EP1318884A1 - Method for producing a moulded body from foamed metal - Google Patents
Method for producing a moulded body from foamed metalInfo
- Publication number
- EP1318884A1 EP1318884A1 EP01974032A EP01974032A EP1318884A1 EP 1318884 A1 EP1318884 A1 EP 1318884A1 EP 01974032 A EP01974032 A EP 01974032A EP 01974032 A EP01974032 A EP 01974032A EP 1318884 A1 EP1318884 A1 EP 1318884A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- powder
- powder mixture
- extrusion device
- partially melted
- casting mold
- 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.)
- Granted
Links
Classifications
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
- B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
- B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
-
- 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
- B22F2998/10—Processes characterised by the sequence of their steps
Definitions
- the invention relates to a method for producing a molded body from metal foam.
- EP 0 804 982 A2 discloses a process for producing molded parts from metal foam, in which a compact mixture of gas-releasing propellant and metal powder is used as the starting material. Such a compacted mixture is usually produced by extrusion. The compacted mixture can be in the form of rods, tubes or as granules. To produce a metal foam, the compacted mixture is heated in a heatable chamber until the metal melts and the blowing agent decomposes. The released gas foams the metal. The metal foam formed is then pressed from the chamber into a mold with a piston.
- DE 197 34 394 AI discloses a method in which a compact semi-finished product is also used to manufacture a molded part from a metal foam.
- non-foamable metal can also be used as the starting material and gas or a blowing agent can be added separately to the melt to form a metal show.
- DE 197 44 300 AI discloses another method for producing a molded body formed from a metal foam. This turns a gas-releasing blowing agent and a semi-finished product made of a metal powder is heated in a recipient. The metal foam that forms arrives in a downstream casting mold.
- DE 1 164 102 discloses a further method for producing molded articles from metal foam.
- a molten metal is fed to a mixer and mixed there with a gas-generating substance.
- the method requires the provision of a separate melting device to produce the molten metal.
- a method for producing molded bodies from a metal foam is known from US Pat. No. 5,865,237.
- a heatable chamber is provided which is connected to a casting mold.
- a compacted mixture which is accommodated in the heatable chamber and is produced by powder metallurgy and contains the metal and a blowing agent is heated until a metal foam is formed.
- the metal foam is then pressed into the mold.
- the structure of the shaped body depends on the filling of the chamber, on the quality of the mixture of the powder with the blowing agent and on the heating of the powder in the chamber. These parameters cannot always be set optimally and reproducibly. In order to lose as little blowing agent as possible and work economically, it is cheap to heat up quickly. On the other hand, rapid heating leads to an uneven temperature distribution and an uneven cell or pore structure of the molded body.
- the components produced using the known method have irregularities in their structure. 5
- the object of the invention is to eliminate the disadvantages of the prior art.
- a method is to be specified by means of which molded articles made of metal foam of constant L0 quality can be produced in the simplest and cheapest possible way.
- a method for producing a molded body from metal foam comprising the following steps:
- non-compacted powder is fed directly to an extrusion device, mixed therein and at least partially melted.
- the costly and time-consuming step of producing a compacted starting powder is avoided.
- the provision of a special device for producing the compacted mixture is omitted.
- the proposed method thorough mixing of the at least partially melted powder mixture is achieved.
- a pressure can also be applied in the extrusion device without great additional effort, which counteracts an undesired premature decomposition of the blowing agent in the extrusion device.
- the heating of the powder mixture can be precisely regulated along the conveying path.
- the second powder can have an average grain diameter in the range from 5 to 20 ⁇ m, preferably from 10 ⁇ m. According to a further design feature, it is provided that the first and the second powder are mixed before being fed to the extrusion device.
- the first and / or second powder can be fed to the extrusion device under an inert gas atmosphere. This prevents undesired oxidation of the powder. The quality of the components and their reproducibility are increased.
- the first and the second powder are expediently mixed in the extrusion device under the action of shear forces.
- the mixing and / or conveying of the powder mixture can be carried out by rotating a screw of the extrusion device. In this case, shear forces are also applied to the at least partially melted powder mixture. Undesired growth of dendritic crystals is avoided.
- the speed of rotation of the screw is about 100 revolutions per minute.
- the powder or the powder mixture is advantageously continuously heated along a conveying path extending from a feed opening in the direction of an antechamber. Along the conveying path, the powder mixture is at least partially converted into a foamable melt in a single process step. Both the powder mixture and the at least partially melted are thereby
- Powder mixture constantly mixed. Furthermore, the powder mixture is conveyed in the direction of an at least partially melted powder mixture on receiving antechambers.
- the process Ren can be carried out inexpensively using a single extrusion device. The separate production of a compacted starting material by extrusion, the subsequent subsequent crushing of the extruded semi-finished product and the transfer of the compacted starting material into the extrusion device are eliminated.
- the powder mixture is heated to a temperature above the solidus temperature.
- the melt is advantageously heated in the extrusion device to a temperature of at most 50 ° C., preferably 20 ° C., above the liquidus temperature. It has proven to be particularly advantageous to heat the powder mixture to a temperature in the range between the solidus and the liquidus temperature.
- the powder mixture is only partially melted.
- the at least partially melted powder mixture can have a solid phase content of 20 to 50%, preferably 30 to 40%.
- the at least partially melted powder mixture is advantageously accumulated in a semi-solid thixotropic state in the antechamber. In the partially melted state, the viscosity is significantly increased compared to the completely melted state.
- the powder mixture can be fed into the extrusion device by means of an external heating device, e.g. by means of external heating tapes or an induction device.
- an external heating device e.g. by means of external heating tapes or an induction device.
- Such a heating device enables a precise adjustment of the heating rate of the powder mixture in the extrusion device. In this way, premature decomposition of the blowing agent and thus expansion of the melt can be avoided.
- the temperature can be adjusted so that undesired growth of dendritic metals is avoided.
- the build-up of a suitable pressure can be controlled via known mechanical and process engineering measures.
- a pressure of more than 10 bar, preferably more than 30 bar, is expediently applied in the extrusion device from a temperature of more than 300 ° C.
- the at least partially melted powder mixture can be injected by an axial movement of the screw in the direction of the casting mold.
- the extrusion device is expediently provided with a mechanical valve for optionally opening and closing an antechamber downstream of the screw. Suitable devices are known for example from US 5,040,589 or EP 0 409 966 B1, the disclosure content of which is hereby incorporated.
- the mold is preheated. This prevents the melt from solidifying too quickly in the contact area with the casting mold.
- magnesium or a magnesium alloy is expediently used as metal 5.
- L0 spray is enlarged.
- a plunge edge tool is expediently used as the casting mold. With such a tool, at least one wall of the casting mold can be moved in the manner of a stamp and the size of the mold cavity can thus be changed.
- Magnesium, aluminum, a magnesium or aluminum alloy can be used as the metal.
- a metal hydride, preferably TiH 2 or MgH 2 can be used as the blowing agent.
- the proportion of the blowing agent in the total weight of the powder is
- FIG. 1 shows a schematic cross-sectional view of a device suitable for carrying out the method according to the invention
- Fig. 2 is a sectional view of a first molded body
- FIG. 3 is a sectional view of a second molded body.
- An injection molding machine generally designated by the reference number 1 in FIG. 1, has a feed hopper 2 which is suitable for receiving granules or powder. The granulate or powder is conveyed to a feed opening 3 of an extrusion cylinder 4 via a conveying device (not described in more detail).
- the conveying device and the feed funnel 2 can be flushed with L0 inert gas.
- the inert gas can be e.g. Argon or nitrogen can be used.
- a screw 5 accommodated in the extrusion cylinder 4 is rotatable and axially movable.
- the screw 5 has a spindle-L5-shaped circumferential wing 6.
- the free end of the screw 5 is designated by the reference number 7.
- the extrusion cylinder 4 has a nozzle 8 at its outlet end.
- the nozzle 8 opens into a gate of a two-part casting mold 9. It can be connected by means of a valve (not shown here)
- the two mold halves of the casting mold 9 form a mold cavity 10.
- the opposite end of the screw 5 is connected to a high-speed injection apparatus 11 known per se.
- This has an accumulator 12 and a cylinder 13 which is accommodated in a fixed bearing 14, 16.
- a shot or injection ram 15 is arranged downstream of the cylinder 13 and extends into a back pressure bearing of a clutch 17. This can be done in a manner known per se
- a connection to a drive shaft 18 can be made, so that the injection plunger 15 can only move back and forth when required, but not rotate.
- the drive shaft 18 extends in a conventional manner through a rotary drive 19. This allows a horizontal reciprocating movement of the drive shaft 18 depending on the movement of the injection plunger 15.
- the drive shaft 18 is coupled to the screw 5 via a drive coupling 20 in a known manner in order to transmit the rotary movement to the screw 5. In the same way, an axial movement can be transmitted to the screw 5.
- Example 1 A powder is added via the feed hopper 2.
- the powder consists of a Mg alloy, eg type AZ 91. This powder has an average grain diameter of 100 ⁇ m. It is mixed with a MgH 2 powder with an average grain diameter of 10 ⁇ m, which serves as a blowing agent.
- the blowing agent has a proportion of 0.5% by weight of the powder.
- the premixed powder is conveyed through a conveyor under an inert gas atmosphere, e.g. Argon gas, conveyed to the feed opening 3 of the extrusion cylinder 4. Due to the action of the screw 5, the powder mixture is moved further in the direction of the nozzle 8. At the same time, the powder mixture is increasingly heated and pressurized.
- the powder mixture is heated e.g. by external heaters, e.g. Heating tapes.
- the screw 5 is rotated at about 100 revolutions per minute.
- the powder mixture is heated with an increasingly closer distance to the nozzle 8 to a temperature above the solidus temperature of 465 ° C.
- the pressure in the prechamber designated by reference number 21 in the extrusion cylinder 4 is more than 30 bar. It can be up to 500 or 1000 bar. Shortly before the injection, the temperature is about 20 ° C higher than the liquidus temperature of the alloy, which is 596 ° C.
- the powder mixture is therefore in the completely melted state.
- the melt is mixed homogeneously.
- the pressure acting on the melt in the prechamber 21 is greater than the gas pressure generated by the blowing agent at the aforementioned temperature. The melt does not foam up.
- the nozzle 8 can be opened.
- the free end 7 on the screw 5 is shot in the direction of the nozzle 8 via the high-speed injection device 11.
- the melt enters the mold cavity 10.
- the gas pressure is greater than the ambient pressure.
- the melt foams suddenly and completely fills the mold cavity 10.
- the mold halves of the casting mold 9 can advantageously be preheated.
- the first powder used is an alloy made from 99% aluminum and 1% magnesium, which contains a small amount of silicon.
- the first powder has an average grain size of approximately 100 ⁇ m.
- TiH 2 with an average grain size of approximately 10 ⁇ m is used as the second powder.
- the first and the second powder are conveyed to the feed opening 3 of the extrusion cylinder 4 under an inert gas atmosphere, for example argon gas.
- the powder mixture is kneaded intensively along the conveying path extending from the feed opening 3 to the pre-chamber 21 and by external heating devices to a temperature of approximately 20 ° C. below the
- Liquidus temperature in this case about 630 ° C, heated. An argon pressure of 100 bar is applied. This melts the powder mixture partially. The melt has a solid phase content of about 35%.
- the nozzle 8 is opened.
- the partially melted powder mixture is injected into the mold in the thixotropic state.
- the pressure in the casting mold is released to 26 bar.
- FIG. 2 shows a cut-away microscopic view of a molded body produced by the aforementioned method.
- the molded body has a bubble-free edge zone. Because the material is injected in the semi-solid thixotropic state, uncontrolled foaming of the melt in the casting mold is avoided.
- the pore structure is homogeneous.
- FIG. 3 shows an incident light microscope image of a cross section through a shaped body produced in this way.
- the length of the sample is again 20 mm. It can be seen that the edge zone is again essentially free of bubbles.
- the pores formed in the interior of the molded body are homogeneously distributed. However, their average pore size is larger than that of the shaped body shown in FIG. 2. This is attributed to the fact that the melt has been expanded here against a smaller counter pressure.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Powder Metallurgy (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
Description
Claims
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10045494 | 2000-09-13 | ||
DE10045494A DE10045494C2 (en) | 2000-09-13 | 2000-09-13 | Process for producing a shaped body from metal foam |
PCT/DE2001/003477 WO2002022295A1 (en) | 2000-09-13 | 2001-09-11 | Method for producing a moulded body from foamed metal |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1318884A1 true EP1318884A1 (en) | 2003-06-18 |
EP1318884B1 EP1318884B1 (en) | 2006-05-31 |
Family
ID=7656201
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP01974032A Expired - Lifetime EP1318884B1 (en) | 2000-09-13 | 2001-09-11 | Method for producing a moulded body from foamed metal |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP1318884B1 (en) |
JP (1) | JP2004508202A (en) |
AT (1) | ATE327851T1 (en) |
DE (2) | DE10045494C2 (en) |
WO (1) | WO2002022295A1 (en) |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10325819B4 (en) * | 2003-06-07 | 2005-06-23 | Friedrich-Alexander-Universität Erlangen-Nürnberg | Process for producing a metal foam body |
DE102005037305B4 (en) | 2005-08-02 | 2007-05-16 | Hahn Meitner Inst Berlin Gmbh | Process for the powder metallurgy production of metal foam and parts made of metal foam |
DE102008000100B4 (en) | 2008-01-18 | 2013-10-17 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | A process for producing a lightweight green body, then manufactured lightweight green body and method for producing a lightweight molded article |
JP2010024468A (en) * | 2008-07-15 | 2010-02-04 | Tohoku Univ | Method for producing porous metal, and porous metal |
JP6443270B2 (en) * | 2015-09-02 | 2018-12-26 | トヨタ自動車株式会社 | Manufacturing method of foam metal |
CN113774248B (en) * | 2021-07-27 | 2022-09-06 | 薛有为 | Equipment and method for producing layered density foamed aluminum |
CN116495023B (en) * | 2023-04-14 | 2024-03-08 | 西南交通大学 | Foam metal filled bamboo-like sandwich circular tube and preparation method thereof |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE4101630A1 (en) * | 1990-06-08 | 1991-12-12 | Fraunhofer Ges Forschung | METHOD FOR PRODUCING FOAMABLE METAL BODIES AND USE THEREOF |
DE4206303C1 (en) * | 1992-02-28 | 1993-06-17 | Mepura Metallpulver Ges.M.B.H., Ranshofen, At | |
AT406027B (en) * | 1996-04-19 | 2000-01-25 | Leichtmetallguss Kokillenbau W | METHOD FOR PRODUCING MOLDED PARTS FROM METAL FOAM |
DE19734394C2 (en) * | 1996-08-13 | 2003-06-18 | Friedrich Wilhelm Bessel Inst | Method and device for producing metal foam |
AT408076B (en) * | 1996-10-07 | 2001-08-27 | Mepura Metallpulver | METHOD FOR THE PRODUCTION OF FOAM METAL OR FOAM / METAL COMPOSITE MOLDED BODIES, SYSTEM FOR THE PRODUCTION AND USE THEREOF |
EP0884123B1 (en) * | 1997-06-10 | 2003-03-26 | Goldschmidt AG | Foamable metal body |
EP1008406A3 (en) * | 1998-12-09 | 2000-09-06 | Bayerische Motoren Werke Aktiengesellschaft | Method for the production of a hollow article filled with a light-metal foam structure |
-
2000
- 2000-09-13 DE DE10045494A patent/DE10045494C2/en not_active Expired - Fee Related
-
2001
- 2001-09-11 WO PCT/DE2001/003477 patent/WO2002022295A1/en active IP Right Grant
- 2001-09-11 JP JP2002526535A patent/JP2004508202A/en active Pending
- 2001-09-11 DE DE50109977T patent/DE50109977D1/en not_active Expired - Lifetime
- 2001-09-11 AT AT01974032T patent/ATE327851T1/en not_active IP Right Cessation
- 2001-09-11 EP EP01974032A patent/EP1318884B1/en not_active Expired - Lifetime
Non-Patent Citations (1)
Title |
---|
See references of WO0222295A1 * |
Also Published As
Publication number | Publication date |
---|---|
DE10045494C2 (en) | 2002-07-18 |
DE50109977D1 (en) | 2006-07-06 |
WO2002022295A1 (en) | 2002-03-21 |
EP1318884B1 (en) | 2006-05-31 |
DE10045494A1 (en) | 2002-04-04 |
ATE327851T1 (en) | 2006-06-15 |
JP2004508202A (en) | 2004-03-18 |
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