EP0256450A1 - Process for manufacturing powder compacts with a high resistance and relatively low density from a heat-resisting aluminium alloy - Google Patents

Process for manufacturing powder compacts with a high resistance and relatively low density from a heat-resisting aluminium alloy Download PDF

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Publication number
EP0256450A1
EP0256450A1 EP87111463A EP87111463A EP0256450A1 EP 0256450 A1 EP0256450 A1 EP 0256450A1 EP 87111463 A EP87111463 A EP 87111463A EP 87111463 A EP87111463 A EP 87111463A EP 0256450 A1 EP0256450 A1 EP 0256450A1
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powder
heat
inert gas
green compact
relatively low
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EP0256450B1 (en
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Malcolm James Dr. Couper
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BBC Brown Boveri AG Switzerland
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/04Making non-ferrous alloys by powder metallurgy
    • C22C1/0408Light metal alloys
    • C22C1/0416Aluminium-based alloys

Definitions

  • Heat-resistant aluminum alloys which are produced from powders obtained at high cooling rates by atomizing a melt. High content of alloy components not permitted under the usual solidification conditions, e.g. Fe and Cr.
  • the invention relates to the production of aluminum alloy powders and the production of moldings from these powders.
  • Aluminum alloys which are suitable for the production of powders from melts by means of gas jet atomization using very high cooling speeds (10 ° C./s and more) and can be used for the production of heat-resistant workpieces, have become known in numerous variations.
  • An important group are the polynary alloys of the type Al / Fe / X, which usually have relatively high iron contents, where X denotes at least one of the elements Ti, Zr, Hf, V, Nb, Cr, Mo, W.
  • the shape and size distribution of the powder particles play an important role in the production of compacts.
  • the result is closely related to the gaseous atomizing agent used.
  • Spherical powders result in low mechanical strength when compressed into green compacts, since the particles are only slightly deformed. At the same time, however, the density is relatively high, which makes it difficult to degas and expel unwanted foreign substances during further processing. In contrast, non-spherical powders provide green bodies of high strength combined with low density. However, the content of substances to be degassed (oxygen, water, hydrogen) is high.
  • the invention has for its object to provide a method for producing an aluminum alloy powder by atomizing a melt, which provides a green compact with the highest possible strength and at the same time low relative density (based on the theoretical maximum value of 100%) during compression.
  • the melt was atomized in a device by means of a gas stream to a powder with a maximum particle diameter of 50 ⁇ m.
  • Inert gases nitrogen, argon
  • oxygen oxygen
  • Example II Analogously to Example I, the melt was atomized into a powder in various ways and subsequently compacted. Samples for determining the compressive strength and the relative density were worked out from the compact. The results are as follows:
  • the green pressed bodies of the above exemplary embodiments were also subjected to a degassing process. It was found that the degassing times of the powders produced with inert atomizing gas with the addition of oxygen were between those with inert atomizing gas and those with air. Before the final thermomechanical treatment (hot pressing, extrusion), in which they reach their full, 100% density, the green pressed bodies should advantageously be degassed at a temperature of 350 to 400 ° C. for 1 to 10 hours.
  • the atomizing gas can be an inert gas such as nitrogen, argon or helium, to which 0.5 to 2% by volume of oxygen is added. It can also be a mixture of at least two of the aforementioned gases.
  • the method is preferably carried out in such a way that in the first step (atomization in the gas stream) a powder is produced which contains relatively small proportions of coarser, non-spherical particles and comparatively high proportions of fine spherical particles.
  • This can be achieved by a suitable choice of the gas composition, in particular the addition of oxygen.

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Powder Metallurgy (AREA)
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Abstract

Ein grüner Presskörper hoher Festigkeit und niedriger relativer Dichte aus einer warmfesten Aluminiumlegierung des Typs Al/Fe/X oder Al/Cr/X mit X = Ti, Ce, Zr, Hf, V, Nb, Cr, Mo, W wird pulvermetallurgisch dadurch hergestellt, dass eine Legierungsschmelze mittels eines inerten Gasstrahls, dem 0,5 bis 2 Vol.-% Sauerstoff beigemengt sind, zu feinen Partikeln zerstäubt wird und das derart erzeugte Pulver verdichtet wird. Als inertes Gas kann Stickstoff, Argon oder Helium verwendet werden. Der grüne Presskörper ist bevorzugt aus einem geringen Anteil gröberer, nicht-sphärischer und einem höheren Anteil feinerer, sphärischer Partikel aufgebaut.A green compact of high strength and low relative density made of a heat-resistant aluminum alloy of the type Al / Fe / X or Al / Cr / X with X = Ti, Ce, Zr, Hf, V, Nb, Cr, Mo, W is produced by powder metallurgy that an alloy melt is atomized into fine particles by means of an inert gas jet, to which 0.5 to 2% by volume of oxygen has been added, and the powder produced in this way is compressed. Nitrogen, argon or helium can be used as the inert gas. The green compact is preferably made up of a small proportion of coarser, non-spherical and a higher proportion of finer, spherical particles.

Description

Technisches Gebiet:Technical field:

Warmfeste Aluminiumlegierungen, welche aus mit hoher Abkühlungsgeschwindigkeit durch Zerstäuben einer Schmelze gewonnenen Pulvern hergestellt werden. Hoher Gehalt an unter sonst üblichen Erstarrungsbedingungen nicht zu­lässigen Legierungsbestandteilen wie z.B. Fe und Cr.Heat-resistant aluminum alloys which are produced from powders obtained at high cooling rates by atomizing a melt. High content of alloy components not permitted under the usual solidification conditions, e.g. Fe and Cr.

Die Erfindung bezieht sich auf die Erzeugung von Alumi­niumlegierungspulvern und die Herstellung von Formkörpern aus diesen Pulvern.The invention relates to the production of aluminum alloy powders and the production of moldings from these powders.

Insbesondere betrifft sie ein pulvermetallurgisches Ver­fahren zur Herstellung eines grünen Presskörpers hoher Festigkeit und niedriger relativer, auf den porenlosen Zustand bezogener Dichte aus einer warmfesten Aluminium­legierung des Typs Al/Fe/X oder Al/Cr/X, wobei X = Ti, Zr, Hf, V, Nb, Cr, Mo, W sein kann.In particular, it relates to a powder metallurgical process for producing a green compact of high strength and low relative density, based on the non-porous state, from a heat-resistant aluminum alloy of the type Al / Fe / X or Al / Cr / X, where X = Ti, Zr, Hf, V, Nb, Cr, Mo, W.

Stand der Technik:State of the art:

Aluminiumlegierungen, welche sich für die Erzeugung von Pulvern aus Schmelzen mittels Gasstrahlzerstäubung unter Anwendung sehr hoher Abkühlungsgeschwindigkeiten (10⁵°C/s und mehr) eignen und für die Herstellung warmfester Werk­stücke verwenden lassen, sind in zahlreichen Variationen bekannt geworden. Eine bedeutende Gruppe stellen die polynären, meist relativ hohe Eisengehalte aufweisenden Legierungen des Typs Al/Fe/X dar, wobei X mindestens eines der Elemente Ti, Zr, Hf, V, Nb, Cr, Mo, W bedeutet.Aluminum alloys, which are suitable for the production of powders from melts by means of gas jet atomization using very high cooling speeds (10 ° C./s and more) and can be used for the production of heat-resistant workpieces, have become known in numerous variations. An important group are the polynary alloys of the type Al / Fe / X, which usually have relatively high iron contents, where X denotes at least one of the elements Ti, Zr, Hf, V, Nb, Cr, Mo, W.

Bei der Herstellung von Presskörpern spielt unter anderem die Form und die Grössenverteilung der Pulverpartikel eine wichtige Rolle. Das Ergebnis hängt eng mit dem ver­wendeten gasförmigen Zerstäubungsmittel zusammen.The shape and size distribution of the powder particles play an important role in the production of compacts. The result is closely related to the gaseous atomizing agent used.

Wird ein inertes Gas (N, Ar, He) verwendet, wird die Oxydation und die Aufnahme von Wasser und Wasserstoff weitgehend unterdrückt. Es werden vorwiegend sphärische Partikel erzeugt.If an inert gas (N, Ar, He) is used, the oxidation and the absorption of water and hydrogen are largely suppressed. Mainly spherical particles are generated.

Wird dagegen Luft als Zerstäubungsmittel verwendet, dann erfolgt eine beträchtliche Oxydation und Hydratation der Pulverpartikel. Letztere haben vorwiegend längliche und verzweigte unregelmässige, nicht-sphärische Form (Vergl. J. Meunier, ASTM Symposium on Rapidly Solidified Powder Aluminium Alloys, Philadelphia, 1984; Y.W. Kim, W.M. Griffith, F.H. Froes, J. of Metals, August 1985, 27.; G. Stanieck, Aluminium 60, 1984, 3; R.F. Singer, W. Oliver, W.D. Nix, Met. Trans. 11A, 1980, 1985; S.T. Morgan et al. in: M.S. Koczak und G.J. Hildeman, High Strength Powder Metallurgy Aluminium Alloys, 1982, TMS­AIME).On the other hand, if air is used as an atomizing agent, the powder particles undergo considerable oxidation and hydration. The latter have predominantly elongated and branched irregular, non-spherical shape (see J. Meunier, ASTM Symposium on Rapidly Solidified Powder Aluminum Alloys, Philadelphia, 1984; YW Kim, WM Griffith, FH Froes, J. of Metals, August 1985, 27 .; G. Stanieck, Aluminum 60, 1984, 3; RF Singer, W. Oliver, WD Nix, Met. Trans. 11A, 1980, 1985; ST Morgan et al. In: MS Koczak and GJ Hildeman, High Strength Powder Metallurgy Aluminum Alloys, 1982, TMSAIME).

Sphärische Pulver ergeben bei der Verdichtung zu grünen Presskörpern geringe mechanische Festigkeit, da die Par­tikel nur wenig verformt werden. Gleichzeitig ist aber die Dichte verhältnismässig hoch, was die Entgasung und Austreibung unerwünschter Fremdstoffe bei der Weiterver­arbeitung erschwert. Demgegenüber liefern nicht-sphäri­sche Pulver grüne Körper hoher Festigkeit kombiniert mit geringer Dichte. Dabei ist jedoch der Gehalt an zu entgasenden Stoffen (Sauerstoff, Wasser, Wasserstoff) hoch.Spherical powders result in low mechanical strength when compressed into green compacts, since the particles are only slightly deformed. At the same time, however, the density is relatively high, which makes it difficult to degas and expel unwanted foreign substances during further processing. In contrast, non-spherical powders provide green bodies of high strength combined with low density. However, the content of substances to be degassed (oxygen, water, hydrogen) is high.

Aus dem oben Gesagten geht hervor, dass die Pulverher­stellung nach den bekannten Methoden im Hinblick auf die anzustrebenden Eigenschaften der fertigen Werkstücke zu wünschen übrig lassen. Entweder ist die mechanische Festigkeit der grünen Presskörper zu gering oder deren Gehalte an eingeschlossenen Schadstoffen zu hoch. Bei­des führt im Verlauf der Weiterverarbeitung zu Werkstücken mit ungenügenden, zum mindesten nicht mit den angestreb­ten Werten vereinbarten Festigkeitseigenschaften.From what has been said above, it can be seen that powder production according to the known methods leaves something to be desired in terms of the desired properties of the finished workpieces. Either the mechanical strength of the green compacts is too low or their levels of trapped pollutants are too high. In the course of further processing, both lead to workpieces with insufficient strength properties, at least not in agreement with the desired values.

Es besteht daher ein grosses Bedürfnis nach einer Ver­besserung der Herstellungsverfahren für Pulver, welche zu besseren Endprodukten führen.There is therefore a great need to improve the manufacturing processes for powders, which lead to better end products.

Darstellung der Erfindung:Presentation of the invention:

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Erzeugung eines Aluminiumlegierungspulvers durch Zerstäuben einer Schmelze anzugeben, welches bei der Verdichtung einen grünen Presskörper mit möglichst hoher Festigkeit und gleichzeitig niedriger relativer Dichte (bezogen auf den theoretischen Höchstwert von 100 %) liefert.The invention has for its object to provide a method for producing an aluminum alloy powder by atomizing a melt, which provides a green compact with the highest possible strength and at the same time low relative density (based on the theoretical maximum value of 100%) during compression.

Diese Aufgabe wird dadurch gelöst, dass beim eingangs erwähnten Verfahren eine entsprechende Legierungsschmelze mittels eines Gasstrahls bestehend aus einem inerten Gas, welchem 0,5 bis 2 Vol.-% Sauerstoff beigemengt ist, zu feinen Partikeln zerstäubt wird und dass das derart erzeugte Pulver einer Verdichtung unterworfen wird.This problem is solved in that at the beginning mentioned method, a corresponding alloy melt is atomized into fine particles by means of a gas jet consisting of an inert gas, to which 0.5 to 2% by volume of oxygen is admixed, and that the powder produced in this way is subjected to compression.

In diesem Zusammenhang wird darauf hingewiesen, dass die vollständige Entfernung des Wassers und des Wasser­stoffs aus den hydrolysierten Al₂O₃-Oberflächenschich­ten der Pulverpartikel bei ca. 400°C während des Ent­gasungsvorganges im Falle der erfindungsgemässen Ver­wendung eines mit Sauerstoff dotierten Zerstäubungsgases bei der Pulvererzeugung schneller vor sich geht als im Falle konventioneller Zerstäubung mit Luft.In this context, it should be noted that the complete removal of the water and hydrogen from the hydrolyzed Al₂O₃ surface layers of the powder particles at about 400 ° C during the degassing process in the case of the use of an oxygen-doped atomizing gas according to the invention in the powder production is faster than in the case of conventional atomization with air.

Weg zur Ausführung der Erfindung:Way of carrying out the invention:

Die Erfindung wird anhand der nachfolgenden Ausführungs­beispiele erläutert.The invention is explained using the following exemplary embodiments.

Ausführungsbeispiel I:Embodiment I:

Es wurde eine Aluminiumlegierung der nachfolgenden Zu­sammensetzung erschmolzen:

    Fe = 9 Gew.-%
    V = 3,5 Gew.-%
    Al = Rest
An aluminum alloy with the following composition was melted:

Fe = 9% by weight
V = 3.5% by weight
Al = rest

Die Schmelze wurde in einer Vorrichtung mittels eines Gasstromes zu einem Pulver von maximal 50 µm Partikel­durchmesser zerstäubt. Als Zerstäubungsgase wurden inerte Gase (Stickstoff, Argon) mit und ohne Sauerstoffzusatz verwendet.The melt was atomized in a device by means of a gas stream to a powder with a maximum particle diameter of 50 μm. Inert gases (nitrogen, argon) with and without the addition of oxygen were used as atomizing gases.

Einige Hundert Gramm des Pulvers wurden in einen Gummi­ beutel abgefüllt, verschlossen und kalt verdichtet. Aus dem grünen Presskörper wurde ein zylindrischer Prüfkörper von 20 mm Durchmesser und 30 mm Höhe herausgearbeitet und einem Druckversuch unterworfen. Desgleichen wurde die jeweilige Dichte bezogen auf den theoretischen Wert bestimmt.A few hundred grams of the powder were put in a gum filled, sealed and cold sealed. A cylindrical test specimen with a diameter of 20 mm and a height of 30 mm was worked out from the green compact and subjected to a pressure test. Likewise, the respective density was determined based on the theoretical value.

Es kann gezeigt werden, dass die aus Pulvern mit Sauer­stoffzusatz hergestellten grünen Presskörper bei ver­gleichsweise geringerer Dichte wesentlich höhere Festig­keiten aufwiesen als diejenigen aus Pulvern ohne Sauer­stoffzusatz (reine inerte Zerstäubungsgase).It can be shown that the green compacts made from powders with the addition of oxygen, with a comparatively lower density, had significantly higher strengths than those from powders without the addition of oxygen (pure inert atomizing gases).

Ausführungsbeispiel II:Working example II:

Es wurde eine Legierung der nachfolgenden de Zusammensetzung erschmolzen:
    Fe = 8 Gew.-%
    V = 2 Gew.-%
    Al = Rest
An alloy of the following composition was melted:
Fe = 8% by weight
V = 2% by weight
Al = rest

Analog Beispiel I wurde die Schmelze auf verschiedene Art und Weise zu einem Pulver zerstäubt und nachher ver­dichtet. Aus dem Presskörper wurden Proben zur Bestimmung der Druckfestigkeit und der relativen Dichte herausge­arbeitet. Die Resultate stellen sich wie folgt:

Figure imgb0001
Analogously to Example I, the melt was atomized into a powder in various ways and subsequently compacted. Samples for determining the compressive strength and the relative density were worked out from the compact. The results are as follows:
Figure imgb0001

Ausführungsbeispiel III:Working example III:

Es wurde eine Legierung der nachfolgenden Zusammensetzung erschmolzen:

    Fe = 8 Gew.-%
    Mo = 2 Gew.-%
    Al = Rest
An alloy of the following composition was melted:

Fe = 8% by weight
Mo = 2% by weight
Al = rest

Es gelang nicht, aus dem mit inertem Gas erzeugten Pulver einen Presskörper durch Kaltpressen herzustellen.

Figure imgb0002
It was not possible to produce a compact by cold pressing from the powder produced with inert gas.
Figure imgb0002

Die grünen Presskörper der vorstehenden Ausführungsbei­spiele wurden ausserdem einem Entgasungsprozess unter­worfen. Dabei zeigte sich, dass die Entgasungszeiten der mit inertem Zerstäubungsgas mit Sauerstoffzusatz erzeugten Pulver zwischen denjenigen mit inertem Zer­stäubungsgas und denjenigen mit Luft lagen. Vorteilhafter­weise sollen die grünen Presskörper vor der endgültigen thermomechanischen Behandlung (Heisspressen, Strangpres­sen), bei welcher sie ihre volle, 100%ige Dichte errei­chen, während 1 bis 10 h bei einer Temperatur von 350 bis 400°C entgast werden.The green pressed bodies of the above exemplary embodiments were also subjected to a degassing process. It was found that the degassing times of the powders produced with inert atomizing gas with the addition of oxygen were between those with inert atomizing gas and those with air. Before the final thermomechanical treatment (hot pressing, extrusion), in which they reach their full, 100% density, the green pressed bodies should advantageously be degassed at a temperature of 350 to 400 ° C. for 1 to 10 hours.

Die Erfindung ist nicht auf die Ausführungsbeispiele beschränkt. Sie lässt sich grundsätzlich auf alle warm­festen Aluminiumlegierungen des Typs Al/Fe/X oder Al/Cr/X anwenden, wobei X = Ce, Ti, Zr, Hf, V, Nb, Cr, Mo, W bedeutet.The invention is not restricted to the exemplary embodiments. It can basically be applied to all heat-resistant aluminum alloys of the type Al / Fe / X or Al / Cr / X, where X = Ce, Ti, Zr, Hf, V, Nb, Cr, Mo, W.

Das Zerstäubungsgas kann ein inertes Gas wie Stickstoff, Argon oder Helium sein, dem 0,5 bis 2 Vol.-% Sauerstoff beigemengt sind. Es kann sich auch um eine Mischung von mindestens zweier der vorgenannten Gase handeln.The atomizing gas can be an inert gas such as nitrogen, argon or helium, to which 0.5 to 2% by volume of oxygen is added. It can also be a mixture of at least two of the aforementioned gases.

Das Verfahren wird vorzugsweise so geführt, dass im er­sten Schritt (Zerstäubung im Gasstrom) ein Pulver erzeugt wird, welches verhältnismässig geringe Anteile gröberer, nicht-sphärischer Partikel und verhältnismässig hohe Anteile feiner sphärischer Partikel enthält. Dies kann durch geeignete Wahl der Gaszusammensetzung insbesondere des Sauerstoffzusatzes erzielt werden.The method is preferably carried out in such a way that in the first step (atomization in the gas stream) a powder is produced which contains relatively small proportions of coarser, non-spherical particles and comparatively high proportions of fine spherical particles. This can be achieved by a suitable choice of the gas composition, in particular the addition of oxygen.

Claims (4)

1. Pulvermetallurgisches Verfahren zur Herstellung eines grünen Presskörpers hoher Festigkeit und niedriger relativer, auf den porenlosen Zustand bezogener Dich­te aus einer warmfesten Aluminiumlegierung des Typs Al/Fe/X oder Al/Cr/X, wobei X = Ti, Ce, Zr, Hf, V, Nb, Cr, Mo, W sein kann, dadurch gekennzeichnet, dass eine entsprechende Legierungsschmelze mittels eines Gasstrahls bestehend aus einem inerten Gas, welchem 0,5 bis 2 Vol.-% Sauerstoff beigemengt sind, zu feinen Partikeln zerstäubt wird und dass das derart erzeugte Pulver einer Verdichtung unterworfen wird.1. Powder metallurgical process for producing a green compact of high strength and low relative density, based on the pore-free state, from a heat-resistant aluminum alloy of the type Al / Fe / X or Al / Cr / X, where X = Ti, Ce, Zr, Hf, V, Nb, Cr, Mo, W, characterized in that a corresponding alloy melt is atomized into fine particles by means of a gas jet consisting of an inert gas, to which 0.5 to 2 vol.% Oxygen is added, and that powder thus produced is subjected to compaction. 2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass als inertes Gas Stickstoff, Argon oder Helium oder eine Mischung mindestens zweier dieser Gase ver­wendet wird.2. The method according to claim 1, characterized in that nitrogen, argon or helium or a mixture of at least two of these gases is used as the inert gas. 3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass im ersten Schritt ein Pulver erzeugt wird, das verhältnismässig geringe Anteile gröberer nicht-sphä­rischer Partikel und verhältnismässig hohe Anteile feiner sphärischer Partikel enthält.3. The method according to claim 1, characterized in that a powder is generated in the first step, which contains relatively small proportions of coarser non-spherical particles and relatively high proportions of fine spherical particles. 4. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der grüne Presskörper während 1 bis 10 h bei einer Temperatur von 350 bis 400°C entgast wird.4. The method according to claim 1, characterized in that the green compact is degassed for 1 to 10 h at a temperature of 350 to 400 ° C.
EP87111463A 1986-08-12 1987-08-07 Process for manufacturing powder compacts with a high resistance and relatively low density from a heat-resisting aluminium alloy Expired - Lifetime EP0256450B1 (en)

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CH673240A5 (en) 1990-02-28
DK415687D0 (en) 1987-08-10
DK415687A (en) 1988-02-13
EP0256450B1 (en) 1991-01-30
NO873364D0 (en) 1987-08-11
JPS6347304A (en) 1988-02-29
US4832741A (en) 1989-05-23
NO873364L (en) 1988-02-15
DE3767807D1 (en) 1991-03-07
US4758405A (en) 1988-07-19

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