CN114932223B - 一种金属基复合材料的共烧结制备方法 - Google Patents
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Abstract
本发明涉及一种金属基复合材料的共烧结制备方法,涉及粉末成形领域,包括以下步骤:S1、通过粉末成形工艺制备预制体;所述预制体包括产品部分和延伸浇道;所述延伸浇道上设有用于放置增强体的放置部;所述放置部远离产品部分;S2、对预制体进行脱脂,获得脱脂坯;S3、将增强体放置在脱脂坯的延伸浇道的放置部后,进行烧结,得到烧结态产品;其中增强体的熔点低于预制体的烧结温度;S4、去除烧结态产品上的延伸浇道及残留增强体,得到最终产品。本发明可使预制体烧结过程中进行增强体的渗入,渗透效果明显优于粉末阶段和后工序浸润进行增强体渗入的效果,使得其对于预制体和增强体的要求少,可适用于各类金属基复合材料的制备。
Description
技术领域
本发明涉及粉末成形领域,特别涉及一种金属基复合材料的共烧结制备方法。
背景技术
在粉末成型领域,金属基复合材料的制备通常使用两种方法,即粉末混合法和热压法。其中,粉末混合法适用范围小,多数材料在粉末阶段混合不匀,或混合后影响原产品的生坯形成和烧结等工序,导致密度等其他性能受到影响;而热压法选择在材料成型后使用高温高压进行固相强行复合,复合效果差,对于尺寸较大产品,增强体通常只能渗入表面一定深度。而金属熔渗法通常采用常压法和真空浸润法,常压法通常在产品表面放置低熔点增强体,因为熔渗速度过快,过程难以控制导致渗透均匀性较差。浸润法是将烧结后产品浸入含有液体增强相的坩埚内,同样产品表面的增强相浓度要远远高于芯部,同时表面包裹的金属层较难处理。
发明内容
本发明的目的是一种金属基复合材料的共烧结制备方法,该方法可使预制体烧结过程中进行增强体的渗入,渗透效果明显优于粉末阶段和后工序浸润进行增强体渗入的效果,使得其对于预制体和增强体的要求少,可适用于各类金属基复合材料的制备。
实现本发明目的的技术方案是:本发明包括以下步骤:
S1、通过粉末成形工艺制备预制体;所述预制体包括产品部分和延伸浇道;当产品部分与延伸浇道为同材质时,产品部分与延伸浇道为一体制备;当产品部分与延伸浇道为不同材质时,产品部分与延伸浇道分开制备后再将产品部分放置在延伸浇道上,并且制备延伸浇道的材料的熔点低于制备产品部分的材料的熔点;
所述延伸浇道上设有用于放置增强体的放置部;所述放置部远离产品部分;
S2、对预制体进行脱脂,得到脱脂坯;
S3、将增强体放置在脱脂坯的延伸浇道的放置部后,进行烧结,得到烧结态产品;其中增强体的熔点低于预制体的烧结温度;
S4、当产品部分与延伸浇道为同材质时,将烧结态产品上的延伸浇道及残留增强体通过机加工方式去除,得到最终产品;
当产品部分与延伸浇道为不同材质时,将烧结态产品上的延伸浇道与产品部分进行分离,得到最终产品。
进一步,上述步骤S3中,将增强体放置在延伸浇道的放置部后,放在适配的烧结治具或掩埋入石英砂中进行烧结。通过适配的烧结治具和埋入石英砂中进行烧结,可让预制体的形状不会被破坏。
进一步,上述延伸浇道包括主浇道和多个子浇道;所述子浇道的一端与主浇道连接成一体,另一端与产品部分连接成一体;所述主浇道上的放置部远离产品部分。
进一步,上述放置部设置在主浇道的两端,各子浇道分别设置在主浇道的两侧。
作为优化,子浇道对称设置在主浇道的两侧。
进一步,上述子浇道包括底座;底座的底面与主浇道连接成一体;底座的上表面的边缘设有多个向上延伸的分支部;多个分支部与产品部分连接成一体。
进一步,多个分支部形成的部件的几何中心与产品部分中心在同一法线上。
进一步,上述放置部为槽体;所述增强体放置在槽体内。进一步,槽体可设计成圆槽型。
进一步,上述粉末成形工艺为粉末注射成形工艺或粉末热压成形工艺或粉末3D打印成形工艺。其中粉末注射成形工艺是将喂料通过注射机注射成形制备预制体,而粉末热压成形工艺是将喂料通过热压成形制备预制体;而3D打印成形工艺是将喂料通过3D打印技术制备预制体。当采用3D打印成形工艺制备预制体时,可直接通过修改打印模型,来适应不同材质预制体的工艺调整。
进一步,上述放置部与延伸浇道之间设有斜坡;所述斜坡从放置部向延伸浇道呈向上延伸的状态。
其中,预制体采用可通过粉末成形工艺中形成预制体的金属粉末或陶瓷粉末等;而增强体可以是粉体或者固体;而增强体的材质可以是纯金属、合金等;其中当采用合金时,合金中的主要元素的熔点不低于预制体的烧结温度,避免在共烧结中远距离扩散。而远距离扩散会导致元素分布不均一,产品性能不稳定。
本发明具有积极的效果:(1)本发明适用于粉末成型工艺中金属基复合材料的制备,打破传统工艺的复合思路,将增强体渗透的过程调整至粉末预制体的烧结过程中进行,预制体的密度远远小于成形材料,在烧结致密化的过程中渗入增强体可有效提升复合效果,通过合理地设计延伸浇道的构型,使得渗透过程平缓而均匀,解决了目前主流金属基复合材料制备工艺复合效果差、适用范围小、复合后影响材料原本性能等问题。其中增强体的渗入的具体过程为:增强体在烧结中逐渐熔融,由于此时预制体尚未烧结致密,内部存在大量孔隙,熔融增强体迅速填充至孔隙中,并持续向周围多孔位置扩散,最终以“类毛细作用”渗透至整个预制体中。
(2)本发明中通过主浇道和子浇道的设计能够在有限空间内,增加扩散路程,从而对渗透速度进行有效控制。
(3)本发明中子浇道上设计了分支部,多个分支部形成的部件的几何中心与产品中心在同一法线上,由于分支部均匀分布,因此可以保证从底座扩散过来的增强体在产品部分中均匀分布,从而提高渗透质量。
(4)本发明中放置部采用槽体,可增强体从多个面向延伸浇道扩散,而且能够在进行烧结摆件时,让增强体不会发生移位。
(5)本发明通过斜坡,能够延缓增强体向产品部分的扩散速度,以避免产品部分在烧结致密之前被大量增强体浸入,影响其致密性。
(6)本发明通过溶液特殊处理延伸浇道,去除毛细管内残留增强相,可实现主浇道和子浇道的重复循环利用,实现低能耗、低成本生产。
附图说明
为了使本发明的内容更容易被清楚地理解,下面根据具体实施例并结合附图,对本发明作进一步详细的说明,其中
图1为本发明中预制件的结构示意图;
图2为本发明中延伸浇道的结构示意图;
图3为斜坡的结构示意图;
图4为本发明实施例2中延伸浇道的结构示意图;
图5为本发明实施例2中子浇道的结构示意图;
图6为本发明实施例2中子浇道与产品的配合示意图。
具体实施方式
(实施例1)
本发明包括以下步骤:
S1、将不锈钢粉末和粘结剂混合并制备形成喂料;其中不锈钢粉末87%、聚甲醛9%、聚乙烯1%、聚丙烯2%、1010抗氧剂0.5%、润滑剂0.5%;将喂料放入3D打印设备进行3D打印,制备获得预制体;在3D打印前,对预制体进行如下设计,见图1和图2:预制体包括一体打印的产品部分1和延伸浇道2;延伸浇道2包括一条主浇道21和六个子浇道22;六个子浇道22以三个为一组对称设置在主浇道21的两侧;同侧的子浇道22的间距为60mm,子浇道22的长度为40mm,宽度为15mm;
子浇道22远离主浇道21的一端设计产品部分1;主浇道21的两端对称设有一个圆槽型的放置部211;其中放置部211与主浇道21之间设有斜坡212;所述斜坡212从放置部211向主浇道21呈向上延伸的状态;斜坡212的具体形式可见图3;斜坡结构设计是为了保证增强体融化后可以缓慢爬坡,在毛细管作用下均匀化渗透到预制体。
S2、将预制体放置于脱脂炉内进行硝酸脱脂,脱脂工艺为氮气氛,通酸时间3小时,温度130℃,从而得到脱脂坯;
S3、将增强体3放置在脱脂坯的延伸浇道2的放置部211内,然后掩埋入石英砂中进行烧结,得到烧结态产品;其中增强体3采用铜铬合金圆块;其中烧结的工艺参数为:保护气氛为氩气气氛,分压80MPa,保温温度1380℃,保温时间2h;
S4、将烧结态产品上的延伸浇道2及残留的增强体3通过CNC工艺去除,得到渗铜不锈钢产品。
(实施例2)
见图4至图6,本发明中子浇道22包括底座221;底座221的底面与主浇道21通过次子浇道222连接成一体;底座221的上表面的边缘设有多个向上延伸的分支部223;多个分支部223与产品部分1连接成一体。多个分支部223形成的部件的几何中心与产品部分1中心在同一法线上。
其中,分支部223向上延伸的高度为15mm,宽5mm,并以R=7mm的圆角与底座221进行过渡。
其他技术特征与实施例1相同。
(实施例3)
本发明包括以下步骤:
S1、选用粒径D50在15微米氧化铝粉末作为原料,通过加入造孔剂如氯化钠、小苏打、尼龙纤维中的一种或多种组合,注射成为子浇道22,通过脱脂烧结制备成形待用,所述子浇道22如实施例2所述;
S2、将子浇道22放入双料注射模具中,通过二次注射,预制体与子浇道22结合为一体,制备获得预制体;
S3、将预制体放置于脱脂炉内进行硝酸脱脂,脱脂工艺为氮气氛,通酸时间3小时,温度130℃;再将增强体3放置圆槽型的放置部211内致密化渗入烧结,得到烧结态产品;其中增强体3采用铜铬合金圆块;其中烧结的工艺参数为:保护气氛为氩气气氛,分压80MPa,保温温度1380℃,保温时间2h;
S4、将烧结态产品上的延伸浇道2及残留的增强体3通过CNC工艺去除,得到渗铜不锈钢产品。
S5、清除增强体和预制体残渣,酸性溶剂去除毛细管道内残留增强体,清洗后循环利用,所述酸可以为盐酸、稀硝酸、硫酸中的一种或多种组合。
以上所述的具体实施例,对本发明的目的、技术方案和有益效果进行了进一步详细说明,所应理解的是,以上所述仅为本发明的具体实施例而已,并不用于限制本发明,凡在本发明的精神和原则之内,所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (7)
1.一种金属基复合材料的共烧结制备方法,其特征在于包括以下步骤:
S1、通过粉末成形工艺制备预制体;所述预制体包括产品部分和延伸浇道;当产品部分与延伸浇道为同材质时,产品部分与延伸浇道为一体制备;当产品部分与延伸浇道为不同材质时,产品部分与延伸浇道分开制备后再将产品部分放置在延伸浇道上,并且制备延伸浇道的材料的熔点低于制备产品部分的材料的熔点;
所述延伸浇道包括主浇道和多个子浇道;所述子浇道的一端与主浇道连接成一体,另一端与产品部分连接成一体;所述主浇道上设有用于放置增强体的放置部;所述放置部远离产品部分;所述放置部设置在主浇道的两端,各子浇道分别设置在主浇道的两侧;
S2、对预制体进行脱脂,得到脱脂坯;
S3、将增强体放置在脱脂坯的延伸浇道的放置部后,进行烧结,得到烧结态产品;其中增强体的熔点低于预制体的烧结温度;
S4、当产品部分与延伸浇道为同材质时,将烧结态产品上的延伸浇道及残留增强体通过机加工方式去除,得到最终产品;
当产品部分与延伸浇道为不同材质时,将烧结态产品上的延伸浇道与产品部分进行分离,得到最终产品。
2.根据权利要求1所述的一种金属基复合材料的共烧结制备方法,其特征在于:所述步骤S3中,将增强体放置在延伸浇道的放置部后,放在适配的烧结治具或掩埋入石英砂中进行烧结。
3.根据权利要求1所述的一种金属基复合材料的共烧结制备方法,其特征在于:所述子浇道包括底座;底座的底面与主浇道连接成一体;底座的上表面的边缘设有多个向上延伸的分支部;多个分支部与产品部分连接成一体。
4.根据权利要求3所述的一种金属基复合材料的共烧结制备方法,其特征在于:多个分支部形成的部件的几何中心与产品部分中心在同一法线上。
5.根据权利要求1或2或3所述的一种金属基复合材料的共烧结制备方法,其特征在于:所述放置部为槽体;所述增强体放置在槽体内。
6.根据权利要求1所述的一种金属基复合材料的共烧结制备方法,其特征在于:所述粉末成形工艺为粉末注射成形工艺或粉末热压成形工艺或粉末3D打印成形工艺。
7.根据权利要求1所述的一种金属基复合材料的共烧结制备方法,其特征在于:所述放置部与延伸浇道之间设有斜坡;所述斜坡从放置部向延伸浇道呈向上延伸的状态。
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