CN101678440B - 功能梯度金属基复合材料板 - Google Patents
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Abstract
一种制造功能梯度金属基复合材料(MMC)产品(20)的方法,所述产品(20)具有夹在外壳(6、8)之间的富含颗粒物(10)的固态中心层(18),该方法包括:向一对前进的铸造表面(D1、D2)提供包含颗粒物(10)的熔融金属(M);使熔融金属(M)凝固;以及从铸造表面(D1、D2)之间取出MMC产品(20)。固态中心层(18)比任何外层(6、8)包含的颗粒物(10)浓度都要高。MMC产品(20)将金属外层的易于机械加工性能和外观与固态中心层(18)提供的改良性能结合起来。
Description
相关申请的交叉引用
本申请要求于2007年4月11日提交的名称为“功能梯度金属基复合材料板”的美国非临时专利申请序列号11/734,121的优先权。
技术领域
本发明涉及铝基金属基复合材料。本发明的一个实施例涉及一种包括具有高密度颗粒的中心层的功能梯度金属基复合材料板以及制造这种板的方法。本发明能够用共同拥有的美国专利5,514,228、6,672,368和6,880,617中公开的设备来实施,这些专利以引用的方式并入本申请中。
背景技术
金属基复合材料(MMC)将金属基体的性能和强化颗粒的性能结合起来,从而提高最终产品的机械性能。例如,铝基MMC产品通常会表现出弹性模量的提高、低的热膨胀系数、更高的耐磨性、断裂应力的改善,而且在某些情况下,抗热疲劳性的提高。
现有的制造MMC的方法包括挤压铸造、挤压渗透、喷射沉积、粉浆浇铸、粉末加工。这些制造方法的目的是使颗粒在整个金属基体中均匀分布,或使颗粒分布在金属产品的外表面附近。然而,过去通过轧制、锻造或挤压把铸造MMC制成成品的方法一直受到颗粒相高负荷特性的阻碍。
因此,存在对铝基金属基复合材料的需求,其能将MMC的增强机械性能与改进的延展性、外观和易于加工结合起来。
发明内容
本发明披露了一种制造具有颗粒物的中心层的功能梯度MMC板的方法。该方法包括向一对前进铸造表面提供包含颗粒物的熔融金属。然后,在使熔融金属在该对前进铸造表面之间前进时使熔融金属凝固,以形成包括第一固态外层、第二固态外层和颗粒物浓度比任何外层都要高的半固态中心层的复合材料。
然后,使中心层凝固,以形成固态复合金属产品,其包括夹在两个外层之间的中心层;并从铸造表面之间取出金属产品。在产品从铸造表面之间取出后,可以在对该产品进行一个或多个热轧或冷轧道次。
铸造表面通常是辊或带的表面,在辊或带的表面之间有夹隙。在一个实施例中,金属产品以约50-300英尺/分钟的速度离开夹隙。在实践中,熔融金属可以是铝合金,颗粒物可以是例如氧化铝。如前所述,根据本发明的方法制成的金属产品包括两个外层和一个具有高浓度颗粒物的中心层。例如,对于铝基MMC,中心层可包括按体积计约70%的氧化铝颗粒。本发明的产品可以是厚度大约0.004英寸到大约0.25英寸的带材、薄板或面板,并且本发明的产品是金属基复合材料,其将MMC的优点与延展性、外观和易于加工方面的增强结合起来。
本发明产品适用于结构应用,诸如在航空航天、汽车、建筑行业中使用的面板。
附图说明
图1是描述本发明方法的流程图;
图2是在本发明方法中使用的一种装置的示意图;
图3是根据本发明运行的装置细节的放大的横截面示意图;
图4是根据本发明生产出的带材的横切面的显微照片;
图5是根据本发明生产并然后热轧成0.008英寸厚的带材的横切面的显微照片。
具体实施方式
附图以及随后的说明将以实施例方式介绍本发明。但是,可以预想的是,通常熟知铸造工艺的技术人员将能够通过改变某些细节而在其他情况下应用这里所示出和描述的结构和方法的新特点。因此,附图和说明不应被视为对本发明范围的限制,而是要被理解成是广泛的和一般的教导。在谈到任何数值范围时,这些范围被理解为包括介于所述范围的最小值和最大值之间的每个数字和/或部分。
最后,为了后面描述的目的,术语“上”、“下”、“右”、“左”、“竖直”、“水平”、“顶部”、“底部”及其派生词都应与本发明有关,正如在附图中所定向的那样。
术语“铝合金”、“镁合金”和“钛合金”意图指这样的合金,其包含以重量计至少50%的所述元素和至少一种改性元素。铝合金、镁合金、钛合金被认为是在航空航天业和汽车业用于结构用途的有吸引力的备选材料,这是因为,它们的重量轻、强度与重量之比高、在室温和高温下的比刚度高。本发明可用所有铝合金来实施。
在图1的流程图中示意性地描述了本发明的最基本的形式。如图所示,在步骤100中,含有颗粒物的熔融金属被输送给铸造设备。铸造设备包括如下文详述的一对分隔开的前进的铸造表面,在步骤102,铸造设备迅速冷却至少一部分熔融金属,以凝固熔融金属的外层和用颗粒物强化的中心层。随着合金的铸造,凝固的外层的厚度逐渐增加。
从铸造设备出来的产品包括在步骤102中形成的夹在外层之间、含有颗粒物的固态中心层。该产品可以被制成各种形式,例如但不限于薄板、中厚板、板坯或箔。在挤压铸造中,产品可以是以下形式:线、杆、棒或其他挤压品形式。在任一种情况下,可在步骤104对产品进行进一步加工和/或处理。应当指出的是,步骤100-104的顺序在本发明的方法中不是固定的,可以顺序地进行,或某些步骤可以同时进行。
在本发明中,选择熔融金属的冷却速率,以实现金属外层的快速凝固。对于铝合金和其他金属合金来说,金属外层可以在至少约每秒1000摄氏度的速率下进行冷却。适用于所披露的本发明的合适铸造设备包括但不限于例如在双辊铸机、带铸机、板坯铸机或锭铸机中的冷却的铸造表面。立式辊铸机也可用于本发明。在连铸机中,铸造表面一般分隔开,并具有这样一区域,在该区域,铸造表面之间的距离为最小。
在辊铸机中,铸造表面之间距离最小的区域称为辊隙。在带铸机中,带铸造表面之间距离最小的区域可以是铸造机的入口带轮之间的夹隙。如下文更具体地描述的,在本发明范围中的铸造设备的运行涉及到在铸造表面之间距离最小的位置处的金属的凝固。虽然下文中描述的本发明的方法是用双辊铸机实施的,但是这并不意味着限制。其他连铸表面也可以被用来实施本发明。
举例来说,辊铸机(图2)可以被操作以实施本发明,如图3详细示出的。现在参考图2(图2一般性地描绘了根据现有技术和本发明的水平连铸),本发明可以用一对反转冷却辊R1和R2来实施,这对冷却辊分别按箭头A1和A2的方向旋转,其中,M是熔融金属,H是保温炉,T是流槽,S是产品。辊铸机在常规的使用中是在低速运行,并且不生产功能梯度产品。如图3更详细示出的,在本发明的实施中,可由耐火材料或其他陶瓷材料制成的喂料嘴T将熔融金属M沿箭头B的方向直接分配到分别按箭头A1和A2的方向旋转的辊R1和R2上。喂料嘴T与各个辊R1和R2之间的间隙G1、G2保持尽可能地小,以便在避免喂料嘴T与辊R1和R2之间接触的情况下,防止熔融金属漏出,并最大程度减少熔融金属沿辊R1和R2暴露到大气中。间隙G1、G2的适宜尺寸大约是0.01英寸。穿过辊R1和R2中心线的平面L经过辊R1和R2之间间隙最小的区域,该区域称为辊隙N。
从图3可以看出,在本发明中含有颗粒物10的熔融金属M被供应到辊铸机的辊R1和R2之间。本领域的技术人员应当明白,辊R1和R2是辊铸机的铸造表面。通常情况下,R1和R2被冷却,以帮助分别在区域2和4与辊R1和R2直接接触的熔融金属M凝固。熔融金属M一旦与辊R1和R2接触,就开始冷却并凝固。冷却的金属凝固成与辊R1相邻的凝固金属的第一外壳6,和与辊R2相邻的凝固金属的第二外壳8。
每个外壳6和8的厚度随着金属M朝向辊隙N的前进而逐渐增加。最初,颗粒物10位于第一外壳6和第二外壳8各自与熔融金属M之间的界面处。随着熔融金属M在冷却辊R1和R2的对向表面之间移动,颗粒物10被拖拽到较慢流动的熔融金属M流的中心部分12中,并沿着箭头C1和C2的方向被携带。在辊隙N上游、被称为区域16的中心部分12,金属M是半固态,包括颗粒物10成分和熔融金属M成分。在区域16中的熔融金属M具有固液相容性,这部分地是由于颗粒物10在其中的分散。
辊R1和R2在辊隙N处向前的旋转基本上只推动金属的固态部分,即第一和第二外壳6和8以及中心部分12中的颗粒物,同时对辊隙N上游的中心部分12中的熔融金属M施力,以使金属在离开辊隙N那一点时基本上为固体。在辊隙N的下游,中心部分12是夹在第一外壳6和第二外壳8之间的包含颗粒物10的固态中心层18。
为清楚起见,上文描述的三层铝制品也被称为功能梯度MMC结构,其中,具有高浓度颗粒物10的中心部分12夹在第一外壳6和第二外壳8之间。在固态中心层18中的颗粒物10的尺寸至少约30微米。在带材产品中,固态中心部分可构成带材总厚度的约20-30%。虽然图2示出的铸机以大体水平的定向来生产带材S,但这并不意味着限制,因为带材S可以成一定角度或竖直地离开铸机。
参考图3所描述的铸造工艺遵循上文概述的图1方法步骤。在步骤100输送给辊铸机R1和R2的熔融金属M开始冷却,并在步骤102凝固熔融金属。冷却的金属逐渐形成凝固金属的外层,即接近或邻近冷却的铸造表面R1和R2的第一和第二外壳6和8。正如前几段所述的,第一外壳6和第二外壳8的厚度随着金属成分前进穿过铸造设备而逐渐增加。经步骤102,颗粒物10被拖拽到中心部分12中,所述中心部分12部分地被凝固的外层6和8包围。在图3中,第一和第二外壳6和8大体上包围中心部分12。
换言之,包含颗粒物10的中心部分12位于第一外壳6和第二外壳8之间。在中心部分12中的熔融金属M形成内层17。换句话说,内层17夹在或设在第一外壳6和第二外壳8之间。在其他铸造设备中,第一和/或第二外壳6、8可完全包围内层17。参考图1,在步骤104,内层17凝固。在内层17完全凝固之前,内层17是半固态,并包括颗粒物成分10和金属成分。在这个阶段,内层17中的金属具有固液相容性,这部分地是由于颗粒物10在其中的分散。
在步骤106,产品完全凝固,并包括包含颗粒物10的固态中心层18以及大体上包围固态中心层18的第一和第二外壳6、8,即外层。固态中心层18的厚度T1可以是产品20厚度T的约10-40%。在一个实施例中,固态中心层18包括按体积计约70%的颗粒物10,而第一和第二外壳6、8包括按体积计约10%的颗粒物10,但组合的外壳厚度(T2+T3)约为产品20的厚度T的60-90%。因此,MMC的最高浓度是在固态中心层18,而外壳6、8具有MMC的低浓度。
尺寸至少约为30微米的颗粒物10在步骤104中向中心部分12中的移动是由熔融金属的内层17与凝固外层6、8之间的速度差导致的剪切力而造成的。为了实现这种向内层17中的运动,辊铸机R1、R2需要以至少约每分钟50英尺的速度运行。以每分钟不到10英尺的常规速度运行的辊铸机R1、R2将不会产生将尺寸约30微米或更大的颗粒物移入内层17所需的剪切力。
本发明的一个重要方面是尺寸至少约为30微米的颗粒物10向内层17中的运动。
本发明公开的功能梯度MMC结构将MMC的优点(例如改良的机械性能)与金属外层的韧性和外观结合起来。在本发明的实施中所使用的铸造表面作为熔融金属M热量的热沉。在操作中,热量均匀地从熔融金属传递到冷却的铸造表面,以确保铸造产品表面的均匀性。冷却的铸造表面可由钢或铜或其他合适的材料制成,并可以被毛化以包括与熔融金属接触的表面不规则。铸造表面也可以用另一种金属涂覆,例如镍或铬,或用非金属涂覆。
表面不规则用于增大从冷却铸造表面的表面传热。对冷却铸造表面施加受控程度的表面非均匀性导致横过冷却铸造表面的传热更均匀。表面不规则的形式可以是沟槽、凹陷、滚花或其他结构,并且表面不规则可以规则地间隔开。在本发明的范围中运行的辊铸机中,对辊R1和R2适宜速度的控制、保持和选择会影响本发明的可操作性。辊速决定熔融金属M朝辊隙N前进的速度。如果速度过慢,颗粒物10将不会受到足以使其能被夹带到金属产品内层17中的力。因此,本发明适宜在大于每分钟50英尺的速度下运行。
在一个实施例中,本发明是在50-300英尺/分钟的速度下运行。熔融铝被输送给辊R1和R2的线速度可以小于辊R1和R2的速度,或者是辊速的约四分之一。根据本发明可实现高速连铸,这部分地是因为毛化表面D1和D2确保了从熔融金属M均匀传热,以及如下文所讨论的,辊分离力是实施本发明的另一个重要参数。
本发明的显著优点是:直到金属到达辊隙N才产生固态带材。厚度T是由辊R1和R2之间的辊隙N的尺寸决定的。辊分离力大到足以挤压辊隙N上游的熔融金属并把熔融金属挤压离开辊隙N。若非如此,通过辊隙N的过多熔融金属将会造成上下外壳6和8和固态中心部分18这些层彼此分离并错位。相反,到达辊隙N的熔融金属不足将使得带材过早形成,就像在常规辊铸过程中发生的那样。过早形成的带材20会被辊R1和R2变形并产生中心偏析。
适宜的辊分离力大约是5-1000磅每英寸铸件宽度。通常,铸造较厚规格的合金时需要较慢的铸造速度,以便从厚合金消除热量。与传统的辊铸不同,在本发明中这种较慢的铸造速度并不会导致过大的辊分离力,这是因为在辊隙上游不产生完全固态的有色金属带材。
可以以50-300英尺/分钟的铸造速度生产厚度约为0.08-0.25英寸的合金带材。
在一个实施例中,熔融金属是铝或铝合金。
在第二个实施例中,颗粒物可以是任何非金属材料,例如氧化铝、碳化硼、碳化硅和氮化硼,或是在铸造过程中现场产生或添加入熔融金属的金属材料。
现在参考图4,示出根据本发明的功能梯度MMC铸件的显微结构。示出的带材400包括以重量计15%的氧化铝,厚度规格是0.004。可以看到,颗粒物10分布在整个带材400中,在中心层401中集中了较高浓度的颗粒,同时可以看到,在外层402和403中分别为低浓度。应当注意,由于在本发明的方法中熔体的快速凝固,颗粒物和铝基体之间没有发生反应。此外,如图5所示,在根据本发明的轧制产品中,在颗粒与金属基体之间的界面处没有损伤。图5示出了功能梯度MMC带材(铝,15%体积的Al2O3,0.2mm厚度的轧态复合材料),其中,金属外层具有良好的成形性,中心层具有改善的刚性。本发明还允许生产冷轧产品,而不需要在冷轧过程中再加热。由于颗粒物并不突出产品的表面,因此颗粒物就不会磨损或磨蚀轧机辊。
虽然已经参考具体实施例对本发明做了详细介绍,但本领域技术人员将明白可以作出各种变化和修改,而不脱离实施例的精神和范围。因此,本公开意在涵盖本公开的各种改变和修改,只要它们落入所附权利要求及其等同物的范围内。
Claims (4)
1.一种基于铝合金的功能梯度金属基复合材料产品,其包括:
第一外壳;
内部部分;和
第二外壳;
其中,颗粒物横过第一外壳、内部部分和第二外壳以浓度梯度分布;
其中,内部部分的颗粒物浓度比第一外壳和第二外壳的颗粒物浓度高;
其中,颗粒物选自由氧化铝、碳化硼、碳化硅、氮化硼组成的组;
其中,该产品是用包括一对分隔开的前进的铸造表面的铸造设备、以50-300英尺/分钟的铸造速度生产的、厚度为0.08-0.25英寸的合金带材,
其中,内部部分包括以体积计约70%的颗粒物。
2.如权利要求1所述的产品,其中,按体积计约70%的颗粒物在内部部分中,按体积计约10%的颗粒物在第一外壳中,以及按体积计约10%的颗粒物在第二外壳中。
3.一种基于铝合金的功能梯度金属基复合材料产品,其包括:
第一壳;
第二壳;和
处于第一壳和第二壳之间的中心层;
其中,颗粒物横过第一壳、中心层和第二壳以浓度梯度分布;
其中,中心层的颗粒物浓度比第一壳和第二壳的颗粒物浓度高;
其中,颗粒物选自由氧化铝、碳化硼、碳化硅、氮化硼组成的组;
其中,该产品是用包括一对分隔开的前进的铸造表面的铸造设备、以50-300英尺/分钟的铸造速度生产的、厚度为0.08-0.25英寸的合金带材,
其中,中心层包括以体积计约70%的颗粒物。
4.一种基于铝合金的功能梯度金属基复合材料产品,其包括:
第一外壳;
内部部分;和
第二外壳;
其中,颗粒物横过第一外壳、内部部分和第二外壳以浓度梯度分布;
其中,第一外壳、内部部分和第二外壳是整体的;
其中,内部部分的颗粒物浓度比第一外壳和第二外壳的颗粒物浓度高;
其中,颗粒物选自由氧化铝、碳化硼、碳化硅、氮化硼组成的组;
其中,该产品是用包括一对分隔开的前进的铸造表面的铸造设备、以50-300英尺/分钟的铸造速度生产的、厚度为0.08-0.25英寸的合金带材,
其中,内部部分包括以体积计约70%的颗粒物。
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- 2008-04-11 JP JP2010503238A patent/JP2010524689A/ja active Pending
- 2008-04-11 ES ES08745622.4T patent/ES2538993T3/es active Active
- 2008-04-11 CN CN200880018281.6A patent/CN101678440B/zh not_active Expired - Fee Related
- 2008-04-11 BR BRPI0811045A patent/BRPI0811045A8/pt active Search and Examination
- 2008-04-11 KR KR20097023409A patent/KR20100016383A/ko not_active Application Discontinuation
- 2008-04-11 AU AU2008240177A patent/AU2008240177A1/en not_active Abandoned
- 2008-04-11 RU RU2009141589A patent/RU2429936C2/ru not_active IP Right Cessation
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US8697248B2 (en) | 2014-04-15 |
JP2010524689A (ja) | 2010-07-22 |
ES2538993T3 (es) | 2015-06-25 |
CA2683970C (en) | 2012-10-16 |
BRPI0811045A8 (pt) | 2017-08-22 |
KR20100016383A (ko) | 2010-02-12 |
US20110036464A1 (en) | 2011-02-17 |
WO2008128061A1 (en) | 2008-10-23 |
BRPI0811045A2 (pt) | 2014-12-09 |
ZA200907378B (en) | 2010-07-28 |
MX2009010937A (es) | 2009-11-02 |
US20110042032A1 (en) | 2011-02-24 |
US7846554B2 (en) | 2010-12-07 |
AU2008240177A1 (en) | 2008-10-23 |
EP2148753B1 (en) | 2015-03-11 |
RU2429936C2 (ru) | 2011-09-27 |
CA2683970A1 (en) | 2008-10-23 |
EP2148753A1 (en) | 2010-02-03 |
CN101678440A (zh) | 2010-03-24 |
US20080254309A1 (en) | 2008-10-16 |
RU2009141589A (ru) | 2011-05-20 |
US8381796B2 (en) | 2013-02-26 |
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