EP1178127A1 - Verfahren zur herstellung von kompositmaterialien auf metallbasis - Google Patents

Verfahren zur herstellung von kompositmaterialien auf metallbasis Download PDF

Info

Publication number
EP1178127A1
EP1178127A1 EP00971764A EP00971764A EP1178127A1 EP 1178127 A1 EP1178127 A1 EP 1178127A1 EP 00971764 A EP00971764 A EP 00971764A EP 00971764 A EP00971764 A EP 00971764A EP 1178127 A1 EP1178127 A1 EP 1178127A1
Authority
EP
European Patent Office
Prior art keywords
metal
aluminum
melt
composite material
container
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00971764A
Other languages
English (en)
French (fr)
Inventor
Toshiaki Kimura
Hideo Nakae
Hideya Yamane
Hideki Yamaura
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.)
Proterial Ltd
Original Assignee
Hitachi Metals Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hitachi Metals Ltd filed Critical Hitachi Metals Ltd
Publication of EP1178127A1 publication Critical patent/EP1178127A1/de
Withdrawn legal-status Critical Current

Links

Images

Classifications

    • 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
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/0405—Rotating moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy

Definitions

  • the present invention relates to a method for producing a metal-based composite material comprising an aluminum alloy, etc., as a matrix, particularly to a method for producing a metal-based composite material by pressureless impregnation.
  • Metal-based composite materials are composed of a combination of matrix metals having basic properties such as strength, ductility, toughness, etc., and various reinforcing fillers.
  • matrix metals having basic properties such as strength, ductility, toughness, etc.
  • reinforcing fillers such as long or short fibers, particles, etc. of ceramics, having moldability and thermal conductivity of the matrix metals themselves and rigidity, wear resistance, low thermal expansion coefficient, etc. of the reinforcing fillers, they are widely used in various applications such as parts of transportation vehicles that are becoming lighter in weight, and circuit boards, etc. of electronics parts requiring low thermal expansion coefficients.
  • metal-based composite materials there are dispersion-strengthened composite materials having reinforcing fillers such as ceramics, etc., dispersed in alloy matrices such as aluminum, magnesium, etc. Particularly aluminum alloys are widely used as matrices for the composite materials because of their lightness in weight and low cost.
  • Dispersion-strengthened composite materials comprising light alloys such as aluminum alloys, magnesium alloys, etc. as matrices not only are light in weight because of the light alloys, but also have various improved properties such as strength, rigidity, wear resistance, thermal expansion coefficient, density, high temperature strength, etc. because of the inclusion of the reinforcing fillers. How much their properties are improved largely depends on the proportions of alloy components and reinforcing fillers, the shapes and sizes of reinforcing fillers, and treatment methods for producing the dispersion-strengthened composite materials.
  • the powder metallurgy method comprises mixing a powdery matrix metal with a reinforcing filler such as long or short fibers, particles, etc., molding the resultant mixture at room temperature, and then sintering or hot pressing the resultant green body to produce a composite material. Because the powder metallurgy method usually comprises press molding, it is not suitable for products having complicated shapes, and thus inevitably directed to products having relatively simple shapes. Also, because the molding is carried out at high temperature and high pressure, it is disadvantageous in high cost for particularly large products.
  • the melt-stirring method comprising adding a reinforcing filler to a molten metal, and stirring the mixture at a high speed for a long period of time to disperse the reinforcing filler in the matrix metal melt, thereby producing a composite material.
  • This method can produce large amounts of composite material ingots at a relatively low cost, it is extremely difficult to provide partially composite material products.
  • the infiltration method comprises infiltrating a molten metal into space between reinforcing fillers, thereby producing a composite material.
  • This method can produce composite materials having complicated final shapes.
  • the SiC particles should have good wettability with the aluminum alloy. "Good wettability" is a characteristic that a liquid has a small contact angle to a solid, meaning that the liquid is easily spread on a solid surface.
  • SiC particles have poor wettability with the aluminum alloy, the infiltration of the aluminum alloy into gaps between SiC particles does not occur spontaneously at atmospheric pressure. Namely, SiC particles are repelled by the aluminum alloy melt, failing to provide a homogeneous composite material.
  • the infiltration methods include a pressurized infiltration method in which a matrix metal melt is infiltrated into a porous green body of a reinforcing filler such as ceramics, etc. at high pressure to produce a composite material, and a pressureless infiltration method in which a matrix metal melt is infiltrated into gaps of a reinforcing filler without pressure to produce a composite material.
  • Japanese Patent Publication No. 6-38968 proposes a method for producing a metal-reinforcing filler composite material comprising compression-molding a mixture of fine pieces of an oxide of the first metal (for instance, NiO powder) and a reinforcing filler (for instance, silicon carbide whisker) to form a porous body, and causing a melt of the second metal (matrix metal), for instance, an aluminum melt, having a larger tendency to form an oxide than the first metal to infiltrate into the porous body under pressure.
  • the first metal for instance, NiO powder
  • a reinforcing filler for instance, silicon carbide whisker
  • this method is disadvantageous in that because a uniform mixture of fine pieces of an oxide of the first metal and the reinforcing filler is compression-molded to form a porous body, and causing a matrix metal melt to infiltrate into the porous body by using a high-pressure casting apparatus, it is disadvantageous in high production cost.
  • this method cannot produce a composite material without pressure, the casting method being limited to a high-pressure casting method or a centrifugal casting method.
  • Japanese Patent 2,801,302 discloses a so-called PRIMAXTM method in which a matrix metal of aluminum, etc. is infiltrated into a reinforcing filler without pressure to produce a metal-reinforcing filler composite material. Specifically, this method comprises placing a mixture or its preform of an infiltration accelerator such as magnesium powder, etc., and reinforcing filler of a silicon carbide, etc.
  • an infiltration accelerator such as magnesium powder, etc.
  • the infiltration accelerator functions to react with a nitrogen gas to improve the wettability of a reinforcing filler surface, thereby accelerating the spontaneous infiltration of the molten matrix metal into the reinforcing filler.
  • Japanese Patent 2,801,302 discloses only specific examples of matrix metal-reinforcing filler composite materials in which the reinforcing filler is dispersed substantially entirely, failing to provide any specific examples of partially composite materials,
  • Japanese Patent 2,905,519 proposes a method for producing a metal matrix composite body comprising charging SiC powder, etc., as a reinforcing filler and magnesium powder as an infiltration accelerator into a copper mold; sealing one end of the copper mold with a copper foil; substituting the atmosphere inside the copper mold with nitrogen; and immersing the copper mold in a molten matrix metal (for instance, magnesium-containing aluminum alloy melt) at about 750°C for about one hour to produce a metal matrix composite material.
  • a molten matrix metal for instance, magnesium-containing aluminum alloy melt
  • the infiltration accelerator appears to improve the wettability of a reinforcing filler surface, accelerating the spontaneous infiltration of the molten aluminum alloy into the reinforcing filler, thereby producing the composite material.
  • the copper mold and the copper foil are melted in the matrix metal melt, the composition of the matrix metal melt undesirably varies.
  • an apparatus for substituting the atmosphere inside the copper mold and the copper foil with nitrogen is needed, and the heating temperature should be at least about 675°C. Accordingly, the resultant metal-reinforcing filler composite materials suffer from high cost, making their practical use difficult.
  • Japanese Patent 2,905,519 discloses only examples for obtaining matrix metal-reinforcing filler composite materials having substantially overall reinforcing fillers dispersed therein, failing to disclose examples of partially composite materials at all.
  • U.S. Patent 3,364,976 discloses a method comprising immersing a mold having at least one opening and containing a gas (for instance, a gas containing oxygen and nitrogen such as air) having reactivity with molten magnesium in a melt of magnesium as a matrix metal; causing the magnesium melt to react with oxygen and nitrogen existing in a mold cavity to generate a reduced pressure state inside the mold; and filling the mold with a matrix metal melt by suction effects by the reduced pressure.
  • a gas for instance, a gas containing oxygen and nitrogen such as air
  • the matrix metals infiltratable into reinforcing fillers are substantially limited to magnesium or Al-Mg alloys, with only specific examples using an Al-5%Mg alloy melt to produce composite materials.
  • the reinforcing filler is charged into a mold made of steel, graphite, glass, etc., and because the mold is immersed in a molten matrix metal, when composite materials partially reinforced with fillers are sought, the mold remains in a boundary between the matrix metal and the metal-reinforcing filler composite material, unsuitable for practical use.
  • an object of the present invention is to provide a method for producing a metal-based composite material at a low cost without using a nitrogen atmosphere, by infiltrating a matrix metal melt into space between reinforcing fillers without pressure and at a relatively low temperature.
  • Another object of the present invention is to provide a method for producing a metal-based, partially composite material by bringing part of the product composite with reinforcing fillers by pressureless infiltration.
  • the inventors have found that by charging a reinforcing filler in the form of fibers or particles and an infiltration-accelerating metal in the form of powder, chip, foil, plate or bulk into an aluminum container; introducing this container into a matrix metal melt or disposing this container in a die or a casting mold; pouring a matrix metal melt thereinto; and bringing the inside of the container into contact with the matrix metal melt in a state where the inside of the container is shut off from the outside atmosphere, the infiltration-accelerating metal is caused to react with an oxygen-containing nitrogen gas in the container, thereby spontaneously generating a reduced pressure state in the container, such that the matrix metal melt is sucked into the container to infiltrate the matrix metal melt into space between reinforcing fillers at a relatively low temperature without control of atmosphere and pressure.
  • the present invention has been completed based on this finding.
  • the method for producing a metal-based composite material comprising a matrix metal containing at least partially a reinforcing filler comprises (1) charging at least one reinforcing filler in the form of fibers or particles and at least one infiltration-accelerating metal into an aluminum container; (2) immersing the aluminum container in a melt of a matrix metal made of an aluminum alloy or a magnesium-aluminum alloy in a state that an oxygen-containing nitrogen gas remains in the aluminum container; (3) melting the aluminum container in the matrix metal melt, so that the matrix metal melt is infiltrated into the reinforcing filler, and then (4) solidifying the matrix metal melt.
  • the aluminum container is introduced into a matrix metal melt in a crucible.
  • the aluminum container is disposed in a cavity of a die or a mold at a predetermined position in advance, and the matrix metal melt is charged into the cavity.
  • an aluminum foil is used as the aluminum container, and a mixture of the reinforcing filler and the infiltration-accelerating metal is completely wrapped by the aluminum foil.
  • an aluminum can with a lid is used as the aluminum container, and after charging a mixture of the reinforcing filler and the infiltration-accelerating metal into the aluminum can, the aluminum can is closed by the lid.
  • the aluminum container By disposing the aluminum container in the matrix metal melt at a predetermined position, it is possible to provide a metal-based composite material whose predetermined portion is only composite with the reinforcing filler. Instead, it is also possible to uniformly disperse the reinforcing filler in the matrix metal melt by stirring the matrix metal melt after the matrix metal melt is infiltrated into the reinforcing filler.
  • the oxygen-containing nitrogen gas is preferably air.
  • the space percentage of the container [(volume of oxygen-containing nitrogen gas / inside volume of container) x 100%] is preferably 30-70%.
  • the infiltration-accelerating metal is preferably at least one metal selected from the group consisting of magnesium, calcium, zirconium and alloys containing these metals, particularly pure magnesium or magnesium alloy. Also, the infiltration-accelerating metal is preferably in the form of at least one selected from the group consisting of powder, chip, foil, plate and bulk.
  • the matrix metal is preferably an aluminum alloy or a magnesium-aluminum alloy.
  • the temperature of the matrix metal melt is preferably between Tm and Tm + 40°C, wherein Tm is the liquidus point of the matrix metal.
  • the reinforcing filler is preferably constituted by ceramics, particularly SiC particles.
  • the matrix metal melt is infiltrated, namely is caused to penetrate, into space or gaps between the reinforcing fillers, even though there is substantially no pressure applied from outside. Further, because the resultant Mg 3 N 2 has good wettability with the aluminum melt, the infiltration of the matrix metal melt is accelerated when the matrix metal is an aluminum alloy.
  • Oxygen contained in a gas in the aluminum container has higher reactivity with magnesium than nitrogen. Accordingly, the degree of evacuation in the aluminum container is higher when the atmosphere in the aluminum container is an oxygen-containing nitrogen gas than when it is a nitrogen gas atmosphere. Because the present invention uses an oxygen-containing nitrogen gas such as air, the degree of infiltration of the matrix metal melt is higher in the present invention than in Japanese Patent 2,905,519 in which a nitrogen gas is used, with lower production cost of the composite body.
  • the equation [1] indicates that in order that the wettability of the reinforcing filler with the matrix metal melt is improved by surface improvement, etc. of the reinforcing filler particles, the infiltration of the matrix metal melt occurring spontaneously, the condition of ⁇ P ⁇ 0, namely, cos ⁇ > 0 should be met.
  • ⁇ P ⁇ namely, cos ⁇ > 0
  • the inventors have confirmed that the larger the particle size of the reinforcing filler (the larger the space between the reinforcing filler), the more easily the infiltration of the matrix metal melt takes place.
  • the generation of reduced pressure in the container greatly contributes to the spontaneous infiltration of the matrix metal melt into the reinforcing filler.
  • the matrix metal melt is spontaneously infiltrated into the reinforcing filler.
  • the reinforcing filler may be selected from ceramics of SiC, Al 2 O 3 , SiO 2 , AlN, TiC, TiO 2 , ZrO 2 , Si 3 N 4 , sialon, etc.
  • the reinforcing filler may be used in various forms of long or short fibers, particles, etc., and various shapes of reinforcing fillers may be combined.
  • the reinforcing filler is in the form of particles, its average particle size is preferably about 1-1000 ⁇ m, more preferably about 10-100 ⁇ m.
  • fiber diameter is preferably about 0.1-1000 ⁇ m, more preferably about 1-100 ⁇ m.
  • the reinforcing filler when dispersed in the matrix metal, imparts excellent properties such as high rigidity and high wear resistance, etc. to the matrix metal.
  • the infiltration-accelerating metal mixed with the reinforcing filler is preferably pure magnesium or a magnesium alloy, though calcium, zirconium or alloys containing these metals may also be used.
  • the infiltration-accelerating metal is preferably in at least one shape selected from the group consisting of powder, chip, foil, plate and bulk.
  • an aluminum container With an aluminum alloy or a magnesium-aluminum alloy as a matrix metal melt, the use of an aluminum container is preferable because the composition variations of the matrix metal melt do not occur unlike Japanese Patent 2,905,519. Though there is an aluminum oxide film on a surface of the aluminum container, which is not melted at a temperature of a matrix metal melt, this oxide film is reduced to easily meltable aluminum, when the infiltration-accelerating metal is oxidized in the container. Accordingly, holes are formed in the aluminum container in the matrix metal melt, so that the melt enters into the aluminum container.
  • the aluminum container may have any structure, as long as (a) it can hold a reinforcing filler and an infiltration-accelerating metal, (b) when immersed in the matrix metal melt, it is substantially sealed to the outside atmosphere, and (c) it can keep its initial shape until the inside of the aluminum container reaches sufficiently reduced pressure to cause the matrix metal melt enter into the reinforcing filler.
  • the aluminum container may be a cylindrical can with a lid, a sealable capsule, or a foil capable of completely wrapping a mixture of the reinforcing filler and the infiltration-accelerating metal.
  • container materials do not remain in boundaries between the matrix metal and the composite material unlike U.S. Patent 3,364,976 using a steel mold, a graphite mold, a glass mold, etc.
  • the matrix metal to which the pressureless infiltration method of the present invention is applicable, is preferably an aluminum alloy, though a magnesium-aluminum alloy can also be used.
  • the percentage of aluminum is preferably 1% by weight or more, more preferably 3% by weight or more to minimize the variations of a matrix alloy composition due to the melting of the aluminum container.
  • the present invention utilizes not only the nitriding reaction of the infiltration-accelerating metal but also the oxidation reaction (exothermic reaction) thereof, resulting in holes formed in the aluminum container even at a relatively low temperature of the matrix metal melt.
  • the temperature of the matrix metal melt may be substantially a casting temperature.
  • the temperature of the matrix metal melt is preferably about a temperature between Tm and Tm + 40°C, wherein Tm is the liquidus point of the matrix metal. Because the matrix metal melt at such a relatively low temperature can be used, the metal-based composite material can be obtained at a low cost.
  • the atmosphere inside the aluminum container should be a gas containing oxygen and nitrogen gas.
  • an oxygen gas should exist in the aluminum container in a sufficient amount as to oxidize the infiltration-accelerating metal in the aluminum container.
  • a nitrogen gas reacts with the infiltration-accelerating metal such as magnesium, etc. in the aluminum container to form nitrides having good wettability with the matrix metal melt. Because the nitrides are attached to the surface of the reinforcing filler, the matrix metal melt is easily infiltrated into the reinforcing filler.
  • the atmosphere inside the aluminum container is preferably an oxygen-containing nitrogen gas having an oxygen partial pressure of about 10-40% and a nitrogen partial pressure of about 90-60%. From the aspect of production cost, it is preferable to use air as the oxygen-containing nitrogen gas. The air makes it unnecessary to use a facility for carrying out atmosphere control such as nitrogen substitution, etc., unlike Japanese Patent 2,905,519. If the container is filled with substantially only a nitrogen gas, for instance, without satisfying this condition, the oxidation reaction (high-temperature exothermic reaction) of the infiltration-accelerating metal and the resultant reduction reaction of an aluminum oxide film do not occur, making it unlikely that the aluminum container is melted.
  • Fig. 1 schematically shows the first pressureless infiltrating apparatus for conducting the method of the present invention.
  • the apparatus comprises a graphite crucible 1 for containing a matrix metal melt, a push member 6 made of stainless steel, etc. for keeping an aluminum container 4 containing a mixture of the reinforcing filler 2 and the infiltration-accelerating metal 3 immersed in the matrix metal melt 5, a pipe 7 communicating with the aluminum container 4 for measuring pressure variations therein, a pressure sensor 8 disposed at the other end of the pipe 7, and a thermocouple 9 disposed substantially in a center portion of the aluminum container 4.
  • the aluminum container 4 may be in any form as long as the inside thereof is substantially shut off from the outside atmosphere, specifically in a shape of a foil, a container with a lid or a capsule.
  • a commercially available aluminum foil can be used as the aluminum container 4 of the present invention, because it is shut off from the outside atmosphere when immersed in the matrix metal melt 5.
  • the lid need not be fixed to a container body unless the lid is detached during immersion.
  • the capsule is preferable, because the inside of the capsule is unlikely to be communicating with the outside atmosphere during immersion.
  • the thickness of the aluminum container is not particularly limited unless premature melting occurs by contact with the matrix metal melt. In practical applications, the thickness of the aluminum container is preferably about 1-2000 ⁇ m, more preferably about 10-1000 ⁇ m.
  • the aluminum container 4 may be disposed in advance at the bottom of the graphite crucible 1 before pouring the matrix metal melt 5.
  • thermocouple 9 is disposed substantially in a center portion of the aluminum container 4, and the other end of thermocouple 9 is connected to a thermometer (not shown).
  • An aluminum melt 5 is poured into the graphite crucible 1 heated at a predetermined temperature, into which the aluminum container 4 is slowly charged. Because there is a lot of air in space in the aluminum container 4, the aluminum container 4 tends to float on a melt surface when it is simply introduced into the aluminum melt 5. This breaks an aluminum foil when reduced pressure is generated, causing the outside atmosphere to enter into the aluminum container 4, thereby not only preventing the generation of reduced pressure, but also burning pure magnesium as the infiltration-accelerating metal 3. Accordingly, the aluminum container 4 is pushed down by a stainless steel push member 6, so that the aluminum container 4 does not float to the surface.
  • the crucible 1 containing the aluminum container 4 is heated at about 620-700°C for 0.5-5 hours in an electric furnace (not shown). During immersion, pressure and temperature variations were measured in the aluminum container 4 to detect the generation of reduced pressure. After completion of turning a portion of the aluminum melt 5 in which the aluminum container 4 exists to have a composite structure, the composite body is cooled in the graphite crucible 1 to obtain a partially reinforced, aluminum-based, composite material, in which only a portion corresponding to the aluminum container 4 has a composite structure.
  • an aluminum can containing a mixture of the reinforcing filler and the infiltration-accelerating metal may be disposed in advance at the bottom of the graphite crucible 1, before pouring the aluminum melt 5.
  • the aluminum melt 5 may be stirred to uniformly disperse the reinforcing filler 2 in the entire aluminum melt 5.
  • the aluminum melt having the reinforcing filler 2 dispersed is poured into an ingot case and solidified to obtain an aluminum-based, reinforced, composite material having the reinforcing filler 2 uniformly dispersed.
  • Fig. 2 schematically shows the second pressureless infiltrating apparatus.
  • This apparatus comprises a die 21 for containing a matrix metal melt, and an aluminum container 24 for containing a mixture of the reinforcing filler 22 and the infiltration-accelerating metal 23.
  • the aluminum container 24 is, for instance, a cylindrical aluminum can to increase pressure reduction effects.
  • a lid is mounted to the aluminum container 24 to shut it from the outside atmosphere.
  • This aluminum container 24 is placed in a die 21 preheated at a predetermined temperature at a predetermined position in such a manner that the lid is not opened.
  • An aluminum melt 25 is poured into the die 21 in which the aluminum container 24 is disposed, and the die 21 is kept at a predetermined temperature in an electric furnace (not shown). Next, the die 21 is taken out of the electric furnace, and cooled to obtain a partially composite body of aluminum and a reinforcing filler.
  • the aluminum can 24 can be sealed, for instance, by disposing the can 24 in a die without a lid, with the opening of the aluminum can abutting against an inner wall of the die 21.
  • the infiltration-accelerating metal 23 in the form of small pieces as shown in Fig. 2, it may be in a shape of flat plate (Fig. 3), chip (Fig. 4), or bulk (Fig. 5). Also in this embodiment, a green sand mold, a shell mold, a gas-hardening mold such as a CO 2 mold, a self-hardening mold, etc. may be used in place of a die with a cavity.
  • the aluminum melt 5 was turned to a composite material in a portion where the aluminum container 4 was immersed after one hour, the aluminum melt 5 was heated to 700°C while sufficiently stirring with a stirrer (not shown) in the electric furnace to diffuse the SiC particles 2 uniformly in the aluminum melt 5. After removing slag, it was poured into an ingot case (not shown). Thereafter, the aluminum melt 5 was cooled in the ingot case, and the solidified aluminum alloy was taken out. Thus, the entire matrix metal was turned to an SiC particle-reinforced, aluminum-based, composite material.
  • the aluminum foil container 4 was immersed in the aluminum melt 5 poured into the graphite crucible 1, the aluminum melt 5 may be poured into the graphite crucible 1 with the aluminum foil container 4 disposed at the bottom thereof in advance, to obtain an SiC particle-reinforced, aluminum-based, composite material.
  • An aluminum-based, composite material uniformly reinforced by SiC particles was obtained in the same manner as in EXAMPLE 1 except for charging mixed powder (SiC particles 2 kg, chip-shaped Mg: 40 g) into a commercially available, cylindrical aluminum can (thickness: 1mm, inner diameter: 100mm, height: 115mm) and closing the can with a lid, instead of being wrapped with an aluminum foil.
  • EXAMPLE 1 was repeated except for using a uniform mixed powder of 20 g of dry SiC particles (GC: #240, average particle size: 58 ⁇ m) and 0.4 g of chip-shaped pure magnesium (available from Chuo Kosan K. K., purity: 99.8%, tradename: CM30), and cooling the aluminum melt in the graphite crucible (#60) 1 without stirring after the aluminum melt was infiltrated into SiC particles, to produce an aluminum-based, composite material partially reinforced by SiC particles, which had a composite structure only in a portion where the aluminum foil container 4 was immersed.
  • GC dry SiC particles
  • chip-shaped pure magnesium available from Chuo Kosan K. K., purity: 99.8%, tradename: CM30
  • an SiC particle-reinforced, aluminum-based, composite material was obtained by a method comprising disposing the aluminum foil container 4 at the bottom of the graphite crucible 1 in advance and pouring the aluminum melt 5 into the graphite crucible 1. Also, with a commercially available aluminum can (thickness: 0.5 mm, inner diameter: 17 mm, height: 40 mm) with a lid in place of an aluminum foil, an aluminum-based, composite material partially reinforced by SiC particles was similarly obtained.
  • SiC particles 20 g were heated at 160°C for 2 hours and sufficiently dried.
  • the resultant dried SiC particles were uniformly mixed with 0.4 g of chip-shaped pure magnesium (available from Chuo Kosan K. K., purity: 99.8%, tradename: CM30) to provide mixed powder.
  • This mixed powder was charged into the same commercially available, cylindrical aluminum can 24 as in EXAMPLE 3, and the can 24 was closed with a lid.
  • this aluminum container 24 was disposed in a cavity of a die 21 preheated at about 500°C at a predetermined position.
  • 500 g of a melt of an aluminum alloy (Al-6%Si) was poured into the die 21.
  • the pouring temperature was 650°C.
  • the aluminum container 24 immersed in the aluminum alloy melt 25 is substantially shut off from the outside atmosphere with the inside of the container in a sealed state.
  • the die 21 After pouring the aluminum melt 25, the die 21 was kept at 650°C for 1.5 hours in an electric furnace (not shown). Next, the die 21 was taken out of the electric furnace and cooled to obtain an aluminum alloy partially reinforced by SiC particles.
  • Fig. 7 is a photomicrograph (x 200) showing a cross section structure of a portion in which the aluminum container 24 containing SiC particles was disposed. It was seen in Fig. 7 that a matrix (white portion) of an aluminum alloy (Al-6%Si alloy) well infiltrated between SiC particles (black portion). On the other hand, in the cross section structure in which the aluminum container 24 containing SiC particles was not disposed, only the aluminum alloy matrix was observed. It was confirmed as a result of the above observation that an aluminum-based, partially composite material in which only a portion corresponding to the aluminum container 24 containing SiC particles had a composite structure was obtained by the method of this EXAMPLE.
  • a 0.3-mm-thick, flat plate 33 of pure magnesium (available from Osaka Fuji Corp., purity: 99%) was disposed in the same commercially available, cylindrical aluminum can 24 as in EXAMPLE 3 along its inner wall.
  • 20 g of SiC particles (GC: #240, average particle size: 58 ⁇ m) heated at 160°C for 2 hours and dried were then charged inside the flat plate 33 of pure magnesium. After closing the aluminum container 24 with a lid, the aluminum container 24 was disposed in a cavity of a die 21 preheated at about 500°C.
  • 1.0 g chip-shaped pure magnesium (available from Chuo Kosan K. K., purity: 99.8%, tradename: CM30) 43 was placed at the bottom of the same commercially available, cylindrical aluminum can 24 as in EXAMPLE 3.
  • 20 g of SiC particles (GC: #240, average particle size: 58 ⁇ m) heated at 160°C for 2 hours and dried were stacked on the chip-shaped pure magnesium 43.
  • the container 24 was closed with a lid.
  • This aluminum container was disposed in a die 21 preheated at about 500°C.
  • a melt 25 of an aluminum alloy (AC4CH) was poured into the die 21 in the same manner as in EXAMPLE 5, and kept at 650°C for 1.5 hours in an electric furnace (not shown).
  • the aluminum container 24 immersed in the aluminum alloy melt 25 was substantially shut off from the outside atmosphere with the inside of the container sealed.
  • an aluminum-based, partially composite material in which only a portion corresponding to the aluminum container 24 containing SiC particles was reinforced, was obtained.
  • a commercially available, bulk-shaped, pure magnesium 53 was placed at the bottom of the same commercially available, cylindrical aluminum can 24 as in EXAMPLE 3.
  • 20 g of SiC particles (GC: #240, average particle size: 58 ⁇ m) heated at 160°C for 2 hours and dried were stacked thereon.
  • the container 24 was disposed in a cavity of a die 21 preheated at about 500°C.
  • a melt of an aluminum alloy (AC4CH) was poured into the die 21 in the same manner as in EXAMPLE 5 and kept at 650°C for 1.5 hours in an electric furnace (not shown).
  • the aluminum container 24 immersed in the aluminum alloy melt 25 was substantially shut off from the outside atmosphere with the inside of the container in a sealed state.
  • an aluminum-based, partially composite material in which only a portion corresponding to the aluminum container 24 containing SiC particles was reinforced, was obtained.
  • SiC particles GC: #240, average particle size: 58 ⁇ m
  • chip-shaped pure magnesium available from Chuo Kosan K. K., purity: 99.8%, tradename: CM30
  • the mixed powder was charged into the same commercially available, cylindrical aluminum can 24 as in EXAMPLE 3.
  • the cylindrical aluminum can 24 was placed without a lid in a vacuum apparatus (not shown), and the pressure inside the vacuum apparatus was reduced to about 10 kPa.
  • a nitrogen gas of 99% in concentration was then introduced into the vacuum apparatus until the pressure of the vacuum apparatus reached atmospheric pressure, and this cycle was repeated four times to conduct nitrogen substitution in the cylindrical aluminum can 24.
  • the aluminum container 24 was closed with a lid. This aluminum container 24 was disposed in the cavity of the die 21 preheated at about 500°C.
  • a reinforcing filler can be impregnated with a matrix metal melt without pressure and at a relatively low temperature without necessitating atmosphere control. Accordingly, without necessitating a special facility that was conventionally required to produce metal-based composite materials, it is possible to achieve drastic reduction of production cost. Further, it is possible to produce metal-based materials partially composite with reinforcing fillers.
EP00971764A 1999-12-21 2000-11-02 Verfahren zur herstellung von kompositmaterialien auf metallbasis Withdrawn EP1178127A1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP36246599 1999-12-21
JP36246599 1999-12-21
PCT/JP2000/007745 WO2001046486A1 (fr) 1999-12-21 2000-11-02 Procede de production d'un materiau composite a base de metal

Publications (1)

Publication Number Publication Date
EP1178127A1 true EP1178127A1 (de) 2002-02-06

Family

ID=18476926

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00971764A Withdrawn EP1178127A1 (de) 1999-12-21 2000-11-02 Verfahren zur herstellung von kompositmaterialien auf metallbasis

Country Status (4)

Country Link
EP (1) EP1178127A1 (de)
CN (1) CN1345382A (de)
CA (1) CA2364391A1 (de)
WO (1) WO2001046486A1 (de)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010058074A3 (en) * 2008-11-18 2010-08-05 Metso Minerals, Inc. Method for preparing a composite material and use of a composite material prepared by the method
WO2014207776A1 (en) 2013-06-27 2014-12-31 Politecnico Di Torino Method for producing aluminum matrix composites through pressureless infiltration
CN105063446A (zh) * 2015-08-12 2015-11-18 中国兵器工业第五九研究所 一种颗粒增强镁基复合材料制备方法

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100408714C (zh) * 2003-03-04 2008-08-06 吉林大学 混杂增强镁基自润滑复合材料及其制备方法
JP2007204808A (ja) * 2006-02-01 2007-08-16 Taiheiyo Cement Corp 金属マトリックス複合体の形成方法
JP4583334B2 (ja) * 2006-05-02 2010-11-17 啓治 山部 鋳造用の金属−セラミックス複合材料の製造法
KR101507945B1 (ko) * 2012-12-26 2015-04-08 주식회사 포스코 용탕 용기 내 반응에 의한 합금 제조방법 및 합금 제조 장치
KR101499855B1 (ko) * 2013-06-26 2015-03-18 주식회사 티앤머티리얼스 가압함침형 금속기지 복합재료 제조방법
JP6984926B1 (ja) * 2021-04-19 2021-12-22 アドバンスコンポジット株式会社 金属基複合材料の製造方法及びプリフォームの作製方法
CN114540725B (zh) * 2022-01-07 2022-09-23 北京电子工程总体研究所 一种燃气舵及其工艺成型方法、火箭

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3364976A (en) * 1965-03-05 1968-01-23 Dow Chemical Co Method of casting employing self-generated vacuum
JPH0638978B2 (ja) * 1985-01-18 1994-05-25 トヨタ自動車株式会社 酸化還元反応を利用した複合材料の製造方法
JP2576188B2 (ja) * 1988-04-30 1997-01-29 トヨタ自動車株式会社 金属基複合材料の製造方法
US5000249A (en) * 1988-11-10 1991-03-19 Lanxide Technology Company, Lp Method of forming metal matrix composites by use of an immersion casting technique and product produced thereby
JPH062149B2 (ja) * 1989-04-13 1994-01-12 三洋電機株式会社 空気供給装置
JPH0693354A (ja) * 1992-09-11 1994-04-05 Agency Of Ind Science & Technol 複合軽金属材料の製造方法
US5669434A (en) * 1994-10-26 1997-09-23 Honda Giken Kogyo Kabushiki Kaisha Method and apparatus for forming an aluminum alloy composite material

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO0146486A1 *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010058074A3 (en) * 2008-11-18 2010-08-05 Metso Minerals, Inc. Method for preparing a composite material and use of a composite material prepared by the method
WO2014207776A1 (en) 2013-06-27 2014-12-31 Politecnico Di Torino Method for producing aluminum matrix composites through pressureless infiltration
CN105063446A (zh) * 2015-08-12 2015-11-18 中国兵器工业第五九研究所 一种颗粒增强镁基复合材料制备方法
CN105063446B (zh) * 2015-08-12 2017-09-19 中国兵器工业第五九研究所 一种颗粒增强镁基复合材料制备方法

Also Published As

Publication number Publication date
CA2364391A1 (en) 2001-06-28
WO2001046486A1 (fr) 2001-06-28
CN1345382A (zh) 2002-04-17

Similar Documents

Publication Publication Date Title
AU621072B2 (en) Method of making metal matrix composites
EP0365978B1 (de) Verfahren zur Herstellung von einem durch Keramik verstärkten Verbundmaterial
US20100183471A1 (en) Metal injection moulding method
FI91723C (fi) Menetelmä metallimatriisikomposiitin valmistamiseksi suunnatulla kiinteytyksellä
EP1178127A1 (de) Verfahren zur herstellung von kompositmaterialien auf metallbasis
US5791397A (en) Processes for producing Mg-based composite materials
JPH02236244A (ja) 自発的浸透による金属マトリックス複合体の形成方法
JP2905517B2 (ja) 金属マトリックス複合体の形成方法
US4943413A (en) Process for producing an aluminum/magnesium alloy
JP2006299304A (ja) マグネシウム基複合材料
EP0527943A1 (de) Sperrwerkstoffe zur herstellung eines verbundwerkstoffes mit metallmatrix.
JP3247364B2 (ja) 金属マトリックス複合材料体の製造方法
EP0933439B1 (de) Verbundkörper, Vorform zur seiner Herstellung sowie Verfahren zu deren Herstellung
Rao et al. New technique for pressureless infiltration of Al alloys into Al2O3 preforms
US20040202883A1 (en) Metal-ceramic composite material and method for production thereof
US5765624A (en) Process for casting a light-weight iron-based material
JP2000017352A (ja) マグネシウム基複合材料
US4221594A (en) Material composition for fired ceramic articles having a high degree of porosity and crushability characteristics
JP4167317B2 (ja) 鋳造用金属−セラミックス複合材料の製造方法
KR0183973B1 (ko) 다층 복합체의 제조 방법
JP3771127B2 (ja) 高密度ＴｉＡｌ金属間化合物の常圧燃焼合成方法
EP0261065B1 (de) Herstellung keramischer, poröse Füllstoffe enthaltender, Artikel
Hou Feasibility of aluminum nitride formation in molten aluminum alloys
CN115917022A (zh) 金属基复合材料的制造方法及预制件的制作方法
Guermazi SiC-reinforced A12O3metal composites by directed metal oxidation

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AT BE CH CY DE DK ES FI FR GB GR IE IT LI LU MC NL PT SE TR

17P Request for examination filed

Effective date: 20011217

RBV Designated contracting states (corrected)

Designated state(s): DE FR GB IT SE

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN

18D Application deemed to be withdrawn

Effective date: 20031201