WO2013041305A1 - Method for producing components from mmcs (metal matrix composites) using overspray powder - Google Patents

Method for producing components from mmcs (metal matrix composites) using overspray powder Download PDF

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Publication number
WO2013041305A1
WO2013041305A1 PCT/EP2012/065885 EP2012065885W WO2013041305A1 WO 2013041305 A1 WO2013041305 A1 WO 2013041305A1 EP 2012065885 W EP2012065885 W EP 2012065885W WO 2013041305 A1 WO2013041305 A1 WO 2013041305A1
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WO
WIPO (PCT)
Prior art keywords
mmc
particles
metal
produced
mmcs
Prior art date
Application number
PCT/EP2012/065885
Other languages
German (de)
French (fr)
Inventor
Thomas Dickmann
Bernd Commandeur
Dirk Krogmann
Gero Sinha
Ralf PELMER
Claudia NAGEL
Andreas Storz
Holger Weiss
Original Assignee
Peak-Werkstoff Gmbh
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 Peak-Werkstoff Gmbh filed Critical Peak-Werkstoff Gmbh
Priority to KR1020147009366A priority Critical patent/KR20140064940A/en
Priority to US14/346,487 priority patent/US20150217373A1/en
Priority to PCT/EP2012/068801 priority patent/WO2013041729A1/en
Priority to EP12761747.0A priority patent/EP2758195A1/en
Publication of WO2013041305A1 publication Critical patent/WO2013041305A1/en

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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
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • 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
    • B22F3/02—Compacting only
    • 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
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • 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
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • 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
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • 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
    • C22C1/10—Alloys containing non-metals
    • 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
    • C22C1/1042—Alloys containing non-metals starting from a melt by atomising
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
    • C22C49/14—Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • F16D2200/0026—Non-ferro
    • F16D2200/003—Light metals, e.g. aluminium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0082—Production methods therefor

Abstract

The invention relates to a method for producing components using an overspray with integrated hard materials, in particular from MMCs (metal matrix composites), wherein MMC particles are subsequently added to the molten and atomised metal, in particular aluminium. As a result of subsequent atomisation, metal (in particular Al) MMC agglomerates are formed in which the MMC particles are integrated firmly and homogeneously into the globular powder particles that have been formed. The powder particles are then compressed and compacted in order to produce a component by way of an SPS method, in particular with high speed. The method allows heavy-duty components, in particular brake disks, to be produced.

Description

Verfahren zur Herstellung von Bauteilen aus MMC's (Metallmatrix - Method for producing components from MMCs (metal matrix -
Verbundwerkstoffen) mit Overspraypulver Composites) with overspray powder
Die Erfindung betrifft ein Verfahren zur Hersteilung von Bauteilen unter Verwendung eines Oversprays mit integrierten Hartstoffen, insbesondere aus MMC's (Metallmatrix - Verbundwerkstoffen) und ein nach dem Verfahren hergestelltes Bauteil. The invention relates to a method for producing components using an overspray with integrated hard materials, in particular from MMCs (metal matrix composite materials) and a component produced by the method.
Es ist bekannt, Bauteile aus Metallen wie Aluminium (AI) durch Sprühkompaktieren herzustellen. Beim Sprühkompaktieren werden Schmelzen in einer Inertgasatrnosphäre (z.B. Stickstoff) verdüst und auf ein Target gesputtert. Vorteile dieses Verfahrens sind die extrem hohen Abkühlraten und die Möglichkeit auch hypereutektische Legierungen herzustellen. Derartige Verfahren sind beispielweise in der EP 0198613, der EP 0200349, der EP 0574458 und der EP 0517882 beschrieben. It is known to produce components from metals such as aluminum (AI) by spray compacting. In spray compacting, melts are atomized in an inert gas atmosphere (e.g., nitrogen) and sputtered onto a target. Advantages of this process are the extremely high cooling rates and the possibility to produce hypereutectic alloys. Such methods are described, for example, in EP 0198613, EP 0200349, EP 0574458 and EP 0517882.
Bei diesen Verfahren ist es ebenso bekannt, zur Verstärkung keramische Partikel wie Siliziumkarbid (SiC) zuzufügen, um so ein Bauteil aus MMC zu fertigen. Dabei werden in bereitgestelltes Metallpulver MMC-Partikel eingemischt. In dem damit erzeugten Gemisch liegen die Partikel der Komponenten (z. B. SiC und AI) einzeln vor. Alternativ werden die MMC-Partikel erst während des Gießens des Gußkörpers in die flüssige AI- Schmelze eingebracht In these methods, it is also known to add ceramic particles such as silicon carbide (SiC) for reinforcement so as to manufacture a component of MMC. In this case, MMC particles are mixed into provided metal powder. In the mixture thus produced, the particles of the components (eg SiC and Al) are present individually. Alternatively, the MMC particles are introduced only during the casting of the casting in the liquid Al melt
Beim ebenfalls bekannten SPS (Spark-Plasma-Sintern)-Verfahren werden Pulver mit hoher Geschwindigkeit verdichtet, wodurch sich eine für den Anwendungszweck optimierte Packungsdichte der Partikel im erzeugten Werkstück oder Halbzeug erzeugen lässt. Auf einen weiteren nachfolgenden Konsolidierungsprozeß kann hierbei verzichtet werden. In the likewise known SPS (Spark Plasma Sintering) process, powders are compacted at high speed, whereby a packing density of the particles optimized in the intended use or semi-finished product can be produced for the intended purpose. In this case, a further subsequent consolidation process can be dispensed with.
Nachteilig beim Stand der Technik ist einerseits die nicht vollständige Verbindung zwischen MMC und AI, andererseits die nicht gewährleistete vollständige Homogenität des Gemisches. Beides wirkt sich nachteilig auf die mechanische Beanspruchbarkeit des mit dem Gemisch erzeugten Gußbauteiles, beispielweise einer Bremsscheibe, aus. Der Erfindung liegt daher die Aufgabe zu Grunde, ein Verfahren bereit zu stellen, mit dem ein Bauteil hergestellt wird, bei dem die MMC-Partikel fest und homogen in den erzeugten globularen Pulverpartikeln gebunden sind A disadvantage of the prior art, on the one hand, the incomplete connection between MMC and AI, on the other hand, the not guaranteed complete homogeneity of the mixture. Both have a disadvantageous effect on the mechanical strength of the cast component produced with the mixture, for example a brake disk. The invention is therefore based on the object to provide a method by which a component is produced in which the MMC particles are firmly and homogeneously bound in the generated globular powder particles
Diese Aufgabe wird nach der Erfindung dadurch gelöst, dass dem geschmolzenen und verdüsten Metall, insbesondere Aluminium, anschließend MMC - Partikel beigegeben werden. Durch eine nachfolgende Verdüsung werden Metall- (insbesondere AI-) MMC- Agglomerate erzeugt, in welchen die MMC-Partikel fest und homogen in den erzeugten globularen Pulverpartikeln gebunden sind. Danach werden die Pulverpartikei zur Erzeugung eines Bauteils mittels eines SPS - Verfahrens verdichtet und kompaktiert, insbesondere mit hoher Geschwindigkeit. This object is achieved according to the invention in that the molten and atomized metal, in particular aluminum, then MMC - particles are added. Subsequent atomization produces metal (in particular Al) MMC agglomerates in which the MMC particles are bound firmly and homogeneously in the globular powder particles produced. The powder particles are then compacted and compacted to produce a component by means of a PLC process, in particular at high speed.
Dadurch bedingt ist ebenfalls in dem daraus erzeugten Bauteil die MMC-Verteilung sehr homogen, was sich sehr positiv im Wesentlichen auf die mechanischen Eigenschaften dieses Bauteiles auswirkt. As a result, the MMC distribution is also very homogeneous in the component produced therefrom, which has a very positive effect essentially on the mechanical properties of this component.
Dies wird erfindungsgemäß durch den dem Sprühen nachfolgenden SPS-Prozess, welcher eine hohe Packungsdichte bei gleichzeitig sehr geringer Korngröße ermöglicht, verstärkt. This is according to the invention by the spraying subsequent PLC process, which allows a high packing density with very small grain size, reinforced.
Der vorstehend aufgeführte Metall-, bzw. AI-Anteil, welchem die MMC-Partikel zugeführt werden, besteht im wesentlichen aus einer hypereutektischen Aluminiumlegierung mit einem Siliziumanteil von 15 bis 25 Gew. -Prozent, einem Eisenanteil von 2 bis 10 Gew. -Prozent und einem Nickelanteil von 2 bis 5 Gew.- Prozent, der Rest ist Aluminium. The above-mentioned metal or Al content, to which the MMC particles are supplied, consists essentially of a hypereutectic aluminum alloy having a silicon content of 15 to 25 wt. Percent, an iron content of 2 to 10 wt. Percent and a nickel content of 2 to 5 percent by weight, the rest is aluminum.
Die globularen MMC-, bzw. Hartstoffpartikel haben vorteilhafterweise eine Größe von 5 bis 30 pm. Die erzeugten Pulverpartikel haben eine Größe kleiner 250 pm. The globular MMC or hard particles advantageously have a size of 5 to 30 pm. The powder particles produced have a size smaller than 250 pm.
Die Erfindung betrifft sowohl das Verfahren, wie vorstehend beschrieben, als auch mit dem Verfahren erzeugte Bauteile, insbesondere solche, welche hohe mechanische und oder thermische Beanspruchungen ertragen müssen. Derartige Bauteile sind beispielsweise Bremsscheiben für Fahrzeuge, die sich vorteilhaft mit dem Verfahren nach der Erfindung herstellen lassen. Bei einer solchen Bremsscheibe kann es sich um eine Monoscheibe, eine belüftete Scheibe welche durch Einleger oder Schieber erzeugt wurde oder um eine mehrteilig aufgebaute belüftete Scheibe handeln. Ebenfalls kann eine solche Bremsscheibe in ihrem Gefügeaufbau entsprechend der Beanspruchung axial und/oder radial gradiert sein, d.h. die Zusammensetzung und Korngröße während der Herstellung bleibt über den Bauteilquerschnitt nicht konstant. The invention relates both to the method as described above and to components produced by the method, in particular to those which have to endure high mechanical and / or thermal stresses. Such components are, for example, brake discs for vehicles, which can be produced advantageously with the method according to the invention. Such a brake disk can be a mono disk, a ventilated disk which has been produced by inserts or slides, or a ventilated disk which is constructed in several parts. Likewise, such a brake disk can be graded axially and / or radially in its structure in accordance with the stress, ie the composition and grain size during production do not remain constant over the component cross section.
Eine Gradierung kann ebenfalls erreicht werden, indem auf einen homogenen Grundkörper zusätzlich ein beanspruchungsgerechtes Pulver durch Sprühen aufkompaktiert wird. A grading can also be achieved by additionally compacting a stress-resistant powder by spraying onto a homogeneous base body.

Claims

Patentansprüche claims
1 . 1 .
Verfahren zur Herstellung von Bauteilen unter Verwendung eines Oversprays mit integrierten Hartstoffen, insbesondere aus MMC's (Metallmatrix - Verbundwerkstoffen), dadurch gekennzeichnet dass  Process for the production of components using an overspray with integrated hard materials, in particular from MMCs (metal matrix composites), characterized in that
dem geschmolzenen und verdüsten Metall, insbesondere Aluminium, anschließend MMC - Partikel beigegeben werden, durch eine nachfolgende Verdüsung Metall- (insbesondere AI-) MMC-Agglomerate erzeugt werden, in welchen die MMC-Partikel fest und homogen in den erzeugten giobularen Pulverpartikeln gebunden sind, und . danach die Pulverpartikel zur Erzeugung eines Bauteils mittels eines SPS - Verfahrens verdichtet und kompaktiert werden, insbesondere mit hoher Geschwindigkeit. the molten and atomized metal, in particular aluminum, then MMC particles are added, are produced by a subsequent atomization of metal (especially AI) MMC agglomerates in which the MMC particles are firmly and homogeneously bound in the generated giobular powder particles, and . then the powder particles are compacted and compacted to produce a component by means of a PLC process, in particular at high speed.
2. Second
Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass der Metall-, bzw. AI-Anteil, welchem die MMC-Partikel zugeführt werden, im wesentlichen aus einer hypereutektischen Aluminiumlegierung mit einem Siliziumanteil von 15 bis 25 Gew.- Prozent, einem Eisenanteil von 2 bis 10 Gew. -Prozent und einem Nickelanteil von 2 bis 5 Gew. -Prozent besteht, wobei der Rest ist Aluminium ist.  A method according to claim 1, characterized in that the metal or AI portion to which the MMC particles are supplied, essentially of a hypereutectic aluminum alloy having a silicon content of 15 to 25 percent by weight, an iron content of 2 to 10 percent by weight and a nickel content of 2 to 5 percent by weight, with the remainder being aluminum.
3. Third
Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die giobularen MMC-, bzw. Hartstoffpartikel eine Größe von 5 bis 30 pm haben und die erzeugten Pulverpartikel eine Größe kleiner 250 μιη aufweisen.  A method according to claim 1 or 2, characterized in that the giobular MMC, or hard particles have a size of 5 to 30 pm and the powder particles produced have a size less than 250 μιη.
4. 4th
Bauteil, insbesondere Bremsscheibe, dadurch gekennzeichnet, dass es mit einem Verfahren gemäß einem der Ansprüche 1 bis 3 hergestellt wurde.  Component, in particular brake disc, characterized in that it has been produced by a method according to one of claims 1 to 3.
PCT/EP2012/065885 2011-09-22 2012-08-14 Method for producing components from mmcs (metal matrix composites) using overspray powder WO2013041305A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
KR1020147009366A KR20140064940A (en) 2011-09-22 2012-09-24 Method for producing components from mmcs (metal matrix composites) using a powder that has been melt-atomised in an inert gas atmosphere
US14/346,487 US20150217373A1 (en) 2011-09-22 2012-09-24 Method for producing components from mmcs (metal matrix composites) using a powder that has been melt-atomised in an inert gas atmosphere
PCT/EP2012/068801 WO2013041729A1 (en) 2011-09-22 2012-09-24 Method for producing components from mmcs (metal matrix composites) using a powder that has been melt-atomised in an inert gas atmosphere
EP12761747.0A EP2758195A1 (en) 2011-09-22 2012-09-24 Method for producing components from mmcs (metal matrix composites) using a powder that has been melt-atomised in an inert gas atmosphere

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011113865 2011-09-22
DE102011113865.3 2011-09-22

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Publication Number Publication Date
WO2013041305A1 true WO2013041305A1 (en) 2013-03-28

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PCT/EP2012/068801 WO2013041729A1 (en) 2011-09-22 2012-09-24 Method for producing components from mmcs (metal matrix composites) using a powder that has been melt-atomised in an inert gas atmosphere

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US (1) US20150217373A1 (en)
JP (1) JP2015508446A (en)
KR (1) KR20140064940A (en)
DE (1) DE102012217214A1 (en)
WO (2) WO2013041305A1 (en)

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DE102014002583B3 (en) * 2014-02-26 2015-05-07 Andreas Storz Method for producing a wear-resistant light metal component

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DE102019000361A1 (en) * 2019-01-18 2020-07-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Wear-resistant lightweight construction alloy made of a metal-matrix composite material with a metallic matrix and a ceramic hard phase, method for producing such a wear-resistant lightweight construction alloy, and brake disc mating with such a wear-resistant lightweight construction alloy
DE102019134748A1 (en) * 2019-12-17 2021-06-17 Getek GmbH Process for the production of a component from an aluminum material and powder for this production
CN111390175B (en) * 2020-03-26 2021-03-02 湖南金天铝业高科技股份有限公司 Near-net-shape hot-pressing method for rail transit brake disc sintering rough blank

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EP0200349A1 (en) 1985-03-25 1986-11-05 Osprey Metals Limited Improved method of manufacture of metal products
EP0517882A1 (en) 1991-01-02 1992-12-16 Osprey Metals Ltd Metal spray forming using multiple nozzles.
EP0574458A1 (en) 1991-03-07 1993-12-22 Osprey Metals Ltd Production of spray deposits.
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Publication number Priority date Publication date Assignee Title
DE102014002583B3 (en) * 2014-02-26 2015-05-07 Andreas Storz Method for producing a wear-resistant light metal component

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WO2013041729A1 (en) 2013-03-28
JP2015508446A (en) 2015-03-19
KR20140064940A (en) 2014-05-28
US20150217373A1 (en) 2015-08-06
DE102012217214A1 (en) 2013-03-28

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