582846C2 (ru) * 2014-07-25 2016-04-27 ООО "Электрический гранулятор пенометаллов" (ООО ЭГПМ) Способ получения гранул пенометаллов
EP3165307A1 (fr) * 2015-11-03 2017-05-10 Havel metal foam GmbH Procédé et dispositif de fabrication de corps composites en mousse métallique et corps composites en mousse métallique
RU2638608C1 (ru) * 2016-10-04 2017-12-14 Общество с ограниченной ответственностью "Электрический гранулятор пенометаллов" (ООО ЭГПМ) Способ получения металлических гранул с открытой пористостью
CN109719297A (zh) * 2019-01-31 2019-05-07 广东科技学院 一种多孔金属复合材料及其制备方法
CN110303158A (zh) * 2019-08-13 2019-10-08 广西大学 一种新型制备泡沫铝的方法
CN112108652A (zh) * 2019-12-27 2020-12-22 航天特种材料及工艺技术研究所 一种轻质泡沫铝夹芯板的一体化制备方法及轻质泡沫铝夹芯板
CN111579442A (zh) * 2020-06-11 2020-08-25 上海交通大学 精确测量铝基复合材料中原位自生TiB2颗粒尺寸分布的方法
CN111579442B (zh) * 2020-06-11 2023-05-30 上海交通大学 精确测量铝基复合材料中原位自生TiB2颗粒尺寸分布的方法
CN112122611A (zh) * 2020-09-25 2020-12-25 航天特种材料及工艺技术研究所 一种夹心结构的泡沫铝及其制备方法
CN113773827A (zh) * 2021-08-31 2021-12-10 广汉市福客科技有限公司 一种自发泡延缓型固体泡沫排水剂及其制备方法

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