CN114908268A - Method for producing metal foam - Google Patents

Method for producing metal foam Download PDF

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Publication number
CN114908268A
CN114908268A CN202210112876.XA CN202210112876A CN114908268A CN 114908268 A CN114908268 A CN 114908268A CN 202210112876 A CN202210112876 A CN 202210112876A CN 114908268 A CN114908268 A CN 114908268A
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CN
China
Prior art keywords
metal
precursor
mold
metal foam
producing
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Pending
Application number
CN202210112876.XA
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Chinese (zh)
Inventor
山本鸿司
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
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Toyota Motor Corp
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Publication of CN114908268A publication Critical patent/CN114908268A/en
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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
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum
    • 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
    • C22C1/08—Alloys with open or closed pores
    • 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
    • C22C1/08—Alloys with open or closed pores
    • C22C1/083—Foaming process in molten metal other than by powder metallurgy
    • C22C1/086—Gas foaming process
    • 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
    • C22C1/08—Alloys with open or closed pores
    • C22C1/083—Foaming process in molten metal other than by powder metallurgy
    • C22C1/087—Foaming process in molten metal other than by powder metallurgy after casting in solidified or solidifying metal to make porous metals
    • 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
    • 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

Abstract

The invention provides a method for manufacturing a foam metal with high productivity, which can simply manufacture a molded product with a required shape. The method for producing a metal foam comprises: a step of dissolving hydrogen in a mixture containing a molten metal and a thickener to prepare a precursor which saturates the amount of dissolved hydrogen in the metal; putting the precursor into a mold; and a step of solidifying the precursor charged into the mold in a reduced-pressure environment, or heating the precursor charged into the mold in a reduced-pressure environment after solidifying the precursor.

Description

Method for producing metal foam
Technical Field
The invention relates to a method for manufacturing a foam metal.
Background
As a porous material having a plurality of pores inside a metal or an alloy, a metal foam is known. Metal foams are excellent in impact energy absorption properties, sound damping properties, and the like, and are lightweight, and therefore are used in various fields as multifunctional materials. On the other hand, since the manufacturing cost is increased due to expensive materials and complicated manufacturing processes, cost reduction is desired.
International publication No. 2010/106883 discloses a method for producing a metal foam precursor and a method for producing a metal foam having the following characteristics. In the production method described in patent document 1, a metal foam precursor or a metal foam can be easily produced without using an expensive blowing agent powder. In this production method, alumina is added during Friction Stir Processing (FSP), thereby increasing the sphericity of pores of the metal foam and increasing the porosity of the metal foam. First, a die-cast molded article containing a gas therein is prepared by a die-casting method. Next, the gas and the pore-forming nuclei contained in the die-cast product are uniformly dispersed in the die-cast product by FSP, thereby producing a metal foam precursor. Further, the metal foam precursor is foamed by performing a heat treatment for heating the metal foam precursor to a temperature near its melting point, thereby producing a metal foam.
Disclosure of Invention
However, the manufacturing process of the manufacturing method described in patent document 1 is complicated. Further, since a die casting device or the like is required, the manufacturing equipment becomes bulky, thereby increasing the manufacturing cost. Therefore, the production method described in patent document 1 has a problem of a decrease in productivity.
The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a method for producing a metal foam with high productivity, which can easily produce a molded article having a desired shape.
A method for producing a metal foam according to an embodiment includes: a step of dissolving hydrogen in a mixture containing a molten metal and a thickener to prepare a precursor which saturates the amount of dissolved hydrogen in the metal; a step of putting the precursor into a mold; and a step of solidifying the precursor charged into the mold in a reduced-pressure environment, or heating the precursor charged into the mold in a reduced-pressure environment after solidifying the precursor.
According to the present invention, a method for producing a metal foam with high productivity is provided, which enables a molded article having a desired shape to be produced easily.
The above and other objects, features and advantages of the present invention will be more fully understood with reference to the detailed description given below and the accompanying drawings, which are given by way of illustration only, and thus should not be taken as limiting the invention.
Drawings
Fig. 1 is a flowchart illustrating a method for producing a metal foam according to a first embodiment.
Fig. 2 is a schematic diagram showing a precursor preparation step and a precursor introduction step in the method for producing a metal foam according to the first embodiment.
Fig. 3 is a schematic view showing an example of a solidification step in the method for producing a metal foam according to the first embodiment.
Fig. 4 is a schematic view showing another example of the solidification step in the method for producing a metal foam according to the first embodiment.
Detailed Description
Implementation mode one
Embodiments of the present invention will be described below with reference to the drawings. However, the present invention is not limited to the following embodiments. In addition, the following description and drawings are simplified as appropriate for clarity of explanation.
An outline of a method for producing a metal foam according to the first embodiment will be described with reference to fig. 1. Fig. 1 is a flowchart illustrating a method for producing a metal foam according to a first embodiment. As shown in fig. 1, the method for producing a metal foam according to the present embodiment includes the following steps S1 to S3.
In the precursor preparation step of step S1, hydrogen is made solid-soluble in the mixture M2 containing the molten metal M1 and the thickener T, and the precursor M3 in which the amount of solid-soluble hydrogen in the metal is saturated is prepared. In the charging step of step S2, the precursor M3 is charged into the mold 1. In the solidification step of step S3, the precursor M3 put into the mold 1 is solidified in a reduced pressure atmosphere.
The above steps will be described in detail with reference to fig. 2 and 3. Fig. 2 is a schematic diagram showing a precursor preparation step and a precursor introduction step in the method for producing a metal foam according to the first embodiment. Fig. 3 is a schematic view showing an example of a solidification step in the method for producing a metal foam according to the first embodiment.
As shown in S1-1 of fig. 2, in the precursor preparation step of step S1, first, a metal serving as a raw material of the metal foam and the thickener T are prepared. As the metal of the raw material of the metal foam, a metal element monomer or an alloy can be used. Examples of such metals and alloys include aluminum, magnesium, titanium, iron, zinc, copper, aluminum alloys, magnesium alloys, titanium alloys, steel materials, zinc alloys, and copper alloys.
The metal of the raw material is melted in the stirring vessel 10. Alternatively, a metal in a previously molten state is put into the stirring vessel 10. Since the form of the metal as the raw material is not particularly limited, an inexpensive bulk material can be used.
In forming the molten metal M1 (hereinafter, also referred to as molten metal M1), the metal of the raw material is heated to an appropriate temperature range of the melting point or higher corresponding to the element or component constituting the metal. For example, when the metal of the raw material is aluminum or an alloy containing aluminum as a main component, the temperature is set to be in the range of 550 to 800 ℃, preferably 650 to 700 ℃. When the metal is magnesium or an alloy containing magnesium as a main component, the temperature is set to be in the range of 550 to 800 ℃. When the metal is zinc or an alloy containing zinc as a main component, the temperature is set to be in the range of 300 to 550 ℃. When the metal is copper or an alloy containing copper as a main component, the temperature is set to be in the range of 900 to 1200 ℃.
The thickener T may be one or more selected from metal powders such as calcium and magnesium, metal oxide powders such as alumina and magnesia, and ceramic powders such as silicon carbide and silica. The tackifier T is a substance that increases the viscosity of the molten metal M1, and is preferably a substance that is chemically stable in the molten metal M1.
When the molten metal M1 is thickened within an appropriate range by using the thickener T, coarsening of cells during foaming can be suppressed. In addition, the thickened molten metal M1 suppresses the release of gas that forms pores to the outside of the molten metal M1, and the gas remains in the molten metal M1 to maintain independent pores. That is, by adjusting the viscosity of the molten metal M1, the form (sphericity, size, etc.) of the pores formed in the molten metal M1 can be controlled, and the pores can be stabilized.
The tackifier T is added to the molten metal M1 in the stirring vessel 10, and sufficiently stirred in the atmosphere using, for example, a stirring blade. Thus, a mixture M2 in which the tackifier T was uniformly dispersed in the molten metal M1 was obtained. The mixture M2 can also be obtained by mixing the metal of the starting materials with the tackifier T and then heating and stirring. If necessary, the tackifier T is more uniformly dispersed in the molten metal M1 by applying ultrasonic waves to the mixture M2.
Next, as shown in S1-2 in FIG. 2, hydrogen is made to dissolve in the metal. As a method of making hydrogen solid-dissolved in metal, there is a method of inserting the tip of the introduction pipe 20 into the mixture M2 obtained above and blowing steam V as a hydrogen source into the mixture M2 through the introduction pipe 20. As another method, a method of leaving the mixture M2 under a condition of high water vapor partial pressure (under high humidity) can be considered. Alternatively, hydrogen gas may be blown into the mixture M2 through the introduction pipe 20.
The method of dissolving hydrogen in the metal is not limited to this as long as the hydrogen concentration in the molten metal M1 is increased. The amount of steam V added is added until the amount of hydrogen solid-dissolved in the metal becomes supersaturated. If the amount of hydrogen dissolved in the metal is insufficient, pores do not grow sufficiently during the foaming process.
Next, as shown in S2 of fig. 2, in the precursor input step of step S2, the precursor M3 is input into the mold 1 corresponding to the product shape. The mold 1 may be any mold having the required heat resistance and durability according to the heating conditions and the reduced pressure conditions in the solidification step of step S3. The material of the mold 1 may be stainless steel, heat-resistant steel, or the like, which is excellent in heat resistance and durability. Further, the mold 1 may also be used as the stirring vessel 10 if the material can be sufficiently stirred and a required amount of hydrogen can be made to be solid-dissolved in the mixture M2. In this case, the efficiency is high since it is not necessary to transfer the metal during the process. The amount of the precursor M3 to be charged into the mold 1 is adjusted in consideration of the degree of foaming.
Next, as shown in fig. 3, in the solidification step of step S3, the precursor M3 put into the mold 1 is solidified in a reduced-pressure atmosphere. To realize a reduced pressure environment, for example, a vacuum apparatus 30a having a vacuum chamber 31, a vacuum pump 32, and a vacuum valve 33 is used. The precursor M3 put into the mold 1 was placed in the vacuum chamber 31, and the vacuum pump 32 was operated to reduce the pressure in the vacuum chamber 31. In this case, the pressure reduction is preferably started at a temperature at which the metal becomes a solid solution state. The vacuum degree in the vacuum chamber 31 is maintained at, for example, a medium vacuum (10) 2 Pa～10 -1 Pa pressure) or so. When the mold 1 is a closed space and the inside of the mold 1 can be in a reduced pressure state, the vacuum pump 32 may be connected to the mold 1.
In this solidification step, as the temperature of the molten metal M1 decreases, hydrogen dissolved in the metal is released. The released hydrogen evolves as a gas. Further, the pressure of the precipitated gas is lowered and expanded, thereby generating a plurality of pores inside the molten metal M1. When the released hydrogen is precipitated as a gas, when alumina, magnesia, or the like is added, these inclusions act as pore-forming nuclei, and thus the gas is easily precipitated. Then, the gas in the molten metal M1 is bubbled by the pressure difference accompanying the pressure reduction in the vacuum chamber 31, and the molten metal M1 is solidified while being entrained in the gas vent. In this way, a metal foam having a plurality of pores inside can be manufactured.
In the solidification step of step S3, instead of the above-described method, a method may be used in which the precursor M3 put into the mold 1 is solidified and then heated in a reduced-pressure atmosphere. Therefore, another embodiment of the solidification step will be described with reference to fig. 4. Fig. 4 is a schematic view showing another example of the solidification step in the method for producing a metal foam according to the first embodiment.
In another embodiment of the solidification step (step S3), first, as shown in S4-1 of fig. 4, the precursor M3 obtained in the steps S1 and S2 is rapidly solidified to form a metal solidified body M4. The precursor M3 is solidified by, for example, immersing the precursor M3 together with the mold 1 in a water bath 40 containing a refrigerant R. This gave a metal solidified material M4 in which the precursor M3 was rapidly solidified. As the refrigerant R, water, liquid nitrogen, or the like can be used. However, the method of solidifying the precursor M3 is not limited to this method.
Subsequently, as shown in S4-2 in FIG. 4, the obtained metal solidified body M4 was subjected to vacuum heat treatment. The vacuum heating process is performed by using, for example, a vacuum heating apparatus 30b having a vacuum chamber 31, a vacuum pump 32, a vacuum valve 33, a heating device 34 such as a heater, and a cooling device (not shown) using nitrogen gas. The obtained metal solidified product M4 was placed in the vacuum chamber 31, and the inside of the vacuum chamber 31 was heated by the heating device 34. At this time, the metal solidified material M4 is heated to a temperature at which the metal contained therein is in a solid solution state. Thereby, hydrogen contained in the metal solidified body M4 is released, and a gas is precipitated.
Further, after the heating was stopped, the vacuum pump 32 was operated to reduce the pressure in the vacuum chamber 31 and the inside of the vacuum chamber 31 was cooled by using a cooling device. The heated metal solidified body M4 was cooled and solidified under a reduced pressure environment to obtain a metal foam. In a reduced-pressure atmosphere and in a cooled state, the precipitated gas is fixed in an expanded state. Thereby, a metal foam having a plurality of pores therein can be produced.
In this way, according to the method of performing the vacuum heat treatment after solidifying the precursor M3, the temperature management of the object to be treated (metal solidified body M4) placed in the vacuum chamber 31 becomes easy, and therefore the productivity is improved. In addition, the quality of the foam metal is improved by improving the precision of temperature management.
The present invention will be described more specifically below with reference to the first and second embodiments. The examples, however, do not limit the invention.
(embodiment one)
In this example, aluminum was used as the metal of the raw material. Heating the aluminum to 650-700 ℃ in the stirring container 10 to obtain the aluminum molten metal. To the aluminum molten metal, granular calcium T1 was added in an amount of 1.5 mass%, alumina powder T2 was added in an amount of 1.5 mass%, and the mixture was stirred at 500 to 1000rpm for 20 minutes to obtain a mixture M2 containing the aluminum molten metal, calcium, and alumina.
The alumina powder T2 used had a particle size of 50 μm. As the alumina powder T2, an oxide (alumina in the case where the metal is aluminum) produced by a reaction between a metal such as aluminum and oxygen when the metal is kept in an atmosphere in a molten metal state can be used. When such an unnecessary oxide (so-called slag) is used as the alumina powder T2, the production cost of the metal foam can be further reduced.
The tip of the introduction tube 20 is put into the above-mentioned mixerIn the compound M2, the steam V was added to the mixture M2 while blowing the steam V through the introduction pipe 20. As the water vapor V, water (H) is added 2 O) in an amount of 3 to 4 mol/kgAl. Thus, a precursor M3 saturated in the amount of solid-solution hydrogen in aluminum was prepared. The preparation of precursor M3 was carried out in atmospheric air.
The prepared precursor M3 was transferred from the stirred vessel into a relatively thin mold 1. In the present embodiment, a bottomed cup-shaped mold having an upper end opening is used as the mold 1.
Next, the precursor M3 is placed in the vacuum chamber 31 of the vacuum apparatus 30a together with the mold 1. Then, the pressure in the vacuum chamber 31 was reduced from atmospheric pressure to about 10Pa at a temperature of about 500 ℃ for the precursor M3, and the precursor M3 was condensed and solidified under a reduced pressure environment. Thereby, hydrogen dissolved in aluminum is released, and gas is precipitated.
Further, the gas expands due to the pressure difference accompanying the decompression, and the aluminum molten metal solidifies with a plurality of pores formed inside. Then, the solidified foamed metal molded body is taken out of the mold 1, whereby porous aluminum having a density of about 0.9g/cc and a porosity of about 65% is obtained.
Further, the generation of hydrogen based on the reaction of aluminum with water vapor V (water) is represented by the following formula (1).
2Al+3H 2 O→AlO 3 +6H … type (1)
Example two
This example was carried out in accordance with the manner of the solidification step shown in FIG. 4. First, precursor M3 was prepared in the same manner as in example one, and was charged into mold 1. Then, the precursor M3 put into the mold 1 was immersed in the water tank 40 containing water as the refrigerant R, to obtain a metal solidified body M4. The metal solidified body M4 contains at least aluminum, calcium oxide, aluminum oxide, and hydrogen.
Next, the obtained metal solidified body M4 was subjected to vacuum heating treatment using the vacuum heating apparatus 30 b. In the vacuum heating treatment, metal solidified body M4 charged into mold 1 is placed in vacuum chamber 31, and metal solidified body M4 is heated to about 500 ℃. Then, the heating was stopped, the pressure in the vacuum chamber 31 was reduced from the atmospheric pressure to about 10Pa, and the heated metal solidified body M4 was rapidly cooled. In this manner, the metal solidified body M4 was subjected to vacuum heat treatment, and the cooled and solidified foamed metal molded body was taken out from the mold 1, thereby obtaining porous aluminum as in the examples.
However, in the production method described in patent document 1, for example, a die casting apparatus is required to produce the metal foam, and thus the production equipment becomes large. Further, in the method using the die casting device, it is difficult to form the metal foam of a complicated shape. Further, the production method described in patent document 1 is a method of obtaining a metal foam precursor by repeatedly performing friction stirring on a die-cast molding, and the process is complicated, and therefore, the productivity is low.
In contrast, in the method for producing a metal foam according to the present embodiment, a die casting device is not required, and the production process is simple. In addition, the die 1 for molding the metal foam can be a thin die as compared with a die-casting die provided in a die-casting device. Therefore, the method for producing a metal foam according to the present embodiment is low in cost and high in productivity. Further, since a mold having a complicated shape can be used, the degree of freedom in the shape of the metal foam produced by the method for producing a metal foam according to the present embodiment is high.
In addition, as another method for producing a metal foam, there is a molten metal foaming method using a hydride such as titanium hydride or zirconium hydride as a foaming agent, but since such a foaming agent is expensive, the production cost of the metal foam increases. In the case of using a foaming agent having a low thermal decomposition temperature, the material of the metal as the raw material is limited to a metal having a low melting point.
In contrast, in the method for producing a metal foam according to the present embodiment, an inexpensive material such as water vapor can be used as a hydrogen source for forming pores. According to this structure, since the metal foam can be produced without using an expensive foaming agent, the production cost of the metal foam can be reduced. In addition, the restriction of the metal material due to the thermal decomposition temperature of the foaming agent is relaxed.
Therefore, according to the method for producing a metal foam of the present embodiment, a molded article having a desired shape can be easily produced using simple equipment and materials.
It will be obvious from the above disclosure that the embodiments of the disclosure can be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Claims (1)

1. A method for producing a metal foam, comprising:
a step of dissolving hydrogen in a mixture containing a molten metal and a tackifier to prepare a precursor which saturates the amount of dissolved hydrogen in the metal;
a step of putting the precursor into a mold; and
and a step of solidifying the precursor charged into the mold in a reduced-pressure environment, or heating the precursor charged into the mold in a reduced-pressure environment after solidifying the precursor.
CN202210112876.XA 2021-02-09 2022-01-29 Method for producing metal foam Pending CN114908268A (en)

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JP2021019331A JP2022122172A (en) 2021-02-09 2021-02-09 Method for manufacturing metal foam
JP2021-019331 2021-02-09

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2895819A (en) * 1957-09-03 1959-07-21 Bjorksten Res Lab Inc Method for preparing a catalytic metal foam and use thereof
US3843353A (en) * 1969-02-19 1974-10-22 Ethyl Corp Preparation of metal foams of aluminum
DE10104340A1 (en) * 2001-02-01 2002-08-08 Goldschmidt Ag Th Process for the production of metal foam and metal body produced thereafter
CN101948962A (en) * 2010-09-19 2011-01-19 昆明理工大学 Vacuum foaming method for preparing foamed aluminum/aluminum alloy
CN110438361A (en) * 2019-08-29 2019-11-12 东北大学 A kind of air blast prepares the device and method of foamed aluminium material

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2895819A (en) * 1957-09-03 1959-07-21 Bjorksten Res Lab Inc Method for preparing a catalytic metal foam and use thereof
US3843353A (en) * 1969-02-19 1974-10-22 Ethyl Corp Preparation of metal foams of aluminum
DE10104340A1 (en) * 2001-02-01 2002-08-08 Goldschmidt Ag Th Process for the production of metal foam and metal body produced thereafter
CN101948962A (en) * 2010-09-19 2011-01-19 昆明理工大学 Vacuum foaming method for preparing foamed aluminum/aluminum alloy
CN110438361A (en) * 2019-08-29 2019-11-12 东北大学 A kind of air blast prepares the device and method of foamed aluminium material

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* Cited by examiner, † Cited by third party
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于利民,王录才,王芳: "熔体发泡法制备工艺的发展与展望" *
王倩;徐方明;许庆彦;熊守美;: "熔体吹气发泡法制备泡沫铝研究" *
王宏伟;李庆芬;李智伟;朱兆军;魏尊杰;: "铸造法制备泡沫金属材料" *
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Application publication date: 20220816