EP0236729B1 - Composite material including silicon nitride whisker type short fiber reinforcing material and aluminum alloy matrix metal with moderate copper and magnesium contents - Google Patents

Composite material including silicon nitride whisker type short fiber reinforcing material and aluminum alloy matrix metal with moderate copper and magnesium contents Download PDF

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Publication number
EP0236729B1
EP0236729B1 EP87101468A EP87101468A EP0236729B1 EP 0236729 B1 EP0236729 B1 EP 0236729B1 EP 87101468 A EP87101468 A EP 87101468A EP 87101468 A EP87101468 A EP 87101468A EP 0236729 B1 EP0236729 B1 EP 0236729B1
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Prior art keywords
composite material
silicon nitride
aluminum alloy
matrix metal
content
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EP87101468A
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German (de)
English (en)
French (fr)
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EP0236729A2 (en
EP0236729A3 (en
Inventor
Masahiro Kubo
Atsuo Tanaka
Tadashi Dohnomoto
Hidetoshi C/O Toyoda Automatic Loom Works Hirai
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Toyota Motor Corp
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Toyota Motor Corp
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    • 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
    • C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
    • C22C49/04—Light metals
    • C22C49/06—Aluminium

Definitions

  • the present invention relates to a composite material made up from reinforcing fibers embedded in a matrix of metal, and more particularly relates to such a composite material utilizing silicon nitride whisker type material as the reinforcing fiber material, and aluminum alloy as the matrix metal, i.e. to a silicon nitride whisker reinforced aluminum alloy.
  • JIS standard AC8A (from about 0.8% to about 1.3% Cu, from about 11.0% to about 13.0% Si, from about 0.7% to about 1.3% Mg, from about 0.8% to about 1.5% Ni, remainder substantially Al)
  • JIS standard AC8B (from about 2.0% to about 4.0% Cu, from about 8.5% to about 10.5% Si, from about 0.5% to about 1.5% Mg, from about 0.1% to about 1% Ni, remainder substantially Al)
  • JIS standard AC4C (Not more than about 0.25% Cu, from about 6.5% to about 7.5% Si, from about 0.25% to about 0.45% Mg, remainder substantially Al)
  • AA standard A201 (from about 4% to about 5% Cu, from about 0.2% to about 0.4% Mn, from about 0.15% to about 0.35% Mg, from about 0.15% to about 0.35% Ti, remainder substantially Al)
  • AA standard A356 (from about 6.5% to about 7.5% Si, from about 0.25% to about 0.45% Mg, not more than about 0.2% Fe, not more than about 0.2% Cu
  • JIS standard 6061 (from about 0.4% to about 0.8% Si, from about 0.15% to about 0.4% Cu, from about 0.8% to about 1.2% Mg, from about 0.04% to about 0.35% Cr, remainder substantially Al)
  • JIS standard 5056 (not more than about 0.3% Si, not more than about 0.4% Fe, not more than about 0.1% Cu, from about 0.05% to about 0.2% Mn, from about 4.5% to about 5.6% Mg, from about 0.05% to about 0.2% Cr, not more than about 0.1% Zn, remainder substantially Al)
  • JIS standard 2024 (about 0.5% Si, about 0.5% Fe, from about 3.8% to about 4.9% Cu, from about 0.3% to about 0.9% Mn, from about 1.2% to about 1.8% Mg, not more than about 0.1% Cr, not more than about 0.25% Zn, not more than about 0.15% Ti, remainder substantially Al).
  • Such a JIS standard 2024 aluminum alloy is used, besides other aluminum alloys, in the EP-A-0 170 396 in a method of manufacturing short inorganic fiber-reinforced metal composites.
  • attention is directed to a homogeneous distribution of the inorganic fibers in the metal matrix without damaging the fibers. This is achieved by first producing a porous preform of a whisker body, and then casting molten metal material into the porous preform under high pressure.
  • JIS standard 7075 (not more than about 0.4% Si, not more than about 0.5% Fe, from about 1.2% to about 2.0% Cu, not more than about 0.3% Mn, from about 2.1% to about 2.9% Mg, from about 0.18% to about 0.28% Cr, from about 5.1% to about 6.1% Zn, about 0.2% Ti, remainder substantially Al)
  • the inventors of the present application have considered the above mentioned problems in composite materials which use such conventional aluminum alloys as matrix metal, and in particular have considered the particular case of a composite material which utilizes silicon nitride whisker type material as reinforcing fiber material, since such silicon nitride whiskers, among the various types of reinforcing fibers used conventionally in the manufacture of a fiber reinforced metal composite material, have particularly high strength and are exceedingly effective in improving the high temperature stability and the strength of the composite material.
  • the present inventors as a result of various experimental researches to determine what composition of the aluminum alloy to be used as the matrix metal for such a composite material is optimum, have discovered that an aluminum alloy having a content of copper and a content of magnesium within certain limits, and containing substantially no silicon, nickel, zinc, and so forth is optimal as matrix metal, particularly in view of the bending strength characteristics of the resulting composite material.
  • the present invention is based on the knowledge obtained from the results of the various experimental researches carried out by the inventors of the present application, as will be detailed later in this specification.
  • a composite material comprising a mass of silicon nitride whiskers embedded in a matrix of metal at a volume proportion selected in a range of 5 to 50 vol.-% , said matrix metal being an alloy consisting of copper at a content selected from a range of 2 to 6 wt.-%, magnesium at a content selected from a range of 0.5 to 3 wt.-% and remainder aluminum and not more than 1 wt.-% in total and 0.5 wt.-% in individual of silicon, iron, zinc, manganese, nickel, titanum and chromium inevitably included in aluminum, wherein the volume proportion of the silicon nitride whiskers, the content of copper and the content of magnesium are selected in relation to one another so as to optimize the bending strength of the composite material.
  • the fiber volume proportion of said silicon nitride whisker type fibers should be between 5% and 50%; but, more preferably, said fiber volume proportion of said silicon nitride whisker type fibers should be between 5% and 40%.
  • the volume proportion of silicon nitride type short fibers in a composite material according to the present invention may be set to be lower than the value required for such a conventional composite material, and therefore, since it is possible to reduce the amount of silicon nitride whiskers used, the machinability and workability of the composite material can be improved, and it is also possible to reduce the cost of the composite material. Further, the characteristics with regard to wear on a mating member will be improved.
  • the strength of the aluminum alloy matrix metal is increased and thereby the strength of the composite material is improved, but that effect is not sufficient if the copper content is less than 2%, whereas if the copper content is more than 6% the composite material becomes very brittle, and has a tendency rapidly to disintegrate. Therefore the copper content of the aluminum alloy used as matrix metal in the composite material of the present invention is required to be in the range of from 2% to 6%, and more preferably is desired to be in the range of from 2% to 5%.
  • oxides or O radicals are inevitably always present on the surfaces of such silicon nitride whiskers used as reinforcing fibers, and if, as is contemplated in the above presented discussion, magnesium, which has a strong tendency to form oxides, is contained within the molten matrix metal, such magnesium will react with the oxides or O radicals on the surfaces of the silicon nitride whiskers, and will reduce the surfaces of the silicon nitride whiskers, as a result of which the affinity of the molten aluminum alloy matrix metal and the silicon nitride whiskers will be improved, and by this means the strength of the composite material will be improved along with an increase in the content of magnesium, as experimentally has been established as will be described in the following, up to a magnesium content of 2%.
  • the magnesium content of the aluminum alloy used as matrix metal in the composite material of the present invention is desired to be from 0.5% to 3%, and preferably from 0.5% to 2.5%, and even more preferably from 0.5% to 2%.
  • the volume proportion of the silicon nitride whisker type short fibers is less than 5%, a sufficient strength cannot be obtained; while, if said volume proportion of the silicon nitride whisker type short fibers is between 5% and 40%, the strength of the composite material increases greatly and substantially linearly along with increase in said silicon nitride whisker volume proportion; and, if said volume proportion of the silicon nitride whisker type short fibers exceeds 40%, and particularly if it exceeds 50%, even if said volume proportion of the silicon nitride whisker type short fibers is further increased, the strength of the composite material is not very significantly improved.
  • the wear resistance of the composite material increases with the volume proportion of the silicon nitride whisker type short fiber material, but when the volume proportion of the silicon nitride whisker type short fibers is in the range from zero to 5% said wear resistance increases rapidly with an increase in the volume proportion of the silicon nitride whisker type short fibers, whereas, on the other hand, when the volume proportion of the silicon nitride whisker type short fibers is in the range of at least 50%, the wear resistance of the composite material does not very significantly increase with an increase in said volume proportion of said silicon nitride whisker type short fibers. Therefore, according to one characteristic of the present invention, the volume proportion of the silicon nitride whisker type short fibers is required to be in the range of from 5% to 50%, and preferably is required to be in the range of from 5% to 40%.
  • the volume proportion of the silicon nitride whiskers is in the relatively high portion of the above described desirable range, that is to say is from 30% to 40%, it is preferable that the copper content of the aluminum alloy should be from 2% to 5%. Therefore, according to another detailed characteristic of the present invention, the volume proportion of the silicon nitride whiskers should be from 30% to 40%, and the copper content of the aluminum alloy should be from 2% to 5%.
  • the copper content of the aluminum alloy used as matrix metal of the composite material of the present invention has a relatively high value, if there are unevennesses in the concentration of the copper or the magnesium within the aluminum alloy, the portions where the copper concentration or the magnesium concentration is high will be brittle, and it will not therefore be possible to obtain a uniform matrix metal or a composite material of good and uniform quality.
  • such a composite material of which the matrix metal is aluminum alloy of which the copper content is at least 2% and is less than 3.5% is subjected to liquidizing processing for from about 2 hours to about 8 hours at a temperature of from about 480°C to about 520°C
  • such a composite material of which the matrix metal is aluminum alloy of which the copper content is at least 3.5% and is less than 6% is subjected to liquidizing processing for from about 2 hours to about 8 hours at a temperature of from about 460°C to about 510°C.
  • these materials are also, preferably, further subjected to aging processing for about 2 hours to about 8 hours at a temperature of from about 150°C to 200°C.
  • the fiber length of the silicon nitride whisker type short fibers is preferably from 10 ⁇ m to 5 ⁇ m cm, and particularly is from 50 ⁇ m to 2 ⁇ m cm, and the fiber diameter of said silicon nitride whisker type fibers is further desired, preferably, to be from 0.1 ⁇ m to 25 ⁇ m and particularly is more preferably desired to be from 0.1 ⁇ m to 20 ⁇ m.
  • the reinforcing fiber material of which was to be silicon nitride whiskers the present inventors manufactured by using the high pressure casting method samples of various composite materials, utilizing as reinforcing material silicon nitride whisker material (manufactured by Tateho Kagaku K.K.) which had composition at least 99% Si3N4 and which had average fiber length 150 ⁇ m and average fiber diameter 1 ⁇ m and utilizing as matrix metal Al-Cu-Mg type aluminum alloys of various compositions. Then the present inventors conducted evaluations of the bending strength of the various resulting composite material sample pieces.
  • silicon nitride whisker material manufactured by Tateho Kagaku K.K.
  • a set of aluminum alloys designated as A1 through A42 were produced, having as base material aluminum and having various quantities of magnesium and copper mixed therewith, as shown in the appended Table 1; this was done by, in each case, combining an appropriate quantity of pure aluminum metal (purity at least 99%), an appropriate quantity of pure magnesium metal (purity at least 99%), and an appropriate quantity of a mother alloy of 50% aluminum and 50% copper.
  • three sets, each containing an appropriate number (actually, forty two), of silicon nitride whisker material preforms were made by, in each case, subjecting a quantity of the above specified silicon nitride whisker material to compression forming without using any binder.
  • each of these silicon nitride whisker material preforms was, as schematically illustrated in perspective view in Fig. 7 wherein an exemplary such preform is designated by the reference numeral 2 and the silicon nitride whiskers therein are generally designated as 1, about 38 x 100 x 16 mm in dimensions, and the individual silicon nitride whiskers 1 in said preform 2 were oriented in a substantially three dimensionally random manner.
  • the fiber volume proportion in a first set of said preforms 2 was 20%, in a second set of said preforms 2 was 10%, and in a third set of said preforms 2 was 5%; thus, in all, there were a hundred and twenty six such preforms.
  • each of these silicon nitride whisker material preforms 2 was subjected to high pressure casting together with an appropriate quantity of one of the aluminum alloys A1 through A42 described above, in the following manner.
  • the preform 2 was was inserted into a stainless steel case 2a, as shown in perspective view in Fig. 8, which was 38 x 100 x 16 mm in internal dimensions and had both of its ends open.
  • each of these stainless steel cases 2a with its preform 2 held inside it was heated up to a temperature of 600°C, and then as shown in schematic sectional view in Fig. 9 said case 2a and said preform 2 were placed within a mold cavity 4 of a casting mold 3, which itself had previously been preheated up to a temperature of 250°C.
  • the molten aluminum alloy was caused to percolate into the interstices of the silicon nitride whisker material preform 2.
  • This pressurized state was maintained until the quantity 5 of molten aluminum alloy had completely solidified, and then the pressure plunger 6 was removed and the solidified aluminum alloy mass with the stainless steel case 2a and the preform 2 included therein was removed from the casting mold 3, and the peripheral portion of said solidified aluminum alloy mass and also the stainless steel case 2a were machined away, leaving only a sample piece of composite material which had silicon nitride whisker material as reinforcing material and the appropriate one of the aluminum alloys A1 through A42 as matrix metal.
  • the volume proportion of silicon nitride whisker material in each of the resulting composite material sample pieces thus produced from the first set (forty two in number) of said preforms 2 was 20%, in each of the resulting composite material sample pieces thus produced from the second set (also forty two in number) of said preforms 2 was 10%, and in each of the resulting composite material sample pieces thus produced from the third set (likewise forty two in number) of said preforms 2 was 5%.
  • the magnesium content when the magnesium content was in the range of from 1% to 2%, the bending strength of the composite material test sample pieces attained a substantially maximum value; and, when the magnesium content increased above or decreased below this range, then the bending strength of the composite material test sample pieces decreased gradually; while, when the magnesium content was either in the low range below 0.5% or was in the high range above 3%, the bending strength of the composite material test sample pieces reduced relatively suddenly with decrease or increase respectively of the magnesium content; and, when the magnesium content was 4%, the bending strength of the composite material test sample pieces had substantially the same value as, or at any rate a not greater value than, when the magnesium content was 0%.
  • the copper content of said Al-Cu-Mg type aluminum alloy matrix metal should be in the range of from 2% to 6%; while the magnesium content of said Al-Cu-Mg type aluminum alloy matrix metal should be in the range of from 0.5% to 3%, more preferably should be in the range of from 0.5% to 2.5%, and even more preferably should be in the range of from 0.5% to 2%.
  • the present inventors manufactured further samples of various composite materials, again utilizing as reinforcing material the same silicon nitride short type fiber material, and utilizing as matrix metal substantially the same forty two Al-Cu-Mg type aluminum alloys, but this time employing, for the one set, fiber volume proportions of 40%, and, for another set, fiber volume proportions of 30%. Then the present inventors again conducted evaluations of the bending strength of the various resulting composite material sample pieces.
  • a set of forty two quantities of aluminum alloy material the same as those utilized in the first set of preferred embodiments were produced in the same manner as before, again having as base material aluminum and having various quantities of magnesium and copper mixed therewith.
  • an appropriate number (actually eighty six) of silicon nitride whisker type fiber material preforms were as before made by the method disclosed above with respect to the first set of preferred embodiments, one group of said silicon nitride short whisker type fiber material preforms now having a fiber volume proportion of 40%, and another set of said silicon nitride short whisker type fiber material preforms now having a fiber volume proportion of 30%, by contrast to the first set of preferred embodiments described above.
  • These preforms had substantially the same dimensions as the preforms of the first set of preferred embodiments.
  • each of these silicon nitride whisker type material preforms was subjected to high pressure casting together with an appropriate quantity of one of the aluminum alloys A1 through A42 described above, utilizing operational parameters substantially as before.
  • the solidified aluminum alloy mass with the preform included therein was then removed from the casting mold, and the peripheral portion of said solidified aluminum alloy mass and the stainless steel case were machined away, leaving only a sample piece of composite material which had silicon nitride short whisker type fiber material as reinforcing material and the appropriate one of the aluminum alloys A1 through A42 as matrix metal.
  • the volume proportion of silicon nitride short whisker type fibers in each of the one group of the resulting composite material sample pieces was thus now 40%, and in each of the other group of the resulting composite material sample pieces was thus now 30%.
  • post processing steps were performed on the composite material samples, substantially as before. From each of the composite material sample pieces manufactured as described above, to which heat treatment had been applied, there was cut a bending strength test piece of dimensions and parameters substantially as in the case of the first set of preferred embodiments, and for each of these composite material bending strength test pieces a bending strength test was carried out, again substantially as before.
  • the magnesium content when the magnesium content was in the range of from 0.5% to 2%, the bending strength of the composite material test sample pieces attained a substantially maximum value; and, when the magnesium content increased above or decreased below this range, then the bending strength of the composite material test sample pieces decreased gradually; while, when the magnesium content was either in the low range below 0.5% or was in the high range above 3%, the bending strength of the composite material test sample pieces reduced relatively suddenly with decrease or increase respectively of the magnesium content; and, when the magnesium content was 4%, the bending strength of the composite material test sample pieces had substantially the same value as, or at least a value not greater than, when the magnesium content was 0%.
  • the copper content of said Al-Cu-Mg type aluminum alloy matrix metal should be in the range of from 2% to 6%, and particularly should be in the range of from 2% to 5%, while the magnesium content of said Al-Cu-Mg type aluminum alloy matrix metal should be in the range of from 0.5% to 3%, and particularly should be in the range of from 0.5% to 2.5%, and even more particularly should be in the range of from 0.5% to 2%.
  • an appropriate number (in fact six) of preforms made of the whisker type silicon nitride material used in the preferred embodiments detailed above, hereinafter denoted respectively as B1 through B6, were made by subjecting quantities of said short fiber material to compression forming without using any binder, in the same manner as in the above described two sets of preferred embodiments, the six ones in said set of silicon nitride whisker type short fiber material preforms having fiber volume proportions of 5%, 10%, 20%, 30%, 40%, and 50%.
  • These preforms had substantially the same dimensions and the same type of three dimensional random fiber orientation as the preforms of the above described sets of preferred embodiments.
  • each of these silicon nitride whisker type short fiber material preforms was subjected to high pressure casting together with an appropriate quantity of the aluminum alloy matrix metal described above, utilizing operational parameters substantially as before.
  • the solidified aluminum alloy mass with the preform included therein was then removed from the casting mold, and as before the peripheral portion of said solidified aluminum alloy mass was machined away along with the stainless steel case which had been utilized, leaving only a sample piece of composite material which had silicon nitride whisker type short fiber material as reinforcing material in the appropriate fiber volume proportion and had the described aluminum alloy as matrix metal.
  • post processing and artificial aging processing steps were performed on the composite material samples, similarly to what was done before.
  • the fiber volume proportion of said silicon nitride type short fiber reinforcing material should be in the range of from 5% to 50%, and more preferably should be in the range of from 5% to 40%.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Inorganic Fibers (AREA)
EP87101468A 1986-02-06 1987-02-04 Composite material including silicon nitride whisker type short fiber reinforcing material and aluminum alloy matrix metal with moderate copper and magnesium contents Expired - Lifetime EP0236729B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2453986A JPS62182235A (ja) 1986-02-06 1986-02-06 窒化ケイ素ホイスカ強化アルミニウム合金
JP24539/86 1986-02-06

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EP0236729A2 EP0236729A2 (en) 1987-09-16
EP0236729A3 EP0236729A3 (en) 1989-07-05
EP0236729B1 true EP0236729B1 (en) 1993-10-27

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EP87101468A Expired - Lifetime EP0236729B1 (en) 1986-02-06 1987-02-04 Composite material including silicon nitride whisker type short fiber reinforcing material and aluminum alloy matrix metal with moderate copper and magnesium contents

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JP (1) JPS62182235A (ja)
DE (1) DE3787904T2 (ja)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5106702A (en) * 1988-08-04 1992-04-21 Advanced Composite Materials Corporation Reinforced aluminum matrix composite
FR2639360B1 (fr) * 1988-11-21 1991-03-15 Peugeot Procede de fabrication d'un materiau composite a matrice metallique, et materiau obtenu par ce procede
CA2054018A1 (en) * 1991-02-25 1992-08-26 Thomas Wesley Gustafson Metal matrix composite composition and method

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0170396A1 (en) * 1984-06-25 1986-02-05 Mitsubishi Aluminium Kabushiki Kaisha Method of manufacturing short inorganic fiber-reinforced metal composites

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Publication number Priority date Publication date Assignee Title
DE1719503A1 (de) * 1968-02-27 1971-05-27 Gen Technologies Corp Whiskerhaltige Legierungen bzw. Gegenstaende und Verfahren zu deren Herstellung
US3833697A (en) * 1969-02-14 1974-09-03 Melpar Inc Process for consolidation and extrusion of fiber-reinforced composites
US4152149A (en) * 1974-02-08 1979-05-01 Sumitomo Chemical Company, Ltd. Composite material comprising reinforced aluminum or aluminum-base alloy
US4463058A (en) * 1981-06-16 1984-07-31 Atlantic Richfield Company Silicon carbide whisker composites
JPS60251922A (ja) * 1984-05-28 1985-12-12 Kobe Steel Ltd ウイスカ−と金属粉末の均一混合法

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0170396A1 (en) * 1984-06-25 1986-02-05 Mitsubishi Aluminium Kabushiki Kaisha Method of manufacturing short inorganic fiber-reinforced metal composites

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
"Registration Record of International Alloy Designations and Chemical Composition Limits for Wrought Aluminium and Wrought Aluminium Alloys", The Aluminium Association, Sept. 1976, page 4 *
Metals Handbook, 9th Ed., Vol. 2 (1979), page 45 *

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DE3787904D1 (de) 1993-12-02
DE3787904T2 (de) 1994-03-17
EP0236729A2 (en) 1987-09-16
JPS62182235A (ja) 1987-08-10
EP0236729A3 (en) 1989-07-05

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