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WO2024157588A1 - Composite à matrice métallique à haute résistance et procédé de production d'un composite à matrice métallique à haute résistance - Google Patents

Composite à matrice métallique à haute résistance et procédé de production d'un composite à matrice métallique à haute résistance Download PDF

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Publication number
WO2024157588A1
WO2024157588A1 PCT/JP2023/042025 JP2023042025W WO2024157588A1 WO 2024157588 A1 WO2024157588 A1 WO 2024157588A1 JP 2023042025 W JP2023042025 W JP 2023042025W WO 2024157588 A1 WO2024157588 A1 WO 2024157588A1
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Prior art keywords
powder
aluminum alloy
aluminum
powders
metal
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PCT/JP2023/042025
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English (en)
Japanese (ja)
Inventor
睦夫 林
修平 勝亦
翔梧 落合
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Advanced Composite Corp
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Advanced Composite Corp
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Priority to CN202380043038.4A priority Critical patent/CN119301284A/zh
Priority to EP23918543.2A priority patent/EP4656750A1/fr
Publication of WO2024157588A1 publication Critical patent/WO2024157588A1/fr
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F3/26—Impregnating
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
    • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
    • C22C29/065—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on SiC
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/12—Metallic powder containing non-metallic particles
    • 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
    • C22C32/0063—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 based on SiC

Definitions

  • the present invention relates to a metal-based composite obtained by combining a ceramic powder and/or a metal powder as a fine powder that functions as a reinforcing material with a molten aluminum or aluminum alloy as a matrix material. More specifically, the present invention relates to a technology for providing a high-strength metal-based composite with high strength and excellent processability, which is realized by using a mixed powder that combines the fine powder with an aluminum powder or an aluminum alloy powder (hereinafter also referred to as "powder of aluminum alloy, etc.”) having a larger particle size than the fine powder, and a manufacturing method thereof.
  • MMCs materials in which ceramics are composited with aluminum or aluminum alloys
  • CFRP Carbon Fiber Reinforced Plastics
  • CMCs Ceramic Matrix Composites
  • aluminum alloys, etc. composite materials in which aluminum and other metal powders are composited
  • MMCs that combine the properties of two different inorganic materials and use aluminum or aluminum alloys (hereinafter referred to as aluminum alloys, etc.) as a matrix material are being developed as described below, and have also been put to practical use, partly because they can reduce the weight of the material.
  • aluminum alloys, etc. aluminum alloys
  • they are widely used in industry as machine parts and electronic substrates that have desired properties such as light weight, high strength, high rigidity, and high heat resistance, as semiconductor liquid crystal manufacturing equipment, robot arms, gas turbine materials, power devices, etc.
  • Patent Document 1 proposes a method of manufacturing an intermediate molded body (preform) by adding ceramic powder and an inorganic binder to it and hardening it, and then high-pressure press-infiltrating molten metal such as an aluminum alloy into the pores other than the powder to form a composite.
  • aluminum high-pressure impregnation method aluminum alloy-based composite materials (MMC) in which ceramic powder is uniformly distributed can be easily produced by forcibly impregnating a unique intermediate molded body (preform) with molten metal such as an aluminum alloy at high pressure.
  • MMC aluminum alloy-based composite materials
  • the above-mentioned manufacturing method can also be applied to aluminum alloy-based composite materials (MMC) that use a powder filler made of ceramic powder as the material to be composited.
  • Patent Document 2 proposes a method in which a unique intermediate molded body (preform) made by adding Mg powder to ceramic powder is placed in a nitrogen atmosphere, and aluminum alloy is infiltrated into it without pressure to form a composite.
  • the principle of this method is to improve the wettability of ceramics and Al alloys, etc. in an Mg and nitrogen atmosphere, and promote the so-called capillary phenomenon to infiltrate molten aluminum alloy, etc. into the voids of the preform.
  • the ceramic filling rate can be increased by increasing the ceramic filling rate and reducing the voids, and as a result, aluminum alloy-based composite materials (MMC) of ceramics and aluminum alloys, etc., with high physical properties such as Young's modulus, thermal conductivity, and thermal expansion coefficient can be manufactured.
  • MMC aluminum alloy-based composite materials
  • by using a preform, aluminum alloy, etc. can be infiltrated while maintaining the shape of the preform, and an MMC composite can be manufactured with a near-net shape close to the product shape.
  • Aluminum alloy matrix composites can also be manufactured by the following casting method other than the above manufacturing method.
  • ceramic powder such as silicon carbide or alumina is first added to a molten aluminum alloy or the like and stirred at high speed to produce a molten aluminum alloy or the like containing the ceramic powder, or a composite impregnated with aluminum alloy or the like in a mixed powder of ceramic powder and Mg is uniformly mixed and dissolved in a nitrogen atmosphere without pressure to produce a molten metal for casting.
  • the molten metal thus produced is then cast into a conventional mold such as a casting sand mold, metal die, or lost wax mold to produce a composite of ceramic and aluminum alloy.
  • MMC aluminum alloy-based composite materials
  • HIP Hot Isostatic Pressing
  • a manufacturing method that utilizes the HIP (Hot Isostatic Pressing) method described below.
  • HIP Hot Isostatic Pressing
  • ceramic powder is mechanically alloyed coated with aluminum alloy or the like to produce a powder compact, which is then sintered and then subjected to high-pressure isostatic pressing by HIP to produce a composite of ceramic powder and aluminum alloy or the like.
  • HIP Het Isostatic Pressing
  • a similar method is known in which a composite deposit is produced by spraying and depositing molten aluminum alloy or the like mixed with ceramic powder, and since this deposit contains pores, the pores are removed by HIP treatment to produce the composite.
  • MMCs aluminum alloy matrix composites
  • the volume percentage of the powder itself in the powder packing or preform is determined by the properties of the powder, and only those with a volume percentage of more than 50 volume percent could be produced.
  • molten metal such as aluminum alloy is impregnated into the gap pores of the powder packing or preform, so it is difficult to reduce the volume of metal powder or ceramic powder and increase the volume of aluminum alloy. For this reason, it was difficult to produce a composite with good processability and a large amount of aluminum alloy impregnation by the high-pressure infiltration method.
  • the method of impregnating molten metal such as aluminum alloy at high pressure could not produce a composite with a volume percentage of ceramic powder or metal powder of 50% or less and good processability.
  • metal powder or ceramic powder of about 10 ⁇ m or more is usually used as a reinforcing material to be compounded, the load on the processing tool is large, and there was a problem that the aluminum alloy matrix composite material (MMC) obtained by the high-pressure infiltration method described above was inferior in processability.
  • MMC aluminum alloy matrix composite material
  • the casting method described above also has the following problems.
  • the particle size of ceramic powders such as SiC powder used in casting methods must be large, at 15 ⁇ m or more, to maintain castability. For this reason, even though the SiC volume percentage is low at 30% or less, the workability is low, and the aluminum alloy-based composite material obtained can only be processed with diamond tools, resulting in a material with poor workability.
  • Another problem is that the molten metal is prone to entraining air during casting, making it difficult to obtain a composite material without defects.
  • the manufacturing method using the HIP method described above uses metal powder as the main metallic raw material, so the surface of the metal powder is easily oxidized during the manufacturing process, making it difficult to obtain sufficient strength for the composite, and the complex HIP process is required, which poses major practical issues in that it is expensive.
  • the object of the present invention is therefore to provide an aluminum alloy-based composite having high strength yet good workability, which could not be achieved with conventional manufacturing techniques, and which is useful in terms of industrial applicability, and is of high practical value, as well as a new technology for a method for manufacturing said composite.
  • the present invention which provides a high-strength metal matrix composite as follows:
  • the "average particle size” refers to the particle size (median size) at an integrated value of 50% in a particle size distribution determined by a laser diffraction/scattering method.
  • the high-strength metal-based composite are as follows.
  • the metal powder constituting the fine powder of the mixed powder is any one selected from the group consisting of silicon powder, iron powder, stainless steel powder, copper powder, and titanium powder
  • the ceramic powder is any one selected from the group consisting of alumina powder, silica powder, aluminum borate powder, silicon carbide powder, silicon nitride powder, and aluminum nitride powder
  • the blending ratio of the fine powder to the aluminum/aluminum alloy powder constituting the mixed powder is 10:90 to 90:10.
  • the present invention provides the following method for producing a high-strength metal matrix composite.
  • a porous packed body or molded body (preform) is obtained using a mixed powder obtained by adding one or more aluminum/aluminum alloy powders selected from the group consisting of aluminum powders and aluminum alloy powders having an average particle size of 10 ⁇ m or more and 300 ⁇ m or less to one or more fine powders selected from the group consisting of metal powders and ceramic powders having an average particle size of 0.3 ⁇ m or more and 8 ⁇ m or less, and then subjecting the resulting packed body or molded body (preform) to Molten aluminum or aluminum alloy is impregnated and filled at a high pressure of 20 MPa or more and 200 MPa or less to form a composite.
  • a method for producing a high-strength metal matrix composite comprising the steps of: obtaining a metal matrix composite having a filling rate of the fine powder of 10 volume % or more and 50 volume % or less, and a bending strength of 500 MPa or more and 800 MPa or less.
  • a mixed powder is obtained by adding one or more aluminum/aluminum alloy powders selected from the group consisting of aluminum powders and aluminum alloy powders having an average particle size of 10 ⁇ m to 300 ⁇ m to one or more fine powders selected from the group consisting of metal powders and ceramic powders having an average particle size of 0.3 ⁇ m to 8 ⁇ m, and further adding magnesium powder in a range of 0.5 parts by mass to 10 parts by mass to 100 parts by mass of the mixed powder to obtain a porous filled body or molded body (preform), and then subjecting the obtained filled body or molded body (preform) to The material is impregnated and filled with molten aluminum or aluminum alloy without pressure to form a composite.
  • a method for producing a high-strength metal matrix composite comprising the steps of: obtaining a metal matrix composite having a filling rate of the fine powder of 10 volume % or more and 50 volume % or less, and a bending strength of 500 MPa or more and 800 MPa or less.
  • a preferred embodiment of the method for producing a high-strength metal matrix composite according to the above item [4] or [5] is as follows.
  • [6] The method for producing a high-strength metal matrix composite according to the above [4] or [5], wherein the metal powder constituting the fine powder of the mixed powder is any one selected from the group consisting of silicon powder, iron powder, stainless steel powder, copper powder and titanium powder, the ceramic powder is any one selected from the group consisting of alumina powder, silica powder, aluminum borate powder, silicon carbide powder, silicon nitride powder and aluminum nitride powder, and further, the blending ratio of the fine powder and the aluminum/aluminum alloy powder constituting the mixed powder is 10:90 to 90:10.
  • the present invention makes it possible to provide a metal matrix composite product of high practical value that could not be realized by conventional manufacturing techniques, in which the volume percentage of reinforcing material made of metal powder and/or ceramic powder is 50 volume % or less, the bending strength is high at 500 MPa or more, and the product also exhibits good processability. Furthermore, a method for manufacturing a metal matrix composite that can produce the above-mentioned metal matrix composite with excellent properties in a simple manner and that is extremely useful in terms of practicality with reduced manufacturing costs is provided.
  • FIG. 2 is a schematic diagram for illustrating a method for producing a high-strength metal matrix composite according to the present invention without applying pressure.
  • a method for manufacturing a composite of a reinforcing material made of a metal powder and/or ceramic powder and a matrix material such as an aluminum alloy has been adopted in which a molten metal such as a molten aluminum alloy is impregnated into a packed body or molded body (preform) of the reinforcing material by high-pressure impregnation or non-pressure infiltration.
  • a molded body has been used as an example, but unlike molded bodies (preforms), filled bodies made by packing raw material powder into a metal box or the like and vibrating and molding them, generally have a volume ratio of 50% or more, and so have the same problem of poor workability as composites made with molded bodies (preforms).
  • filled bodies or molded bodies (preforms) made of metal powder or ceramic powder will also be referred to as "preforms, etc.”.
  • the present inventors have conducted intensive research into the difficulty of producing preforms and the like made of metal powders or ceramic powders with a filling rate of 50 volume % or less in the above-mentioned conventional technology, and have found that the problem can be solved by configuring as follows. Specifically, the above problem can be solved by configuring a preform and the like made of metal powders or ceramic powders that are impregnated and filled with molten metal such as an aluminum alloy, which constitutes a metal-based composite, as follows. First, for the above purpose, it is effective to use fine materials with an average particle size of 0.3 ⁇ m or more and 8 ⁇ m or less for the metal powders or ceramic powders used to form the preforms and the like.
  • the above problem can be solved by using a mixed powder in which the above-mentioned fine metal powders and/or ceramic powders are mixed with powders of aluminum alloys or the like with an average particle size of 10 ⁇ m or more and 300 ⁇ m or less, and producing a preform and the like made of the mixed powder.
  • the "average particle size" defined in the present invention is the particle size at 50% of the cumulative value in the particle size distribution obtained by the laser diffraction/scattering method, that is, the so-called 50% median diameter.
  • the present invention was arrived at by discovering that a preform or the like is made from a unique mixed material in which the above-mentioned fine metal powder and/or ceramic powder (hereinafter also referred to as "fine powder of metal powder, etc.") is further mixed with powder of aluminum alloy, etc., having a particle size larger than these powders, and impregnating the obtained preform or the like with molten aluminum alloy, etc., thereby realizing an amount of aluminum alloy, etc., constituting a metal-based composite of more than 50 volume %.
  • fine powder of metal powder, etc. the above-mentioned fine metal powder and/or ceramic powder
  • the amount of aluminum alloy, etc., constituting the metal-based composite of the present invention is the sum of the amount attributable to the powder of aluminum alloy, etc., added in advance to the forming material of the preform, etc., and the amount of molten aluminum alloy, etc., melted and impregnated.
  • the metal-based composite of the present invention has a new configuration that has not been seen before, in which the aluminum alloy, etc., constituting the metal-based composite is more than 50 volume %.
  • the high-strength metal-based composite of the present invention is a composite obtained by impregnating and filling a porous preform or the like made of a mixed powder to which "powder of aluminum alloy or the like" has been added with "molten aluminum alloy or the like," and therefore the form may change due to a part or all of the "powder of aluminum alloy or the like" melting. For this reason, it can be said that the high-strength metal-based composite of the present invention has a part that cannot be directly specified by its structure or characteristics as an invention of a product.
  • the degree of melting and the state of melting of each of the metal powders forming the porous preform or the like which are caused by the impregnation and filling of the complex pores of the porous preform or the like constituting the high-strength metal-based composite of the present invention with molten aluminum alloy or the like, naturally vary, and it is impossible or almost impractical to directly specify the individually different microscopic melting states that occur in the metal powders forming such porous preform or the like by the structure or characteristics of the product.
  • the high-strength metal-based composite of the present invention which is an invention of a product, is specified as a manufacturing method for a composite, which is "a composite in which molten aluminum or an aluminum alloy is impregnated and filled into a porous filled body or molded body (preform) made of a mixed powder to which aluminum and aluminum alloy powders have been added.”
  • the manufacturing method of the metal matrix composite of the present invention differs from the conventional method of manufacturing preforms consisting only of metal powder or ceramic powder by adding powder of an aluminum alloy or the like that is larger than the fine metal powder or ceramic powder to the raw material to manufacture a porous preform, and by impregnating the voids in the preform with molten aluminum alloy, the volume percentage of the aluminum alloy can be made to exceed 50%, making it possible to manufacture a metal matrix composite material that is highly workable and has high strength.
  • the metal matrix composite of the present invention having the above-mentioned composition is a high-strength metal matrix composite with a bending strength of 500 MPa or more, for example, 550 MPa or more, or even 700 MPa or more. Even more surprisingly, it has been confirmed that the metal matrix composite of the present invention has good processability despite having the above-mentioned high bending strength, and can be processed with carbide tools, which was not possible with conventional composites.
  • the above bending strength is a value measured in accordance with JIS R1601. Specifically, the value is measured by preparing a test piece of the specified dimensions in accordance with JIS R1601 and performing a three-point bending test. The value is also measured at 25°C (room temperature).
  • the manufacturing method of the metal matrix composite of the present invention allows the ratio of fine powder such as metal powder and powder such as aluminum alloy used in combination as the forming material of the preform, etc. to be freely changed, so that the ratio of fine powder such as metal powder and aluminum alloy, etc. in the final metal matrix composite can be freely designed. Furthermore, the manufacturing method of the present invention allows the material and particle size of fine powder such as metal powder used as the forming material of the preform, etc., to be freely designed within the range specified in the present invention, so that a metal matrix composite with desired characteristics can be obtained. For example, according to the investigations of the present inventors, the smaller the average particle size of fine powder such as metal powder, the greater the strength of the final metal matrix composite.
  • the metal matrix composite and the manufacturing method of the metal matrix composite of the present invention will be described in detail below. First, the manufacturing method of the metal matrix composite of the present invention will be described.
  • the manufacturing method of the present invention is a completely new manufacturing method that makes it possible to increase the volume percentage of the aluminum alloy or the like in the finally obtained metal matrix composite to more than 50% by adding a powder of an aluminum alloy or the like in advance to a forming material of a preform, etc. That is, in the present invention, the effective influence on the physical property values of the finally obtained metal matrix composite due to the average particle size of fine powder such as metal powder used as a raw material can be realized by obtaining a metal matrix composite by the following procedure, unlike the conventional method of manufacturing a metal matrix composite using a preform or the like made only of a metal powder or ceramic powder.
  • Fine metal powder or ceramic powder In the manufacturing method of the metal matrix composite of the present invention, one or more fine powders selected from the group consisting of metal powders and ceramic powders having an average particle size of 0.3 ⁇ m or more and 8 ⁇ m or less are used as a material for forming a porous filler or a molded body (preform).
  • the metal powder is not particularly limited, and examples thereof include at least one selected from the group consisting of silicon powder, iron powder, stainless steel powder, copper powder, titanium powder, etc.
  • examples of the ceramic powder include any one selected from the group consisting of alumina powder, silica powder, aluminum borate powder, silicon carbide powder, silicon nitride, aluminum nitride powder, etc.
  • a fine metal powder or ceramic powder within the range of the average particle size specified in the present invention.
  • a powder having an average particle size in the range of 0.3 ⁇ m or more and 8 ⁇ m or less is used.
  • the reason for making the particle size of the metal powder or ceramic powder 8 ⁇ m or less is that if a larger material is used, the interface between the metal powder or ceramic powder and the aluminum alloy, etc., becomes too large after impregnation with molten aluminum alloy, etc., resulting in a decrease in the strength of the final product, the metal matrix composite.
  • the reason for making the particle size 0.3 ⁇ m or more is that the strength of the obtained metal matrix composite does not change much even if the particle size is made smaller than this, and if the powder is too fine, it is likely to aggregate, which may impair the uniform dispersion of the reinforcing material in the preform, etc., formed from the mixed powder.
  • the method for producing a metal matrix composite of the present invention is characterized in that a mixed powder in which an aluminum powder or an aluminum alloy powder having an average particle size of 10 ⁇ m to 300 ⁇ m is added to a fine powder such as the metal powder described above is used to form a porous filled body or a molded body (preform).
  • a mixed powder in which an aluminum powder or an aluminum alloy powder having an average particle size of 10 ⁇ m to 300 ⁇ m is added to a fine powder such as the metal powder described above is used to form a porous filled body or a molded body (preform).
  • the total amount of the aluminum alloy, etc. of the metal matrix composite, which is the final product can be controlled by combining it with the molten aluminum alloy, etc., impregnated into the voids of the porous preform, etc.
  • the desired physical property value can be obtained by changing the ratio of one or more fine powders selected from the group consisting of metal powders and ceramic powders constituting the metal matrix composite, which is the final product, and the aluminum alloy, etc.
  • the powder of aluminum alloy or the like used to form the porous preform or the like that characterizes the present invention and that constitutes the metal matrix composite of the present invention has an average particle size of 10 ⁇ m or more and 300 ⁇ m or less. If it is less than 10 ⁇ m, it will be prone to aggregation and will be difficult to mix uniformly with the fine powder of metal powder or the like used in combination. On the other hand, if it exceeds 300 ⁇ m, the powder of aluminum alloy or the like is too large, and the uniformity with the fine powder of metal powder or the like used in combination with the mixed powder will be lost, and the strength of the preform or the like may decrease.
  • the powder of aluminum alloy or the like having the specific particle size described above it is possible to control the volume ratio of the metal powder and/or ceramic powder that functions as a reinforcing material that constitutes the final product, the metal matrix composite.
  • the powder volume percentage of a molded body (preform) made from a mixture of ceramic powder and/or metal powder and aluminum alloy powder, etc., used in the present invention varies depending on the particle size and mixing ratio of the powder used, but is generally 50 to 60 volume percent overall, with voids at 40 to 60 volume percent. Therefore, the volume percentage of metal powder, etc. can be controlled by the molten aluminum alloy, etc., impregnated into the voids of a porous preform, etc., and the aluminum alloy powder, etc., added to the molded body, etc., which characterizes the present invention. In other words, if the amount of aluminum alloy powder, etc.
  • the amount of addition is not particularly limited. Roughly speaking, the total volume percentage of the metal powder and/or ceramic powder used and the aluminum alloy powder, etc., added is 50-70%, so the total amount of aluminum alloy, etc. can be controlled by changing the ratio of aluminum alloy powder, etc., added as necessary and taking into account the amount of molten aluminum alloy, etc., that is impregnated into the porous voids.
  • Fine metal powders constituting the metal-based composite of the present invention include, for example, silicon powder, iron powder, stainless steel powder, copper powder, and titanium powder.
  • fine ceramic powders constituting the metal-based composite of the present invention include, for example, alumina powder, silica powder, aluminum borate powder, silicon carbide powder, silicon nitride powder, and aluminum nitride.
  • one or more types of powders selected from the metal powders and ceramic powders listed above can be used.
  • the metal matrix composite of the present invention is preferably a porous preform or the like made of a mixed powder of the above-mentioned metal powder or ceramic powder and the above-mentioned aluminum alloy powder, etc., impregnated and filled with molten aluminum alloy under pressure or without pressure, and the mixed powder is mixed in the following ratio. That is, the mixing ratio of the fine powder of metal powder, etc. and the powder of aluminum alloy, etc. in the mixed powder is preferably 10:90 to 90:10. If the ratio of the fine powder of metal powder, etc. to the powder of aluminum alloy, etc. is less than 10:90, the ratio of the fine powder of metal powder, etc.
  • the ratio of the fine powder of metal powder, etc. to the powder of aluminum alloy, etc. exceeds 90:10, the ratio of the fine powder of metal powder, etc. that constitutes the metal matrix composite becomes too large, which is not preferable because the processability of the final metal matrix composite becomes poor.
  • fine powders such as metal powders with a particle size of 0.3 ⁇ m or more and 8 ⁇ m or less are used to improve the strength of the composite.
  • a mixed powder is used to which relatively large powders such as aluminum alloys with a particle size of 10 ⁇ m to 300 ⁇ m are added. This configuration has the secondary effect of suppressing the agglomeration of the reinforcing metal powder and/or ceramic powder, and ultimately realizes a good metal matrix composite made of uniformly dispersed metal powder and/or ceramic powder and aluminum alloys.
  • the pores are enlarged by adding a powder of an aluminum alloy or the like having an average particle size of 10 ⁇ m or more and 300 ⁇ m or less to prepare a porous preform, etc., so that even when the above-mentioned non-pressurized infiltration method is applied, the molten aluminum alloy or the like can be easily impregnated.
  • the mixed powder consisting of aluminum alloy powder or the like having an average particle size of 10 ⁇ m to 300 ⁇ m added to the fine powder such as metal powder described above can be easily obtained by uniformly mixing using a conventional mixer.
  • a porous preform or the like is obtained using the prepared specific mixed powder. Since the use of the fine powder as described above results in low filling property, for example, when obtaining a molded body (preform) by a method such as press molding, CIP, and sedimentation method, a binder may be used in combination with the mixed powder as necessary.
  • inorganic binders such as ethyl silicate, silicone, water glass, etc., alumina-based inorganic binders such as aluminum alkoxide, and organic inorganic binders can be suitably used.
  • the amount of binder used is preferably added to the mixed powder within the range of 0.5% to 10% by mass.
  • organic binders such as PVA and PVB may be added.
  • Preforms, etc. prepared using the mixed powder having the above-mentioned composition may be fired at a temperature of, for example, about 200°C to 700°C so as to facilitate subsequent operations.
  • the firing temperature is desirably 700°C or less to prevent oxidation.
  • Mg powder is added to the mixed powder for impregnation with molten metal such as an aluminum alloy using a non-pressure infiltration method, the firing temperature is desirably 500°C or less to prevent oxidation and deterioration of Mg during firing.
  • High-pressure impregnation of molten metal such as aluminum alloy In the manufacturing method of the high-strength metal-based composite of the present invention, whether high-pressure impregnation or non-pressure infiltration is used, the molten metal such as aluminum alloy can be impregnated and filled in a good state into the porous preform obtained as described above to obtain a metal-based composite.
  • the molten metal such as aluminum alloy at about 700 ° C to 800 ° C is impregnated at a pressure of, for example, about 20 MPa to 200 MPa.
  • a pressure of less than 20 MPa is not preferable because the pressure is too low and there is a concern that the material may not be sufficiently impregnated.
  • a pressure of 200 MPa or less is sufficient in consideration of the energy cost and the life of the pressure vessel.
  • Example 1 1200g of SiC powder with an average particle size of 5 ⁇ m and 800g of A6061-based aluminum alloy powder with an average particle size of 25 ⁇ m were placed in a plastic pot, and mixed for 2 hours with alumina balls. 100g of ethyl silicate hydrolysis liquid was added to the pot so that 40g of SiO2 was included, and the mixture was mixed for another 30 minutes. The mixture was placed in a mold with an inner dimension of 200mm x 200mm and press molded at a pressure of 45t. The mixture was further fired at 500°C for 2 hours to produce a molded body (preform) containing SiC powder and aluminum alloy powder. The obtained molded body was placed in a metal mold, and molten A6061-based aluminum alloy melted at 750°C was poured in, and the preform was impregnated at a pressure of 100MPa to cast a composite.
  • preform molded body
  • the composite obtained by the above method was an aluminum alloy-based composite with 30 volume % SiC fine powder and 70 volume % remainder.
  • Test pieces for measurement of the specified dimensions were cut out from the obtained composite, and the bending strength of the composite was measured at room temperature in accordance with JIS R1601 using the test pieces. Measurements were also performed for other examples in the same manner. The measurement result was 740 MPa, which was quite high strength. It was also confirmed that the obtained composite had good workability and could be machined with carbide tools.
  • Example 2 1200g of SiC powder having an average particle size of 5 ⁇ m, 800g of A6061-based aluminum powder having an average particle size of 25 ⁇ m, and 40g of Mg powder having an average particle size of 50 ⁇ m were added to the mixture and mixed for 2 hours in the same manner as in Example 1.
  • a silicone resin product name: KR-220L, manufactured by Shin-Etsu Chemical Co., Ltd.
  • isopropyl alcohol was added in an amount equivalent to 30 g% of SiO 2 , and mixed for 30 minutes. This was press-molded and fired in the same manner as in Example 1 to produce a molded body (preform).
  • a preform having a size of 100 mm x 100 mm x 30 mm was cut out from this molded body. Then, as shown in FIG. 1, the preform 1 was impregnated and filled with molten A6061-based aluminum 2 without pressure to form a composite aluminum alloy-based composite. Specifically, as shown in Fig. 1, a preform 1 and an A6061-based aluminum 2 were placed in a carbon container 4, and the container was placed in a furnace in a nitrogen atmosphere, and the temperature was raised at a rate of 100°C/hour, and then the container was held at 780°C for 2 hours, after which the composite was taken out. 3 in Fig. 1 indicates a penetration path of the same material as the preform 1. The taken-out composite was processed for measurement, and the physical properties were measured in the same manner as in Example 1.
  • Example 2 The composite obtained in Example 2 was an aluminum alloy-based composite, similar to Example 1, with 30 volume % SiC micropowder and 70 volume % aluminum alloy.
  • the bending strength measured in the same manner as in Example 1 was 650 MPa, making it a high-strength composite. Furthermore, the obtained composite had good workability and could be machined with carbide tools.
  • Example 3 800 g of SiC powder having an average particle size of 3 ⁇ m and 1200 g of A1050-series aluminum alloy powder having an average particle size of 30 ⁇ m were mixed with 100 g of ethyl silicate hydrolyzed liquid so as to contain 40 g, calculated as SiO 2 , and a preform containing the SiC powder and the aluminum alloy powder was produced in the same manner as in Example 1. The obtained preform was then impregnated with molten A1050-series aluminum alloy at high pressure in the same manner as in Example 1 to obtain the composite of this example.
  • the composite obtained above When the physical properties of the composite obtained above were measured, it was found to be an aluminum alloy-based composite with 20 volume % SiC fine powder and 80 volume % remainder.
  • the bending strength measured in the same manner as in Example 1 was 700 MPa, making it a fairly high-strength composite. Furthermore, the composite obtained had good workability and could be machined with carbide tools.
  • Example 4 1200 g of metal silicon powder having an average particle size of 5 ⁇ m was mixed with 200 g of A6061-based aluminum alloy powder having an average particle size of 25 ⁇ m in the same manner as in Example 1, and 100 g of ethyl silicate hydrolyzed liquid was added thereto so that 40 g was contained in terms of SiO 2 , and further mixed for 30 minutes. Using the obtained mixture, a molded body (preform) was produced in the same manner as in Example 1. Then, using the obtained preform, a molten A6061-based aluminum alloy was high-pressure impregnated in the same manner as in Example 1 to obtain a composite.
  • the physical properties of the composite obtained above were measured, it was found to be an aluminum alloy-based composite containing 25 volume % silicon powder and 75 volume % aluminum alloy powder.
  • the bending strength, measured using the same method as in Example 1, was 580 MPa, which was a high strength. Furthermore, the obtained composite had good processability and could be processed with carbide tools.
  • Comparative Example 1 In the same manner as in Example 1, 100 g of ethyl silicate hydrolyzate liquid was added to 2000 g of SiC powder having an average particle size of 14 ⁇ m larger than that specified in the present invention so that 40 g of SiO 2 was contained, and a preform was produced from the mixed material. The obtained preform was then impregnated with molten aluminum alloy similar to that used in Example 1 to produce a composite. Comparative Example 1 differs from the present invention in that the average particle size of the SiC powder is larger than that specified in the present invention and that aluminum powder or the like is not used in the raw material mixture.
  • the composite obtained was 55 volume % SiC and 45 volume % aluminum alloy.
  • the bending strength measured in the same manner as in Example 1 was 320 MPa, which is comparable to that of a general aluminum alloy, and it was confirmed that this was not a high-strength composite.
  • the composite obtained had poor workability and could not be machined with carbide tools, so it was machined with a diamond end mill.
  • Example 2 The composite of this example was produced by the same operation as in Example 1, except that a mixture of 1200 g of SiC powder having an average particle size of 14 ⁇ m, which is larger than that specified in the present invention, and 800 g of 6061-series aluminum alloy powder having an average particle size of 25 ⁇ m was used.
  • the physical properties of the obtained composite were 28 vol% SiC and 72 vol% aluminum.
  • the bending strength measured by the same method as in Example 1 was 330 MPa, which was comparable to that of a general aluminum alloy and was not a high-strength composite.
  • the obtained composite had poor processability and could not be processed with a cemented carbide tool, so it was necessary to process it with a diamond end mill.
  • Example 3 A molded body (preform) was produced in the same manner as in Example 1, except that a mixture of 1200 g of SiC powder having an average particle size of 22 ⁇ m, which is larger than that specified in the present invention, and 800 g of A6061-series aluminum alloy powder having an average particle size of 25 ⁇ m was used. Then, in the same manner as in Example 1, the preform obtained above was impregnated with molten A6061-series aluminum alloy to obtain the composite of this example.
  • the obtained composite When the physical properties of the obtained composite were measured, it was found to be an aluminum-based composite with 31 volume % SiC powder and 69 volume % remainder.
  • the bending strength measured in the same manner as in Example 1 was 410 MPa, which was lower than the composites of Examples 1 to 4 and had a bending strength comparable to that of ordinary aluminum, and was not a high-strength composite.
  • the obtained composite had poor workability and could only be processed with diamond tools.
  • a molded body (preform) was produced in the same manner as in Example 1 using 1,200 g of metal silicon powder having an average particle size of 45 ⁇ m, which is larger than that specified in the present invention, and 800 g of A6061-series aluminum alloy powder having an average particle size of 25 ⁇ m. The preform was then impregnated with the A6061-series aluminum alloy in the same manner as in Example 1 to obtain a composite.
  • Example 2 When the physical properties of the obtained composite were measured, it was found to be a composite containing 29 volume % 45 ⁇ m metal silicon powder and 71 volume % A6061 aluminum alloy. In addition, the bending strength measured in the same manner as in Example 1 was 270 MPa, making it a composite with low strength.
  • Example 5 A commercially available ingot of a composite material of 30% by volume of SiC powder/70% by volume of aluminum manufactured by Duralcan, USA was used, and the ingot was melted at 730°C and cast into a sand mold to produce a composite material of 200 mm x 200 mm x 50 mm (thickness). From this, a test piece for measurement was cut out in the same manner as in Example 1, and the bending strength was measured in the same manner. As a result, the composite material obtained above had a low bending strength of 380 MPa, and was also poor in workability, and could only be processed with a diamond tool.
  • Table 1 shows the preparation conditions of the composites of the examples and comparative examples, and the evaluation results of each of the composites obtained.
  • the evaluation of the processability was evaluated as "good” for composites that could be processed with a cemented carbide tool, and “poor” for composites that could not be processed with a cemented carbide tool and could only be processed with a diamond tool.
  • Comparative Example 5 a commercially available composite material (commercial product) of SiC powder and aluminum metal was used.
  • Example 2 the molten aluminum alloy was impregnated into the preform without pressure.
  • the molten aluminum alloy was impregnated and filled into the preform at a high pressure of 100 MPa.
  • Preform 2 Aluminum alloy, etc. 3: Infiltration channel made of the same material as the preform 4: Carbon container

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Abstract

L'invention concerne un composite à matrice d'alliage d'aluminium qui ne peut pas être obtenu avec des techniques de fabrication classiques, qui présente une bonne aptitude au façonnage tout en présentant une résistance élevée, et qui, en permettant une limitation des coûts de fabrication, a une valeur d'utilité économique élevée. L'invention concerne également un procédé de production du composite.　Plus particulièrement, l'invention concerne : un composite à matrice métallique à haute résistance qui est un composite obtenu par imprégnation ou chargement d'un aluminium fondu ou d'un alliage d'aluminium fondu dans une charge poreuse ou un produit moulé poreux (préforme) consistant en une poudre mixte dans laquelle au moins une poudre d'aluminium ou d'alliage d'aluminium choisie dans le groupe constitué des poudres d'aluminium et des poudres d'alliage d'aluminium ayant un diamètre de particule moyen de 10 µm à 300 µm, est ajoutée à au moins une poudre fine choisie dans le groupe constitué de poudres métalliques et de poudres céramiques ayant un diamètre de particule moyen de 0,3 µm à 8 µm, le taux de chargement de ladite poudre fine étant de 10 à 50 % en volume et la résistance à la flexion de ladite poudre fine étant de 500 à 800 MPa ; et un procédé de production du composite à matrice métallique.
PCT/JP2023/042025 2023-01-26 2023-11-22 Composite à matrice métallique à haute résistance et procédé de production d'un composite à matrice métallique à haute résistance Ceased WO2024157588A1 (fr)

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CN202380043038.4A CN119301284A (zh) 2023-01-26 2023-11-22 高强度金属基复合体及高强度金属基复合体的制造方法
EP23918543.2A EP4656750A1 (fr) 2023-01-26 2023-11-22 Composite à matrice métallique à haute résistance et procédé de production d'un composite à matrice métallique à haute résistance

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JPH04214825A (ja) * 1990-04-12 1992-08-05 Toyota Motor Corp 金属間化合物ＴｉＡｌ３　及びＴｉＡｌ３　を含む複合材料の製造方法
JPH11106848A (ja) * 1997-10-06 1999-04-20 Mitsubishi Alum Co Ltd セラミックス粉末高含有Ａｌ合金基複合材料の製造方法
JP2010099686A (ja) * 2008-10-23 2010-05-06 Denki Kagaku Kogyo Kk アルミニウム−炭化珪素質複合体及びその製造方法
JP2010258458A (ja) * 2010-04-26 2010-11-11 Dowa Holdings Co Ltd セラミックス絶縁基板一体型金属−セラミックス複合体放熱板及びその製造方法
JP2017075357A (ja) * 2015-10-14 2017-04-20 国立大学法人広島大学 予備成形体およびそれを用いた金属基複合材料ならびにその製造方法
JP6837685B2 (ja) 2019-06-04 2021-03-03 アドバンスコンポジット株式会社 アルミニウム合金基複合材料の製造方法
JP6984926B1 (ja) 2021-04-19 2021-12-22 アドバンスコンポジット株式会社 金属基複合材料の製造方法及びプリフォームの作製方法

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JPH03285756A (ja) * 1990-03-30 1991-12-16 Toyota Motor Corp 金属基複合材料の製造方法
JPH04214825A (ja) * 1990-04-12 1992-08-05 Toyota Motor Corp 金属間化合物ＴｉＡｌ３　及びＴｉＡｌ３　を含む複合材料の製造方法
JPH11106848A (ja) * 1997-10-06 1999-04-20 Mitsubishi Alum Co Ltd セラミックス粉末高含有Ａｌ合金基複合材料の製造方法
JP2010099686A (ja) * 2008-10-23 2010-05-06 Denki Kagaku Kogyo Kk アルミニウム−炭化珪素質複合体及びその製造方法
JP2010258458A (ja) * 2010-04-26 2010-11-11 Dowa Holdings Co Ltd セラミックス絶縁基板一体型金属−セラミックス複合体放熱板及びその製造方法
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JP6837685B2 (ja) 2019-06-04 2021-03-03 アドバンスコンポジット株式会社 アルミニウム合金基複合材料の製造方法
JP6984926B1 (ja) 2021-04-19 2021-12-22 アドバンスコンポジット株式会社 金属基複合材料の製造方法及びプリフォームの作製方法

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See also references of EP4656750A1

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