CN101594954A - Metal injection moulding method - Google Patents
Metal injection moulding method Download PDFInfo
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- CN101594954A CN101594954A CNA2007800330705A CN200780033070A CN101594954A CN 101594954 A CN101594954 A CN 101594954A CN A2007800330705 A CNA2007800330705 A CN A2007800330705A CN 200780033070 A CN200780033070 A CN 200780033070A CN 101594954 A CN101594954 A CN 101594954A
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- 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
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
- B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
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- 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
- B22F3/1003—Use of special medium during sintering, e.g. sintering aid
- B22F3/1007—Atmosphere
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- 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
- B22F3/1017—Multiple heating or additional steps
- B22F3/1021—Removal of binder or filler
- B22F3/1025—Removal of binder or filler not by heating only
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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Abstract
The present invention relates to metal injection moulding method.Specifically, the present invention relates to a kind of metal injection molded method that forms goods, said method comprising the steps of: form and contain the sintering aid mixture that aluminium powder or Al alloy powder or both reach optional ceramic particle, the binding agent that exists and comprise low-melting-point metal by aluminum or aluminum alloy; Make mixture injection moulding; Remove binding agent, form green compact; The sintering green compact carry out described sintering in containing the atmosphere of nitrogen and in the presence of oxygen absorbent.
Description
Technical field
The present invention relates to a kind of metal injection moulding method.
Background technology
Metal injection molded mixed-powder metal and the binding agent of comprising forms raw material.Use is similar to the injection molding apparatus that is used for plastics industry and makes this mixture injection moulding then.Form like this on " green compact ".Green compact have enough rigidity and intensity, can handle.Then green compact are further handled, with the removal binding agent, and the sintering metal powder particle, form end article.
Binding agent generally includes more than one thermoplastic compound, plasticizer and other organic substance.Ideal situation is that binding agent is fusion or liquid under injecting forming temperature, but solidify in mould when the cooling green compact.Raw material can change into solid particle, for example by granulation.These particles can store and be added in the injection (mo(u)lding) machine in the time after a while.
Typical injection forming equipment comprises the screw rod or the extruder of the heating with nozzle, is extruded in the die cavity by the nozzle mixture.Extruder is heated, and is liquid form to guarantee binding agent, and carefully controls nozzle temperature usually, to guarantee controlled condition.Aptly, the temperature of mould is also controlled, makes temperature enough low, to guarantee that it is a rigidity when taking out green compact from mould.
Because binding agent may occupy the large volume part of green compact, thereby green compact are greater than end article.
The further processing of green compact comprises removes binding agent and sintering.Binding agent can be removed before sintering fully.Selectively, binding agent can partly be removed before sintering step, and realized the removal fully of binding agent during sintering step.
By using the dissolution with solvents binding agent or making the binding agent fusing, decompose and/or evaporation, can remove binding agent by the heating green compact.Also can be used in combination removal of solvents and heat abstraction.
Sintering step comprises the heating base substrate, and independent metallic particles is bonded to together metallurgically.Sintering in the metal injection molded parts production is similar to used sintering in traditional powder metal component production usually.In sintering step, use nonoxidizing atmosphere usually, to avoid the oxidation of metal.In the sintering of metal injection moulding method, remove the densified and contraction of the porous body that stays behind the binding agent.Sintering temperature and Temperature Distribution be usually by strict control, keeping shape of products in sintering process, and prevents product deformation.By this way, can reclaim clean molded article from sintering step.
Metal injection molded being applicable to by coming article of manufacture with almost any metal of suitable Powdered preparation.Yet, in metal injection molded, be difficult to use aluminium, can suppress sintering because be present in the pellumina of the adhesion on the aluminum or aluminum alloy particle surface all the time.
The U.S. Patent No. 6,761,852 that transfers Advanced Materials Technologies Pte Ltd has been put down in writing a kind of metal injection moulding method from aluminium and alloy formation parts thereof.In the method, the powder of aluminum or aluminum alloy with contain allegedly the powder that forms the material (as carborundum or metal fluoride) of eutectic with aluminium oxide.This then mixed-powder mixes with binding agent, and binding agent is removed in injection moulding, and sintering.
At US 6,761, in 852 the method, carborundum or metal fluoride it is said and form eutectic mixture with aluminium oxide that this eutectic mixture solubilized aluminium oxide contacts thereby realization is tight between the aluminium surface in sintering process by inference.
The prior art that the applicant does not think in this manual to be discussed constitutes the part of Australia or any other national common practise.
In the entire description, unless context has explanation in addition, term " comprises " and is equal to term and should be considered to adopt open implication.
Summary of the invention
The purpose of this invention is to provide a kind of metal injection moulding method, this method makes can be from aluminium, aluminium alloy and aluminum matrix composite article of manufacture.
In first aspect, the invention provides a kind of method of passing through the metal injection molded formation goods of aluminum or aluminum alloy, said method comprising the steps of:
Formation contains the sintering aid mixture that aluminium powder or Al alloy powder or both reach optional ceramic particle, the binding agent that exists and comprise low-melting-point metal;
Make mixture injection moulding;
Remove binding agent; With
Sintering; Wherein in containing the atmosphere of nitrogen and in the presence of oxygen absorbent, carry out described sintering.
Oxygen absorbent can comprise for oxygen having more any metal of high-affinity than aluminium.Some examples that are used as the suitable metal of oxygen absorbent comprise alkali metal, alkaline-earth metal and rare earth metal.If more than one rare earth metal is used as oxygen absorbent, so preferably use the rare earth metal of lanthanide.
Magnesium is the preferable alloy as oxygen absorbent, because it has higher vapour pressure, is easy to obtain, and relatively cheap.
In some embodiments, Kuai Zhuan oxygen absorbent can be arranged in around the goods that sintering process is sintered.In other embodiments, pulverous oxygen absorbent can be arranged in around the goods that sintering process is sintered or on it.As a further alternative, oxygen absorbent can mix with aluminium or aluminium powder alloy, perhaps be added to injection forming equipment in mixture mix.
In another embodiment, oxygen absorbent exists as the component that is added to the alloy in the mixture, as is present in the alloy powder that is added to mixture.For example, the alloy powder that contains aluminium and magnesium (with other possible component) can add to mixture or incorporate in the mixture.The example that can incorporate some alloys in the mixture into comprises Al-7.9 weight %Mg and Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si.
Do not wish bound by theory, the inventor supposes that the oxygen absorbent removal may be present in any oxygen in the parts atmosphere on every side in sintering process.Oxygen absorbent also can be used for reducing the aluminium oxide that surrounds the aluminum or aluminum alloy particle.This helps to destroy circumgranular alumina layer, exposes fresh metal, thereby the sintering of aluminum or aluminum alloy particle is taken place.
As mentioned above, magnesium is a kind of suitable oxygen absorbent.Except relatively cheap, magnesium also has higher vapour pressure.Therefore, in sintering step (at high temperature take place), magnesium vapor just can surround the goods at sintering.
Before the injection moulding of mixture, sintering aid is added to mixture.Sintering aid is low-melting metal.For example, sintering aid can be the metal that fusing point is lower than the fusing point of aluminium.Preferably, sintering aid is included in low-melting-point metal insoluble in the solid aluminium.Some examples of the sintering aid that is fit to comprise tin, lead, indium, bismuth and antimony.Have been found that tin is particularly suited for helping the sintering of aluminium and aluminium alloy.Therefore, tin is a kind of preferred sintering aid.
Tin is to be used for preferred sintering aid of the present invention, because have been found that, tin suppresses the formation of aluminium nitride in the sintering process and (thereby avoids forming excessive aluminium nitride, this may have adverse effect to the performance of end article), and also changed the surface tension of molten aluminum, thereby the liquid aluminium phase is well distributed in the acceleration of sintering process.
By the gross weight of metal powder and sintering aid, the addition of sintering aid is not higher than 10 weight %.Preferably, the sintering aid amount is 0.1%～10 weight %, more preferably 0.5%～3 weight %, 2 weight % more preferably from about again.
If as sintering aid, its addition can be 0.1%～10 weight % of mixture so with tin, more preferably 0.5%～4 weight %, more preferably 0.5%～2.0 weight % again.
Tin is significantly less than aluminium (660 ℃), and does not have intermetallic phase 232 ℃ of following fusion.Tin is indissoluble in solid aluminium: maximum solid solution degree is less than 0.15%.Aluminium and liquid tin complete miscibility form miscible liquid.In addition, the surface tension of liquid tin is significantly less than aluminium, and the inventor has shown that Determination of Trace Tin can improve the wetting characteristics and the sintering behavior of aluminium.Owing to these reasons, tin is a kind of particularly preferred sintering aid.
In nitrogen atmosphere, carry out sintering step.Do not wish bound by theory, the formation that sintering step can promote aluminium nitride is carried out in inventor's supposition in nitrogen atmosphere.Inventor's supposition forms the pellumina that aluminium nitride can help to destroy or break common encirclement aluminum or aluminum alloy particle in sintering step.Use tin also can help to control the formation of AlN, may the performance of end article be caused damage because in sintering process, form excessive aluminium nitride as sintering aid.
If as feed powder, the inventor has been found that the sintering that carries out aluminium powder in nitrogen atmosphere may cause aluminium to change into aluminium nitride rapidly with raffinal.Because aluminium can change into the fast velocity of aluminium nitride in these cases, therefore exist whole goods may be converted into the danger of aluminium nitride.Use tin to may be limited to the excessive AlN of formation under these situations as sintering aid.
Do not wish bound by theory, inventor's supposition is by forming aluminium nitride, and nitrogen atmosphere has destroyed the pellumina on the aluminum or aluminum alloy particle surface.Further supposition is thought, the destruction of pellumina makes the sintering of aluminum or aluminum alloy particle take place.
The atmosphere of carrying out sintering step can have low water content, for example, can have the steam partial pressure less than 0.001kPa.The dew point of the atmosphere of using in the sintering step can be lower than-60 ℃, more preferably less than-70 ℃.When magnesium was used as oxygen absorbent, itself and oxygen G﹠W reacted, thereby further reduced the water content in the atmosphere.Think that water vapour is very harmful to the sintering of aluminium.
Described atmosphere is a kind of nitrogen containing atmosphere.Described atmosphere can mainly be nitrogen.Described atmosphere can be 100% nitrogen.Described atmosphere can also comprise inert gas.Inert gas can account for the fraction of described atmosphere.Described atmosphere can not have oxygen and hydrogen basically.At this on the one hand, the gas that is supplied in sintering process as atmosphere is not contain oxygen or hydrogen aptly.
Being used for binding agent of the present invention can be known any binding agent or the adhesive composition that is suitable as metal injection molded binding agent.Such as is known to persons skilled in the art, normally a kind of organic component of binding agent or two or more mixture of organic components.
Binding agent preferably includes the thermoplastic component that binding agent is melted when applying heat.Binding agent also should be for green compact provide sufficient intensity after injection moulding, so that green compact are processed.Preferably, binding agent can be removed from green compact to keep the mode of the integrality of green compact in binding agent removal process.Preferably, after removal, binding agent can not stay any residue.
Binding agent can be made by two or more materials.Can select to constitute the two or more material of binding agent, make them from green compact, to remove successively.By this way, the control of easier realization binding agent is removed, thereby promotes to keep in binding agent removal process the integrity of shape of green compact.At this on the one hand, should be appreciated that the green compact risk that loses its integrity of shape can increase so if remove binding agent too quickly.
Can use one or more known technology that are used to remove binding agent in metal injection molded to remove binding agents.For example, can be by in solvent, dissolving, make binding agent fusing, evaporation or decompose by heat treatment, by catalytic elimination or pass through capillarity and remove binding agent.
Can use two or more binding agent removal technology in the binding agent stage of removing.For example, the first step during binding agent is removed can comprise solvent extraction, is the heat abstraction of residue binding agent then.
It will be understood by those skilled in the art that and to use large-scale binder material.Some examples include organic polymer, as stearic acid, wax, paraffin and polyethylene.
Do not wish restrictedly by any way, the inventor has used the binding agent that comprises stearic acid, palm oil wax and high density polyethylene (HDPE) in the relevant experimental work of the present invention.
The sintering step that uses among the present invention comprises the temperature that green compact is heated to aluminum or aluminum alloy sintering formation DB.Sintering step preferably includes and is heated to about 550 ℃～about 650 ℃ temperature, and more preferably 590 ℃～640 ℃, most preferably 610 ℃～630 ℃.Sintering time can change.Usually, for higher sintering temperature, can use shorter sintering time.Basically, sintering time should long enough, and is maximum densified to guarantee that goods have taken place.Have been found that the sintering that is not higher than 2 hours under 620 ℃～630 ℃ temperature provides gratifying result.But the present invention comprises longer sintering time and shorter sintering time.
The rate of heat addition and the heat distribution used in the common strict control sintering step in metal injection moulding method are to obtain optimum performance in end article.The rate of heat addition and the Temperature Distribution that are fit to that how the easy understanding of those skilled in the art is determined to use in the sintering step.
Method of the present invention is applicable to aluminum metal and aluminium alloy.Any aluminium alloy all can be used for the present invention, comprises the aluminium alloy of 1000 series, 2000 series, 3000 series, 4000 series, 5000 series, 6000 series, 7000 series and 8000 series.
Ceramic particle can with the aluminum or aluminum alloy powder, to produce aluminum metal-matrix composite material.Ceramic particle is used to improve or control the performance of sintered article.This performance can include but not limited to wearability, hardness or thermal coefficient of expansion.The non-limitative example of typical ceramic material comprises SiC, Al
2O
3, AlN, SiO
2, BN and TiB
2
Can in known metal injection molded equipment, carry out method of the present invention.
Description of drawings
Fig. 1 shows the microphoto according to the break surface of prod after unsticking of an embodiment of the invention preparation;
Fig. 2 shows according to the green compact of the prod of an embodiment of the invention preparation and the photo of sintered body;
Fig. 3 is the figure of the density and hardness of the test block for preparing according to the embodiment of the present invention;
Fig. 4 is presented at the figure of the stress strain curve of prod after the sintering under the different condition;
Fig. 5 shows the microstructure of the sintered products of preparation according to the embodiment of the present invention;
Fig. 6 shows the figure of the adding of simple substance magnesium to the influence of sintered density;
Fig. 7 shows that content liquid is with variation of temperature for the alloy of listing among Fig. 7;
Fig. 8 shows the figure of the sintered density of AA6061+X%Sn bulky powder with variation of temperature; With
Fig. 9 shows that sintered density is with the figure of variation of temperature for the raw mix of listing among this figure.
The specific embodiment
Test various alloys and powder constituent, particle diameter and grain shape.D
50Be that the spherical AA6061 powder of 10 μ m and the spherical tin of particle diameter＜45 μ m are preferred.Metal injection molded raw material comprises 6061 powder that contain 2 weight % tin and the binder system of 3 weight % stearic acid, 52 weight % palm oil wax and 45 weight % high density polyethylene (HDPE)s.Raw material mixed 180 minutes down at 165 ℃.After the granulation, use the Arburg make-up machine that feed injection is shaped to the standard tensile rod.In n-hexane, under 40 ℃, carried out the solvent unsticking 24 hours.In the sealing tube furnace, be combined into the removal and the sintering of the surplus binding agent in Xingqi.Preferred atmosphere is 1 liter/minute high-purity nitrogen air-flow.The heat distribution of using in the experimental work is shown in table 1.In sintering process the magnesium rod be placed in goods around.
Material to such sintering carries out tension test.The extensometer length of the scale is 25mm, and crosshead speed is 0.6mm/min.
Use the Rockwell hardness (HRH) of 1/8 inch steel ball and 60kg load measurement upper surface and lower surface.
Table 1: the heat distribution of unsticking and sintering
| |
1 | 2 | 3 | 4 | 5 | 6 | 7 |
| Speed (℃/min) | 3 | 0.5 | 0.5 | 0.5 | 0.8 | 0.5 | 10 |
| Temperature (℃) | 150 | 250 | 375 | 450 | 620 | 550 | 25 |
| Retention time (minute) | 0 | 120 | 120 | 60 | 120 | 0 | Finish |
The result
Fig. 1 shows the break surface of unsticking parts.Powder morphology changes with the initial phase ratio.
Fig. 2 shows the bad and sintered component of injection moulding (life).Sintered component is not such as defectives such as foaming, cracking and warpages.It also has surface of good fineness.
Fig. 3 is presented at the density and hardness of prod under the different sintering conditions.For in nitrogen in 1 hour parts of 620 ℃ of following sintering, sintered density is 90.0 ± 0.6%, hardness is 39.1 ± 12.3.The big variation of hardness may be the reason owing to the high porosity level.Bring up to 2 hours when sintering time, density and hardness brings up to 94.9 ± 0.3% and 66.9 ± 2.9 respectively.Yet, further improve sintering temperature to the 630 ℃ not remarkable density and hardness that increases.Density with this understanding is 95.3 ± 0.3%, and hardness is 69.0 ± 0.9.
The typical stress/strain curves of the parts of sintering is plotted among Fig. 4 under various conditions.Have best mechanical performance at 2 hours parts of 620 ℃ of following sintering, 0.2% yield strength is 58MPa, and tensile strength is 156MPa, and elongation at break is 8.9%.At the tensile property of the parts of 630 ℃ of following sintering a little less than this, although density is higher.This may be the reason owing to microstructure alligatoring under higher sintering temperature.
For at 1 hour parts of 620 ℃ of following sintering, low-density produces relatively poor mechanical performance.Tensile strength is that 98MPa and strain are 1.7%.
Fig. 5 is presented at the microstructure of the sample of 620 ℃ of following sintering after 2 hours.Light micrograph shows, crystallite dimension remains on approximately original particle diameter and less than 20 μ m.Backscattered electron image shows the distribution and the size of Fu Xixiang (white contrast in electronic image, black contrast in optical imagery).Do not see tangible hole.
Further embodiment
-325 order simple substance magnesium dusts of preparation percentage or the pre-alloyed powder of rich magnesium, and be mixed into raw material.Use thermoforming machine raw material to be compacted into the disk of 25.4mm diameter then.With disk sintering in nitrogen, in stove, there is not MAG block.Wherein contain at sintering before the disk of pre-alloyed powder, with stove dry running 4 hours in a vacuum under 680 ℃, to remove any magnesium residue in the stove.Parts are installed in the steel crucible that has loose lid, with the influence of minimum airflow.
The result
The adding of simple substance magnesium is seen Fig. 6 to the influence of sintered density.Found that the magnesium of 1.0 weight % obtains～94% the highest sintered density.When the content of magnesium of 0.5 weight %, oxygen is not fully absorbed, and parts are because the former thereby distortion of porous surface layer.2.0 weight % simple substance magnesium dusts are added in the raw material owing to nitrogenize causes low frit density (～80%).For security consideration, it is not preferred that the simple substance magnesium dust is added in the raw material.Yet, magnesium is added to some shortcomings that can overcome the simple substance powder in the raw material with the form of pre-alloyed powder.
Embodiment-AlMg the powder is added in the raw material
Obtain consisting of the pre-alloyed powder of Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si and Al-7.9 weight %Mg from Aluminium Powder Company.The average grain diameter of Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si powder is about 25 μ m, and the average grain diameter of Al-7.9 weight %Mg powder is about 40 μ m.The two all has the grain shape of rule.About 540 ℃ of the solid-state temperature of Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si, it is 600 ℃ of liquefaction fully.About 540 ℃ of the solid-state temperature of Al-7.9 weight %Mg, it is 620 ℃ of liquefaction fully.Fig. 7 has shown that content liquid is with variation of temperature for these alloys and alloy A A6061 with for the mixture of AA6061+7.5 weight %Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si.
Have been found that in nitrogen that in the mixture of 610 ℃ of following sintering AA6061+7.5%Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si+2 weight %Sn raw materials 2 hours producing not have the parts that are out of shape, solid density is～97%.
Embodiment-use tin is as sintering aid
For the compacting by rapid prototyping preparation or uncompacted aluminium alloy and product compaction, tin has been used as effective sintering aid.The inventor shows, tin plays an important role in the sintering of bulky powder that makes real and powder injection-molded aluminium product compaction.Yet tin will be retained in the crystal boundary place behind sintering, because tin is almost insoluble in solid aluminium.Excess amounts of tin will worsen mechanical performance, particularly ductility, and this is in demand for the aluminium alloy from powder preparation.
The unsticking parts of powder injection-molded aluminium product compaction (brown parts) only have an appointment～85% relative density.After removing polymeric binder, in the unsticking parts of porous, has the open channel on attaching parts surface.Only have an appointment 40～60% relative density of the bulky powder that makes real, the hole of connection can form the open channel that arrives the surface.Need a large amount of liquid to seal these passages.In embodiment before, we find that 4% tin helps the sintering of the fine aluminium powder of loose compacted; Add 2% tin and strengthened the sintering of powder injection-molded AA6061 product compaction.In the present embodiment, we reduce the addition of tin as far as possible, keep liquid volume by adding some prealloy aluminium powders simultaneously.Add a large amount of pre-alloyed powders and also will help to improve alloy content in the sintered component, and improve its intensity.Reducing tin content has and helps improve ductility.By this method, can further improve the mechanical performance of alloy system.
Simple substance tin (＜43 μ m) is used as sintering aid, is mixed with the liquid-phase sintering of the thin AA6061 powder (＜20 microns) of prealloy Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si powder (＜30 μ m) with enhancing.According to the preparation of AA6061+X weight %Sn+Y weight %Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si, in the Turbula blender, mixed various powder 30 minutes.Mixed-powder is poured in the alumina crucible, made real and seal with aluminium foil.Then, flow down at 0.5 liter/minute nitrogen, under different temperatures in the steel pipe type stove sintering 2 hours.Obtain sintered density by the Archimedes method, and convert the percentage of the solid density (TD%) of every kind of alloy to.Use the sample that polishes for optics and SEM (SEM).
Fig. 8 shows that the sintered density of AA6061+X weight %Sn bulky powder increases with the rising of sintering temperature.Increase and increase 590 ℃ of lower densities 580 ℃ of lower densities for 2 weight %Sn alloy systems for 1 weight %Sn system.Add tin and obviously strengthened sintering, and obtain much higher sintered density for the alloy that contains tin.In 600～630 ℃ sintering range, the sintered density that contains the alloy of 1.0 or 2.0 weight % tin is more than～95%.On the contrary, there is not the AA6061 bulky powder of tin under 610 ℃, 620 ℃ and 630 ℃, only to obtain 83%, 88% and 93% sintered density respectively.
For liquid-phase sintering, liquid volume is one of most critical factor of keeping of densified and component shape.Liquid volume by temperature, aluminium alloy composition and tin content control Al-Sn alloy system.Fig. 7 shows that temperature is to the influence of liquid volume fraction for tested alloys.These data are to use ThermoCalc to calculate.Do not consider the adding of tin.For AA6061+x weight %Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si alloy, calculate based on final total alloy content.The solidus of prealloy Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si powder is 582 ℃, and it is 604 ℃ of liquefaction fully.Therefore, if this alloy is sintered separately, then extremely difficult control in processing procedure is because fusion range is narrow.Yet the liquid of the early stage high content of magnesium that forms can be removed oxygen in the sintering furnace, and at the open channel that before about 580～600 ℃ begin severe oxidation takes place, helps usually in the sealing bulky powder.
Fig. 9 was presented in the nitrogen under different temperatures sintering after 2 hours, added the sintered density of the AA6061+0.5 weight %Sn bulky powder that 0%, 2.5% and 7.5% prealloy Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si powder is arranged.Because liquid volume increases, the sintered density of AA6061+0.5 weight %Sn increases steadily with temperature, up to 630 ℃.For 2.5 weight % be added in 600 ℃ of sintering temperatures down with for being added under 590 ℃ of the sintering temperatures of 7.5 weight %, the liquid that fusing Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si powder obtains has sharply increased density.Yet for AA6061+0.5 weight %Sn+7.5 weight %Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si alloy system, after peaking, excess liq causes reducing 620 ℃ of lower densities very soon under 610 ℃.The density reduction may be the reason owing to the gas of the folder speed liquid that forms in early days in components interior.The prealloy Al-2 weight %Cu-9.3 weight %Mg-5.4 weight %Si powder that adds 2.5 weight % helps to keep in 600～620 ℃ temperature range～97% density platform.Begin to reduce 630 ℃ of lower densities.
It will be understood by those skilled in the art that except specifying the present invention can change and revise.Be appreciated that and the present invention includes all changes and the modification that falls in its spirit and scope.
Claims (21)
1. metal injection molded method that forms goods by aluminum or aluminum alloy said method comprising the steps of:
Formation contains the sintering aid mixture that aluminium powder or Al alloy powder or both reach optional ceramic particle, the binding agent that exists and comprise low-melting-point metal;
Make described mixture injection moulding;
Remove described binding agent; With
Sintering; Wherein in containing the atmosphere of nitrogen and in the presence of oxygen absorbent, carry out described sintering.
2. the method for claim 1, wherein said oxygen absorbent comprise for oxygen and have the more metal of high-affinity than aluminium.
3. method as claimed in claim 2, wherein said oxygen absorbent is selected from alkali metal, alkaline-earth metal and rare earth metal.
4. method as claimed in claim 3, wherein said oxygen absorbent is a magnesium.
5. the method for claim 1, wherein Kuai Zhuan oxygen absorbent is arranged in around the goods that sintering process is sintered, perhaps pulverous oxygen absorbent is arranged in around the goods that sintering process is sintered or on it, perhaps oxygen absorbent mixes with aluminium or aluminium powder alloy, perhaps be added to injection forming equipment in mixture mix, perhaps oxygen absorbent exists as the component that is added to the alloy in the mixture.
6. the method for claim 1, wherein said sintering aid are to have that fusing point is lower than the fusing point of aluminium and insoluble metal in solid aluminium.
7. method as claimed in claim 6, wherein said sintering aid comprises tin.
8. the method for claim 1, wherein by the gross weight of metal powder and sintering aid, the amount of described sintering aid is not higher than 10 weight %.
9. method as claimed in claim 8, the amount of wherein said sintering aid are 0.1%～10 weight %.
10. method as claimed in claim 8, the amount of wherein said sintering aid are 0.5%～3 weight %.
11. the method for claim 1, the atmosphere of wherein carrying out sintering step has low water content, and wherein steam partial pressure is less than 0.001kPa.
12. the method for claim 1, wherein said binding agent comprises the thermoplastic component that binding agent is melted when applying heat.
13. the method for claim 1, wherein said binding agent is made by two or more materials, and selects described material to make them remove successively from green compact.
14. the method for claim 1 wherein by dissolving, makes binding agent fusing, evaporation or decomposition by heat treatment in solvent, by catalytic elimination, perhaps remove described binding agent by capillarity.
15. method as claimed in claim 14 wherein uses two or more binding agent removal technology to remove described binding agent.
16. the method for claim 1, wherein said binding agent comprises stearic acid, palm oil wax and high density polyethylene (HDPE).
17. the method for claim 1, wherein said sintering step comprise green compact are heated to the temperature that the aluminum or aluminum alloy sintering forms DB.
18. method as claimed in claim 17, wherein said temperature is in about 550 ℃～about 650 ℃ scope.
19. the method for claim 1, wherein said mixture comprises ceramic particle, and described ceramic particle is selected from SiC, Al
2O
3, AlN, SiO
2, BN and TiB
2
20. the method for claim 1, wherein said atmosphere comprises the mixture of nitrogen or nitrogen sheet and inert gas.
21. the method for claim 1, wherein said atmosphere is substantially free of oxygen or hydrogen.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2006904265 | 2006-08-07 | ||
| AU2006904265A AU2006904265A0 (en) | 2006-08-07 | Metal Injection Moulding of Aluminium Alloys and Composites |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN101594954A true CN101594954A (en) | 2009-12-02 |
Family
ID=39032541
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNA2007800330705A Pending CN101594954A (en) | 2006-08-07 | 2007-08-07 | Metal injection moulding method |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US20100183471A1 (en) |
| EP (1) | EP2056984A1 (en) |
| JP (1) | JP2010500469A (en) |
| CN (1) | CN101594954A (en) |
| AU (1) | AU2007283448A1 (en) |
| CA (1) | CA2660484A1 (en) |
| WO (1) | WO2008017111A1 (en) |
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2007
- 2007-08-07 WO PCT/AU2007/001108 patent/WO2008017111A1/en active Application Filing
- 2007-08-07 JP JP2009523110A patent/JP2010500469A/en active Pending
- 2007-08-07 AU AU2007283448A patent/AU2007283448A1/en not_active Abandoned
- 2007-08-07 EP EP07784748A patent/EP2056984A1/en not_active Withdrawn
- 2007-08-07 CA CA002660484A patent/CA2660484A1/en not_active Abandoned
- 2007-08-07 CN CNA2007800330705A patent/CN101594954A/en active Pending
- 2007-08-07 US US12/376,775 patent/US20100183471A1/en not_active Abandoned
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Also Published As
| Publication number | Publication date |
|---|---|
| US20100183471A1 (en) | 2010-07-22 |
| JP2010500469A (en) | 2010-01-07 |
| EP2056984A1 (en) | 2009-05-13 |
| AU2007283448A1 (en) | 2008-02-14 |
| CA2660484A1 (en) | 2008-02-14 |
| WO2008017111A1 (en) | 2008-02-14 |
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