[go: up one dir, main page]

WO2012164581A2 - Procédé de production de composites à matrice métal-aluminium renforcés - Google Patents

Procédé de production de composites à matrice métal-aluminium renforcés Download PDF

Info

Publication number
WO2012164581A2
WO2012164581A2 PCT/IN2012/000374 IN2012000374W WO2012164581A2 WO 2012164581 A2 WO2012164581 A2 WO 2012164581A2 IN 2012000374 W IN2012000374 W IN 2012000374W WO 2012164581 A2 WO2012164581 A2 WO 2012164581A2
Authority
WO
WIPO (PCT)
Prior art keywords
molten
matrix
metal
compound
aluminum
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/IN2012/000374
Other languages
English (en)
Other versions
WO2012164581A3 (fr
Inventor
Vivek Srivastava
Walter Hotz
Yogesh Borole
Anurag TILAK
Anirban GIRI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Novelis Inc Canada
Aditya Birla Science and Technology Co Ltd
Original Assignee
Novelis Inc Canada
Aditya Birla Science and Technology Co Ltd
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 Novelis Inc Canada, Aditya Birla Science and Technology Co Ltd filed Critical Novelis Inc Canada
Publication of WO2012164581A2 publication Critical patent/WO2012164581A2/fr
Publication of WO2012164581A3 publication Critical patent/WO2012164581A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0005—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with at least one oxide and at least one of carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1047—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1057—Reactive infiltration
    • C22C1/1063—Gas reaction, e.g. lanxide
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C22C32/0052—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides

Definitions

  • the present disclosure relates to a process for producing an aluminum-metal matrix composite.
  • the present disclosure particularly relates to a process for producing Titanium- Carbide (TiC) reinforced aluminum-metal matrix composite.
  • a metal matrix composite is a composite material with at least two constituent parts, one being a metal.
  • the other material may be a different metal or another material, such as a ceramic or organic compound.
  • These composites are generally tailor-made depending upon the application requirements.
  • the composite includes a reinforced material embedded in the metal matrix.
  • the reinforced material can be synthesized externally and then embedded in the metal matrix or can be prepared in-situ in the metal matrix.
  • Aluminum is a most preferred matrix for metal matrix composites due to its low density and capacity to be strengthened.
  • One particular class of aluminum- based MMC that has gained popularity in the recent times is the titanium- carbide (TiC) particulate reinforced aluminum-metal matrix composite, especially wherein the TiC particulates are in-situ formed in the aluminum- metal matrix.
  • US 4,772,452 discloses a process for TiC reinforced aluminum matrix composites wherein the aluminum metal, titanium bearing compound and the carbide, all provided in the powder form are pre-mixed, compacted and further heated at a reaction temperature approximating melting point of the aluminum to produce the composite.
  • US 6,843,865 discloses a process for TiC reinforced aluminum matrix composites wherein the mixture of aluminum and titanium metals in its molten form is reacted with a halide of carbon to produce the composite. The reaction is carried out under vigorous mechanical stirring.
  • US 4,748,001 discloses a process for TiC reinforced aluminum matrix composites wherein the carbon powder preheated to 700°C is added to the molten mixture of aluminum and titanium metals and the melt is stirred vigorously at high temperature and additional processing is carried out at a very high temperature (1 100 to 1400°C) to produce the desired composite.
  • the melt is agitated by mechanical stirring.
  • Indian Patent Application No. 168/MUM/2010 discloses a method using pneumatic injection of a mixture of titanium bearing compounds and carbon containing material for the in-situ synthesis of TiC-aluminum composites. During synthesis of aluminum-titanium carbide matrix, graphite powder is used to react with titanium to form TiC.
  • US 4,808,372 discloses a process for producing a composite by introducing a gas into a molten composition comprising a matrix liquid and a refractory material-forming component and subsequently adding a reactive component which reacts with the refractory material-forming component to cause the refractory material to disperse in the matrix liquid.
  • the gas may be an inert carrier gas comprising a carbonaceous material such as methane which is introduced through a tube into the molten composition.
  • the composites so obtained have enhanced mechanical properties compared to aluminum metal and aluminum metal alloys and these composites find wide applications in transportation, electronics, and recreational products.
  • one severe drawback with the known techniques is that it is very difficult to obtain a homogenous dispersion of the TiC particles in the aluminum metal matrix. This leads to a variation in composite properties not only from batch to batch but even within the sample.
  • the process is carried out at very high temperatures, typically in the range of 1100 - 1400 °C, for duration of 1 - 2 hours. This leads to high processing costs.
  • Another drawback of the known processes is that they require preheating of the precursors to allow wetting of the powders in the melt.
  • the powder size is also to be controlled within tight specifications to enable good mixing and wetting.
  • the processes can be used to obtain only up to 5 % particulate reinforcement, beyond which mixing is poor.
  • a main object of the present disclosure is to provide a process for producing metal carbide reinforced aluminum-metal matrix composites, which reduces the formation of carbon agglomerates in the composites.
  • Another object of the present disclosure is to provide a process for producing metal matrix composites which provides a fine and homogenous distribution of the carbide particulate in the aluminum-metal matrix.
  • Another object of the present disclosure is to provide a simple and cost- effective process for producing metal matrix composites.
  • Still another object of the present invention is to provide a process for producing metal matrix composites which requires low operating temperature and reduced processing times.
  • One more object of the present invention is to provide a process for producing metal matrix composites with high amount of particulate reinforcement.
  • said metal compound is injected into said molten matrix through a feeder attached to a submersible lance, said lance being immersed in said molten matrix.
  • the hydrocarbon compound is injected into said melt through a feeder attached to a submersible lance, said lance being immersed in said molten matrix.
  • the hydrocarbon compound is selected from the group consisting of paraffin and acetylene gas.
  • said metal compound is injected along with the hydrocarbon into said molten matrix.
  • said metal compound and the hydrocarbon compound is injected pneumatically using pressurized carrier gas.
  • the carrier gas is selected from the group consisting of argon and nitrogen.
  • said metal compound is in the powder form.
  • said metal compound is a titanium compound.
  • the titanium compound is selected from the group consisting of potassium titanium fluoride and titanium oxide.
  • said molten matrix is maintained at a temperature in the range of 850°C to 1000°C.
  • the molten alloy formed in step c) is further agitated with the carrier gas for the uniform distribution of metallic carbide particulate in the molten alloy.
  • said molten matrix further comprises at least one alloying element selected from the group consisting of copper, zinc, magnesium and silicon.
  • the process further comprises the step of adding at least one alloying element to the molten alloy containing metallic carbide particulate, said alloying element selected from the group consisting of copper, zinc, magnesium and silicon.
  • Another aspect of the present disclosure provides a reinforced aluminum-metal matrix composite having number of defects less than 15/lOQmicron .
  • Figure 1 illustrates XRD patterns of Aluminum-Titanium carbide (AL-TiC) composites prepared by using different carbon sources.
  • Figure 2 illustrates effect of alternate carbon sources like Graphite Powder and Paraffin Wax on tensile properties of Aluminum Matrix Composites.
  • Metal matrix composites are tailor made material consisting a reinforcing material dispersed in a metal matrix.
  • the matrix is a monolithic material into which the reinforcement is embedded.
  • the reinforcement is provided to improve physical properties such as wear resistance, friction coefficient, or thermal conductivity of the metal.
  • Aluminum Matrix Composites are used for manufacturing automotive parts (pistons, pushrods, brake components), brake rotors for high speed trains, bicycles, golf clubs, electronic substrates, cars for high voltage electrical cables.
  • MMC Various methods are used to prepare MMC such as i) Solid state method, where powdered metal and reinforcement material are mixed and then bonded through a process of compaction, degassing, and thermo-mechanical treatment, ii) Liquid state method wherein reinforcement material is stirred into the molten metal and allowed to solidify, iii) A chemical reaction between the reactants to form reinforcement material in-situ in metal matrix. iv)Vapor deposition wherein the fiber is passed through a thick cloud of vaporized metal, coating it.
  • Aluminum Matrix Composites are manufactured by the fabrication methods such as Powder metallurgy (sintering), Stir casting and Infiltration. Usually the reinforcement of Aluminum Matrix Composites results in high strength, high stiffness (modulus of elasticity), Low density, High thermal conductivity and excellent abrasion resistance of the reinforced metal compared to properties of pure metal.
  • the present disclosure is accomplished taking into account the above described goals and objects of the present disclosure.
  • the present disclosure envisages generating in-situ carbon for reacting with the metal containing compound.
  • a hydrocarbon compound is selected as a carbon source.
  • the present disclosure provides a process for producing a reinforced aluminum- metal matrix composite which involves following steps:
  • a pressurized injection lance is used to inject the metal bearing compound and the hydrocarbon compound in to the molten matrix.
  • the hydrocarbon compound and the metal bearing compound may be injected simultaneously or sequentially or as a mixture into the molten matrix.
  • An inert gas, preferably nitrogen or argon serves as a carrier gas.
  • the lance is submerged in the bottom of the reactor system containing the molten aluminum.
  • the hydrocarbon compound in the form of a liquid or gas undergoes spontaneous combustion on exposure to high temperature, thereby forming in- situ carbon which then reacts with the metal bearing compound in the molten aluminum matrix.
  • the metal containing compound is in a powder form.
  • the metal compound is a titanium compound selected from the group consisting of potassium titanium fluoride and titanium oxide.
  • the pressurized gas helps to agitate the melt to ensure intimate mixing, which enhances the reaction kinetics and lowers the processing temperature (800- 1000°C) and processing time (5 to 60 min).
  • the process thus avoids mechanical stirring which may lead to irregular particulate size. Improvement is also observed in the homogeneity of mechanical properties, e.g. hardness variation is ⁇ 5% within the casting.
  • This process allows higher amount of reinforcement to be introduced in the melt (up to 20%), without compromising casting integrity.
  • Composites prepared by this process have a finer and more uniform distribution compared to those prepared by conventional route of mechanical stirring. Therefore for the same volume fraction of particles, composites according to the process described herein have superior mechanical properties.
  • hydrocarbon compound instead of the carbon (graphite) powder reduces the occurrence of carbon agglomerates in the composites and reduces lance choking due to the accumulation of the graphite particles inside the lance. Since the flow rate and duration of hydrocarbon compound can be controlled independently of the titanium bearing compound feed stream, the process of the present disclosure allows more flexibility in controlling the different process parameters to improve composite quality.
  • the process is carried out using liquid paraffin as a source for generating carbon.
  • Liquid paraffin is taken into a distributor column which is connected on one end to an argon cylinder and to an alumina lance on the other.
  • the column is provided with a valve to control the flow rate of the liquid paraffin.
  • the process is canned out using acetylene gas as a source for generating carbon.
  • acetylene gas instead of a distribution column for addition of paraffin, a simple header is used for mixing the argon and acetylene gas stream. Individual valves provided in both the gas streams allow the argon/acetylene ration to be easily controlled.
  • the molten aluminum matrix may include alloying elements selected from the group consisting of silicon, zinc, magnesium or copper. in accordance with one of the embodiments of the present disclosure, at least one of the alloying elements selected from the group consisting of silicon, zinc, magnesium or copper may be added during the process to further enhance the properties of reinforced aluminum matrix.
  • the carbon either forms metallic-carbide or leads to surface modification of A1 3 M from long needles and plates to a more equi-axed structure.
  • Example 1 Using Carbon powder
  • the composite was extruded at 400°C. Instead of a distribution column for addition of paraffin, a simple header is used for mixing the argon and acetylene gas stream. Individual valves in both the gas streams allow the argon/acetylene ratio to be easily controlled.
  • Figure 1 illustrates the formation of TiC using graphite and acetylene variants.
  • Figure 2 illustrates effect of paraffin and graphite powder on the tensile properties of the Aluminum matrix composites. Using Paraffin, marked improvement in ductility is observed over the graphite source. Furthermore it is seen that the standard deviations in strength is lower for inventive process compared to prior art. The minor decrease in strength for the inventive process compared to prior art is attributed to lower reinforcement content.
  • Table 3 illustrates the number of defects in Al-TiC composite prepared by using different carbon sources.
  • the defect density was measured by taking the cross section of the composite samples at three locations: top, middle and bottom of the cast ingot respectively. The cross section was then ground and polished for microscopic examination. The defect density was estimated by counting the number of defects in an area of 100 microns by 100 microns. The average defect size was estimated by measuring the average linear intercept size of the defects. Number of defects in Al-TiC composite prepared by graphite route was much higher compared to that prepared by acetylene route as reflected in Table 3. The size of defects in graphite route samples are also found slightly larger compared to acetylene route samples. Table 3
  • a reinforced aluminum-metal matrix composite prepared in accordance with the present disclosure is found to have number of defects less than 15/lOOmicron 2 .
  • carbon source has an effect on the defect density of the composite. This, in turn, affects the tensile properties like yield strength (ys), ultimate tensile strength (uts) and ductility (% elongation) of the composite. Effect of carbon sources like graphite powder and paraffin wax on tensile properties of aluminum matrix composites is shown in Table 4.
  • a process for producing metal matrix composites, particularly titanium-carbide (TiC) reinforced aluminum-metal matrix composite, as described in the present disclosure has several technical advantages including but not limited to the realization of:
  • the process of the present disclosure helps in achieving 'homogenous mixing, thus, giving a uniform distribution of the particulate reinforcement in the metal matrix and thereby giving homogeneity in the mechanical properties of the composite, e.g. variation in the hardness of the composite is less than 5 %, within the casting;
  • reaction kinetics are enhanced due to the pneumatic injection which results in lowering the process temperature to 850 - 1000 °C and the process time to 5 - 20 minutes;
  • the process of the present disclosure allows up to 20 % of the particulate reinforcement (TiC) to be introduced in aluminum matrix;

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Composite Materials (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

La présente invention concerne un procédé de production de composite à matrice en alliage d'aluminium renforcé par des particules de carbure métallique. La présente invention prévoit la génération in situ de carbone pour qu'il réagisse avec le composé contenant du métal dans la matrice d'aluminium fondu afin de produire les particules de carbure métallique. Un composé hydrocarboné est sélectionné en tant que source de carbone. Le procédé selon la présente invention permet d'introduire dans la matrice d'aluminium jusqu'à 20% de la matière de renforcement particulaire au carbure métallique.
PCT/IN2012/000374 2011-06-01 2012-05-30 Procédé de production de composites à matrice métal-aluminium renforcés Ceased WO2012164581A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN1618MU2011 2011-06-01
IN1618/MUM/2011 2011-06-01

Publications (2)

Publication Number Publication Date
WO2012164581A2 true WO2012164581A2 (fr) 2012-12-06
WO2012164581A3 WO2012164581A3 (fr) 2013-03-28

Family

ID=47260002

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IN2012/000374 Ceased WO2012164581A2 (fr) 2011-06-01 2012-05-30 Procédé de production de composites à matrice métal-aluminium renforcés

Country Status (1)

Country Link
WO (1) WO2012164581A2 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018074179A1 (fr) * 2016-10-17 2018-04-26 株式会社ベイシティ Composite d'aluminium-graphite-carbure
WO2022093447A2 (fr) 2020-09-24 2022-05-05 Novelis Inc. Produits en alliage d'aluminium à gradient fonctionnel et leurs procédés de fabrication
CN115505779A (zh) * 2022-10-08 2022-12-23 秦皇岛峰越科技有限公司 原位生成铝基碳化钛复合材料的制备方法
CN117385236A (zh) * 2023-10-23 2024-01-12 哈尔滨工业大学 一种抗疲劳非连续层状结构B4C/Al纳米复合材料及其制备方法
CN119870459A (zh) * 2025-01-07 2025-04-25 广东省科学院新材料研究所 一种球形SiC/Al-Si复合粉末及其制备方法和应用

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4007062A (en) * 1972-06-09 1977-02-08 Societe Industrielle De Combustible Nucleaire Reinforced composite alloys, process and apparatus for the production thereof
RU2020042C1 (ru) * 1990-09-19 1994-09-30 Акционерное общество открытого типа "Всероссийский алюминиево-магниевый институт" Способ получения отливок из композиционного материала на металлической основе
US6843865B2 (en) * 1996-01-31 2005-01-18 Alcoa Inc. Aluminum alloy product refinement and applications of aluminum alloy product refinement

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018074179A1 (fr) * 2016-10-17 2018-04-26 株式会社ベイシティ Composite d'aluminium-graphite-carbure
JP2018065703A (ja) * 2016-10-17 2018-04-26 富士先端技術株式会社 アルミニウム−黒鉛−炭化物の複合体
CN109862976A (zh) * 2016-10-17 2019-06-07 海湾城市株式会社 铝-石墨-碳化物的复合体
WO2022093447A2 (fr) 2020-09-24 2022-05-05 Novelis Inc. Produits en alliage d'aluminium à gradient fonctionnel et leurs procédés de fabrication
CN115505779A (zh) * 2022-10-08 2022-12-23 秦皇岛峰越科技有限公司 原位生成铝基碳化钛复合材料的制备方法
CN117385236A (zh) * 2023-10-23 2024-01-12 哈尔滨工业大学 一种抗疲劳非连续层状结构B4C/Al纳米复合材料及其制备方法
CN119870459A (zh) * 2025-01-07 2025-04-25 广东省科学院新材料研究所 一种球形SiC/Al-Si复合粉末及其制备方法和应用

Also Published As

Publication number Publication date
WO2012164581A3 (fr) 2013-03-28

Similar Documents

Publication Publication Date Title
US4915908A (en) Metal-second phase composites by direct addition
EP2954083B1 (fr) Composite à matrice métallique et procédé de formage
EP0567284B1 (fr) Composite à matrice métallique à base d'aluminium
EP2531630B1 (fr) Matériaux à base de métal dur
CN102791893B (zh) 纳米颗粒增强铝基复合材料及其生产工艺
Almadhoni et al. Review of effective parameters of stir casting process on metallurgical properties of ceramics particulate Al composites
CN110423915B (zh) 一种铝基复合材料的制备方法
US20210254194A1 (en) Preparation method for magnesium matrix composite
WO2012164581A2 (fr) Procédé de production de composites à matrice métal-aluminium renforcés
US20210062315A1 (en) Preparation method of a lithium-containing magnesium/aluminum matrix composite
Gezer et al. Production of Al–Ti–C grain refiners with the addition of elemental carbon
Vivekananda et al. Combined effect of process parameters during aluminothermic reaction process on the microstructure and mechanical properties of in situ Al/TiB2 composite
Bahador et al. Microstructural and mechanical characterizations of stir cast aluminum 356–Nb2O5 composite
Khandelwal et al. Surface modified reinforcements on the structure properties of A356/SiC stir cast composite
JP3478930B2 (ja) 高剛性高靱性鋼およびその製造方法
CN112662909B (zh) 一种碳化物纳米颗粒改性的压铸铝合金及其制备方法
JP4220598B2 (ja) 鋳造用金属−セラミックス複合材料の製造方法
CN101148721B (zh) 一种铝基复合材料及其制备方法
Zulfia et al. Fabrication and characteristics of ADC-12 reinforced nano-SiC and nano-Al2O3 composites through stir casting route
Luts et al. Self-propagating high-temperature synthesis of (Al–2% Mn)–10% TiC and (Al–5% Cu–2% Mn)–10% TiC nanostructured composite alloys doped with manganese powder
Gupta et al. Development and characterization of in-situ aluminum–titanium carbide composites prepared by pneumatic powder injection route
US20250283187A1 (en) Additive for treating molten iron to produce cast iron with zero contraction and with lonsdaleite-type spheroidal graphite
AU2013203102B2 (en) Hard metal materials
Shakirin et al. A Short Review on Grain Refinement Techniques in Semisolid Metal Processing
CN115584420A (zh) 颗粒增强镁基复合材料及其加工方法

Legal Events

Date Code Title Description
NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 12793332

Country of ref document: EP

Kind code of ref document: A2