EP1877594A1 - Procede de preparation d'un composite de matrice metallique, couche de revetement et melange ainsi obtenu - Google Patents

Procede de preparation d'un composite de matrice metallique, couche de revetement et melange ainsi obtenu

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Publication number
EP1877594A1
EP1877594A1 EP06732828A EP06732828A EP1877594A1 EP 1877594 A1 EP1877594 A1 EP 1877594A1 EP 06732828 A EP06732828 A EP 06732828A EP 06732828 A EP06732828 A EP 06732828A EP 1877594 A1 EP1877594 A1 EP 1877594A1
Authority
EP
European Patent Office
Prior art keywords
metal
powder
matrix composite
preparing
metal matrix
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Withdrawn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
EP06732828A
Other languages
German (de)
English (en)
Other versions
EP1877594A4 (fr
Inventor
Kyung-hyun AJOU Univ. Mat.Science & Eng. Dept. KO
Ha-yong AJOU Univ. Mat.Science & Eng. Dept. LEE
Jae-Hong Lee
Jae-jung 433-1201 Samsung APT LEE
Young-Ho Yu
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.)
SK Enpulse Co Ltd
Original Assignee
SNT Co 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 SNT Co Ltd filed Critical SNT Co Ltd
Publication of EP1877594A1 publication Critical patent/EP1877594A1/fr
Publication of EP1877594A4 publication Critical patent/EP1877594A4/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

  • This invention relates to a method of preparing a metal matrix composite, and a metal matrix composite coating layer and metal matrix composite bulk prepared by using the same. More particularly, the invention relates to a method of preparing a coating layer with wear resistance and excellent resistance against fatigue crack by securing high hardness by the dispersion of intermetallic compounds and ceramic particles without causing damages such as heat strain to a substrate in the process of preparing the coating layer and a method of providing a bulk which is prepared by separating the coating layer from the substrate, and a coating layer and bulk prepared thereby.
  • Dispersion reinforcement methods are used to improve the strength, hardness, wear resistance of alloys or metals.
  • the dispersion reinforcement methods form a structure of intermetallic compounds being dispersed within the matrix of alloys or metals and their representative examples are precipitation hardening or dispersion of high hardness particles.
  • aluminum alloys are easy to dispersion reinforcement by the precipitation hardening of intermetallic compounds within the aluminum matrix and accordingly, it contributes to the improvement of their mechanical properties.
  • the aluminum alloys have excellent strength, heat resistance and durability as well as light weight that is attributable to the aluminum itself and thus they have been widely used as a material for thermal, mechanical parts of aircrafts or engine parts of automobiles.
  • Prior dispersion strengthened aluminum alloys have been prepared by casting, powder metallurgy, thermal spraying and so on.
  • the powder metallurgy is a method of preparing aluminum alloys by forming aluminum and a dispersion (metal powder or ceramic powder) as an additive into the form of powder and sintering them, and the thus prepared alloys are characterized in that fine dispersion phases are evenly dispersed within the alloys and in case of the ceramic powder, the coarsening of the dispersion phases does not occur at high temperatures and thus show excellent characteristics at high temperatures.
  • the powder metallurgy involves complex manufacturing process including the suitable control of sintering atmosphere in order to prevent the oxidation of aluminum at high temperature in the course of sintering and according to the powder metallurgy, the formation of intermetallic compounds with transition metals having high melting points such as Ti or Ni has been known to be very difficult.
  • the powder metallurgy as a desired shape is prepared by a mold, it costs a lot to prepare the mold and it also has size limitation.
  • the thermal spraying is a method of preparing dispersion strengthened aluminum alloys by spraying molten metals and cooling them. This method generates the same problems as in the casting. In particular, where aluminum-transition metal alloys are prepared by the thermal spraying, coarse secondary phases are formed within the aluminum matrix and they exhibit inferior alloy characteristics.
  • the coating materials to improve wear-resistance materials having high hardness, that is, ceramic materials such as oxides, for example, alumina, carbides, for example, SiC or TiC, and nitrides for example, Si N , TiN are mostly used.
  • Korean Patent Laid-Open No. 1997-0045010 discloses a method of forming a coating membrane instead of prior cast iron liners on the inner walls of cylinder bores and in this method, wear resistance is improved by forming coating powders comprising ceramics and their mixtures on the inner walls of bores by thermal spraying using plasma or arc as heat source.
  • Korean Patent Laid-Open No. 1998-017171 discloses a method of forming wear- resistant coating layer on the bore side of aluminum cylinder blocks by plasma spray using silicone carbide particles.
  • Korean Patent Laid-Open No. 2003-0095739 discloses a method of forming a coating membrane by spraying a powder composition for spray coating on the inner walls of stainless cylinder bores while fusing it with heat source of high temperature, and the powder composition for spray coating is a mixture alumina and zirconia.
  • the present invention provides a method of preparing a metal matrix composite, the method comprising the steps of:
  • preparing a mixed powder comprising i) a first metal powder comprising a metal, alloy or mixture particle thereof, ii) a second metal powder comprising an intermetallic compound forming metal particle which forms an intermetallic compound along with the metal or the alloy element of the alloy, and iii) a ceramic powder comprising a ceramic or mixture particle thereof;
  • the invention provides a metal matrix composite coating layer characterized in that it is prepared by the metal matrix composite preparation method and a metal matrix composite bulk characterized in that it is prepared by the separation of the substrate from the substrate and coating layer prepared by the metal matrix composite preparation method.
  • the invention can be applied to prepare members with excellent mechanical strength and also, it can be used to dispersion reinforce the surface of the existing members. In particular, as it is carried out at low thermal treatment temperatures, there is a slight possibility of exercising bad influence on the properties of the members upon surface hardening.
  • Fig. 1 is a schematic view of a low-temperature spray (cold spray) apparatus which is used to prepare metal matrix composites in this invention.
  • Fig. 2 to Fig. 5 are phase diagrams illustrating intermetallic compounds formable with regard to Al matrix by a method of preparing metal matrix composites of the invention.
  • FIG. 6 to Fig. 9 illustrate embodiments of the nozzle used in a method of preparing coating layers of the invention.
  • Fig. 10 is X-ray diffraction test results showing whether an intermetallic compound is generated and how much it is generated according to thermal treatment temperatures where the ratio of aluminum powder and nickel powder is 9: 1.
  • Fig. 11 is X-ray diffraction test results showing whether an intermetallic compound is generated and how much it is generated according to thermal treatment temperatures where the ratio of aluminum powder and nickel powder is 75:25.
  • Fig. 12 is EDX photographing results of each part where the ratio of aluminum powder and nickel powder is 75:25 and the thermal treatment temperature is 550 °C.
  • Fig. 13 is EDX photographing results of each part where the ratio of aluminum powder and nickel powder is 75:25 and the thermal treatment temperature is 500 °C.
  • Fig. 14 is X-ray diffraction test results showing whether an intermetallic compound is generated and how much it is generated according to thermal treatment temperatures where the ratio of aluminum powder and titanium powder is 9:1.
  • Fig. 15 is X-ray diffraction test results showing whether an intermetallic compound is generated and how much it is generated according to thermal treatment temperatures where the ratio of aluminum powder and titanium powder is 75:25.
  • Fig. 16 is EDX photographing results of each part where the ratio of aluminum powder and titanium powder is 75:25 and the thermal treatment temperature is 630 °C.
  • connection section 30 buffer chamber
  • the present invention relates to a method of preparing a metal matrix composite, which comprises the steps of providing a substrate, preparing a mixed powder comprising i) a first metal powder comprising a metal, alloy or mixture particle thereof, ii) a second metal powder comprising an intermetallic compound forming metal particle which forms an intermetallic compound along with the metal or the alloy element of the alloy, and iii) a ceramic powder comprising a ceramic or mixture particle thereof, injecting the mixed powder prepared above into a spray nozzle for coating, coating the mixed powder on the surface of the substrate by accelerating the mixed powder in the state of non-fusion at a speed of 300 to 1,200 m/s by the flow of transportation gas flowing in the spray nozzle, and forming the intermetallic compound by the thermal treatment of the coated coating layer.
  • the invention focuses on the improvement of mechanical properties including fatigue characteristics, wear resistance, hardness of coating layers in the methods of preparing metal matrix composites on substrates by using cold spray (low-temperature spray) method and for the maximum improvement thereof, the invention is characterized in that in addition to mixing a metal matrix which is an existing metal matrix composite component with ceramic particles, it further comprises an intermetallic compound forming metal particle which forms an intermetallic compound along with the alloy element of an alloy or a metal that constitutes the metal matrix and such a mixed powder is sprayed and laminated via cold spray methods at relatively low temperatures in comparison with thermal spraying or sintering temperature.
  • Fig. 1 shows a schematic view of a low-temperature spray (cold spray) apparatus (100) for preparing a coating layer on a substrate (S) in the invention.
  • the spray apparatus (100) provides the substrate (S) with powders to form a coating layer by accelerating them at subsonic or supersonic speed.
  • the spray apparatus (100) comprises a gas compressor (110), gas heater (120), powder feeder (130), and nozzle for spray (140).
  • Compressed gas of about 5 to 20 kgf/cm provided by the gas of about 300 ⁇ 1200 m/s through the nozzle for spray (140).
  • a convergence-divergence nozzle (de Laval-Type) as shown in Fig. 1 is generally used as the nozzle for spray (140) and supersonic flow can be generated by such convergence and divergence process.
  • a gas heater (120) on the route to feed the compressed gas in the apparatus (100) is an additional one for heating the compressed gas to increase its spray speed at the nozzle for spray by increasing kinetic energy thereof and it is not necessarily necessary. Also, as shown in Fig. 1, to enhance the powder supply to the nozzle of spray (140), a portion of the compressed gas in the gas compressor (110) can be supplied to the powder feeder (130).
  • the compressed gas in the apparatus common gas, for example, helium, nitrogen, argon and air can be used and it can be suitably selected in consideration of spray speed at the nozzle for spray (140) and costs.
  • the first step is to provide a substrate.
  • (S) can be various kinds of known material that can be substrates of parts requiring wear-resistance where the improvement of wear resistance in parts requiring wear resistance is aimed and further, it can comprise any other materials.
  • the substrate can be aluminum, aluminum alloys, especially, Al-Si or Al-Mg aluminum alloys that are widely used as thermal, mechanical members, or iron alloys such as cast iron, or it can be semi-conductive materials such as silicone.
  • the substrate is aluminum or aluminum alloys that have poor wear resistance because it is remarkably improved according to the coating layer preparation of the invention.
  • the substrate is preferably ceramic materials having low reactivity with metal powders or resin materials that can be destroyed and thus disappeared in thermal treatment step.
  • the metal, alloy or mixture particle thereof used in the first metal powder in the invention various known metals, alloys or mixture particles thereof can be used and preferably, there are used iron, nickel, cupper, aluminum, molybdenum, titanium or alloys thereof or mixture thereof. More particularly, in case of aluminum and titanium, aluminum, aluminum alloys, mixture of aluminum and aluminum alloys, mixture of aluminum and titanium, mixture of aluminum and titanium alloys, mixture of aluminum alloys and titanium alloys can be mentioned and especially, they can be aluminum alloys or titanium alloys that are often used as ordinary thermal, mechanical members. More preferably, the metal or alloy is aluminum or aluminum alloys because they are homogeneous with aluminum or aluminum alloy substrates that exhibit well- improved wear resistance according to the coating layer preparation of the invention.
  • the intermetallic compound forming metal particle which forms an intermetallic compound along with the metal or the alloy element of the alloy used in the second metal powder is determined by the metal, alloy or mixture particle thereof of the first metal powder.
  • a metal having higher melting point than aluminum among transition metals can be the second metal powder and as specific examples, it can be a metal selected from the group consisting of titanium, nickel, chromium, iron and combination thereof.
  • aluminum can form intermetallic compounds with regard to titanium, nickel, chromium, and iron, respectively.
  • Fig. 2 to Fig. 5 are phase diagrams of two-element aluminum alloys as examples of aluminum alloys which are formable by the method of the invention.
  • Fig. 2 is a phase diagram of Al-Ti type.
  • Al phase where Ti is solid solubilized in a small amount in alloys and TiAl phase which is an intermetallic compound of Al-Ti exist as stable phases at temperatures lower than 664 °C (937 K).
  • Al Tiphase and Al Ti phase exist as stable phases of the alloys.
  • the relative weight ratio of Al, Al Ti and Al Tiphases present in the alloys according to the mixing ratio of the metal powders is determined by so called "the lever rule", which has been known by a person having ordinary knowledge in the art to which the invention pertains.
  • Fig. 3 is a phase diagram of Al-Ni type. With reference to Fig. 3, at temperatures lower than 636 °C, intermetallic compounds of Al Ni, Al Ni , AlNi, AlNi and the like form the stable phases of alloys according to the amount of Ni.
  • Fig. 4 is a phase diagram of Al-Cr type. With reference to Fig. 4, at temperatures lower than 663 °C (936 K), intermetallic compounds of CrAl form stable phases according to the addition of Cr.
  • Fig. 5 is a phase diagram of Al-Fe type and as shown in the figure, even in case of Al-Fe type, intermetallic compounds of metastable phase such as FeAl can be formed at temperatures lower than 654 °C (927 K).
  • Al-Ti, Al-Ni, Al-Cr and Al-Fe two-element system exist as stable phases below certain temperature, the formation of intermetallic compounds within the alloys is possible by mixing Al metal powder with Ti, Ni, Cr or Fe metal powders.
  • the second metal component can comprise alloy elements that can be obtained from existing Al alloys through precipitation hardening. That is, as precipitation hardening type aluminum alloys, various alloy systems such as Al-Cu, Al-Li and Al-Mg are possible, and in these cases, the alloys obtain dispersion reinforcement effects by precipitating precipitates that are intermetallic compounds and thus, the second metal components can comprise Cu, Lu or Mg where the metal matrix composite coating layer or bulk of the invention is applied to relatively low temperature.
  • the ceramic or mixture thereof that is the ceramic powder in the invention can be various kinds of known ceramic and mixture thereof used in metal matrix composites for the improvement of known , alumina, nitrides such as TiN and Si 3 N 4 , and carbides such as TiC and SiC can be used, and alumina or SiC is preferable for the enhancement of wear resistance.
  • the ceramic particle to be mixed into the mixed powder in the invention can be provided in the form of an agglomerated powder.
  • the agglomerated powder is easy to be pulverized into fine particles and thus become fine particles when the powder particles collide with substrates in the coating process. Accordingly, it is advantageous in that a coating layer where fine ceramic particles are uniformly dispersed can be formed.
  • particles having various sizes used in the known cold spray can be used and preferably, ones having size of 1 to 100 um are advantageous in respect to dispersion and mixing. More preferably, as the second metal powder is changed into intermetallic compounds by subsequent thermal treatment step, finer particles are advisable to obtain uniform, strong dispersion reinforcement effects and preferably it has smaller particle size than the first metal powder.
  • the aluminum powder is 50 to 100 um and the nickel powder is 1 to 100 um, preferably, 1 to 50 um, and in case of mixing aluminum powder and Ti powder, the aluminum powder is 50 to 100 um, and the Ti powder is 1 to 100 um, preferably, 1 to 50 um.
  • the ceramic powder to be mixed together powders having various sizes used in the preparation of known metal matrix composites can be employed and preferably, ones having size of 1 to 100 um are advantageous in respect to dispersion and mixing.
  • the ceramic powder is preferably SiC or alumina because they are advantageous in respect to reactivity and dispersion effects and in connection with their sizes, where the aluminum powder is 50 to 100 um, the ceramic powder is preferably 1 to 50 um. That is, in case of the first metal powder and the ceramic powder, if the size of the particles is too small, the weight of the particles is less and thus impulse becomes too less in spite of their fast speed when they collide with coating layers and as a result, processed hardening such as shot peening is less generated. On the other hand, if the size of the particles is too big, dispersion reinforcement effects is decreased. Thus, optimal medium size ranges as described above exist to maximize the processed hardening and dispersion reinforcement.
  • the mixing ratio of the first metal powder, the second metal powder and the ceramic powder various mixing ratios can be chosen and in case of the second metal powder, as it is almost changed into intermetallic compounds in subsequent thermal treatment step, it is mixed in a ratio corresponding to the amount of dispersion required when metal matrix composite is designed and in case of the ceramic powder, as it functions as a dispersion by itself without additional reactions, it is mixed in a ratio corresponding to the amount of dispersion required when metal matrix composite is designed.
  • the mixing ratio of the first metal powder and the ceramic powder is preferably 1:1 to 3:1 of metal: ceramic by volume to maximize micro Vickers hardness value that is a relative index of wear resistance.
  • the mixed powders of the first metal powder, the second metal powder and the ceramic powder can be prepared by ordinary methods. As simple methods, these powders can be dry mixed by v-mill. The dry mixed powders themselves can be used in the powder feeder without additional treatment. Although the mixing ratio of each powder of the mixed powders can be suitably controlled according to their use, they are mixed within appropriate ranges according to their designed values for the optimization of mechanical properties such as wear resistance. When the volume ratio of the ceramic particles exceeds 50 %, there is a problem that coating layers may not increase beyond certain thickness and accordingly, it is mixed within the above ranges.
  • a convergence-divergence nozzle is used for the nozzle in the invention, and in case of having a common structure, a compressed gas of about 5 - 20 kgf/cm is supplied to the mixture powder.
  • a compressed gas for the compressed gas, helium, nitrogen, argon or air can be used.
  • the gas is supplied, while being compressed to about 5 - 20 kgf/cm by a gas compressor.
  • the compressed gas can be supplied in the state of being heated to the temperature of about 200 - 500 °C by heating means such as the gas heater (120) in Fig. 1.
  • the temperature of the transportation gas supplied to the nozzle may be maintained relatively low when the mixed powders are coated through the nozzle.
  • the temperature of the transportation gas is 280 + 5 °C. More preferably, the temperature of the transportation gas is advisable because it shows appropriate coating efficiency in case that aluminum is used as the first metal powder.
  • the in- termetallic compound forming metal particle in the second metal powder is a metal selected from the group consisting of titanium, nickel, chromium, iron, combination thereof, if the speed of the powder to be coated on the substrate is maintained at 300 to 500 m/s regardless of the types of the ceramic particles, the processed hardening effects of the coating layer as described above can be obtained and accordingly, wear resistance can be maximized.
  • nozzle of the cold spray apparatus besides ordinary convergence- divergence nozzles of de Laval-Type as described above, there can be used convergence-straight nozzles or convergence-divergence nozzles with throat as depicted in Fig. 6 to 9.
  • the injection of the mixed powders can be carried out at the divergence or straight section of the nozzle via an injection tube located through a throat.
  • the pressure for the injection of the mixed powder can be maintained low and it is thus possible to design a cold spray apparatus with low costs and further, as the powders are injected in the divergence or straight section, it can prevent the powders from being coated inside the nozzle, especially, throat and accordingly, long time operation is possible.
  • the pressure when the mixed powders are injected into the nozzle is as low as 90 to 120 psi, which is much lower than the ordinary pressure.
  • the pressure when the mixed powders are injected into the nozzle is 90 to 120 psi and the temperature of the transportation gas is 280 + 5 °C for the formation of coating layers with excellent wear resistance, especially when the first metal powder is aluminum and the ceramic is SiC.
  • the mixing ratio of the ceramic powder or the mixing ratio of the second metal powder to the first metal powder may have a concentration gradient as it goes to outer surface from the substrate surface and the particle size of the ceramic powder or the particle size of the second metal powder may have a constant gradient with regard to particle sizes as it goes to outer surface from the substrate surface.
  • the mixing ratio of the second metal powder to the first metal powder can be designed to have various concentration gradients such as i) increase from the substrate surface to outer surface, ii) decrease from the substrate surface to outer surface, iii) peak in the middle and decrease to the substrate surface and outer surface, iv) be lowest in the middle and increase to the substrate surface and outer surface, etc.
  • concentration gradient can be equally applied to the ceramic powder and the concentrations of the ceramic powder and the second metal powder can be adjusted altogether, and the concentration gradient direction of the ceramic powder and the second metal powder can be designed differently or conversely.
  • particle sizes can have gradient and in case of the ceramic powder, its particle size can i) increase as it goes to outer surface from the substrate surface, ii) decrease as it goes to outer surface from the substrate surface, iii) peak in the middle and decrease to the substrate surface and outer surface, iv) be lowest in the middle and increase to the substrate surface and outer surface, etc.
  • particle size gradient can be equally applied to the second metal powder and the particle size of the ceramic powder and the second metal powder can be adjusted altogether, and the particle size gradient direction of the ceramic powder and the second metal powder can be designed differently or conversely.
  • Such gradient can minimize the heat stress which is generated by difference in thermal expansion coefficients between the substrate and the coating layers and minimize peeling, residual stress, etc. which might be generated by heat cycling by activating heat transfer.
  • the mixed powder sprayed at high speed forms a coating layer with high density upon collision with the substrate.
  • the coated coating layer is subject to thermal treatment where intermetallic compounds are formed, which is intended in the preparation step of the mixed powder.
  • the thermal treatment step in this invention is characterized in that it is carried out at low temperatures. While in the prior casting and thermal spray, the metal mixed powder was heat-treated at a high temperature of 900 -1200 °C or so, the thermal treatment in the method of the invention is carried out at temperatures not higher than 900 °C.
  • the thermal treatment is preferably carried out below the lowest liquid phase formation temperature which the mixed combination of different first metal powder and second metal powder can attain, that is, below eutectic temperature.
  • the term "eutectic temparature" encompasses peritectic temperature.
  • the thermal treatment of the invention is preferably carried out at temperatures not higher than 664 °C as shown in Fig. 2.
  • the thermal treatment step is preferably carried out at temperatures not higher than 636 °C, 663 °C or 654 °C (927 K), respectively. More preferably, the thermal treatment step is carried out above about 500 °C because of the easiness of thermal treatment and the appropriate maintenance of time for intermetallic compound formation.
  • the coating layer formed on the substrate by the thermal treatment step forms Al matrix composite where intermetallic compounds and ceramic powders are dispersed inside.
  • thermal treatment is carried out below eutectic temperature as in this invention, intermetallic compounds are formed by solid-phase diffusion by solid- phase reaction. Accordingly, as liquid phase is not involved in the formation of intermetallic compounds as in the casting or thermal spraying, it is possible to obtain Al matrix composites where fine intermetallic compounds are dispersed within Al matrix phase.
  • the coating layer formed by the method of the invention has a very high density. Accordingly, although it is exposed to oxygen included in air or atmosphere gas in the process of thermal treatment, the possibility of forming oxidation membrane on the surface of individual Al powder particle is decreased. For such a reason, the thermal treatment step of the invention can be carried out not only in inert gas atmospheres such as nitrogen and argon but also in air.
  • the reason why the thermal treatment in this invention is preferably carried out below eutectic temperature (including peritectic temperature) is that liquid phase is not involved in thermodynamic equilibrium state below this temperature and thus the intermetallic compounds of fine dispersion phase are suitably obtained.
  • eutectic temperature including peritectic temperature
  • the role of the liquid phase affecting the formation of the intermetallic compounds can be ignored. Therefore, "below eutectic temperature” described in the appended claims is not intended to be literally interpreted to exclude the temperature ranges including such variation.
  • the thermal treatment step may have thermal treatment effects for the improvement of the adhesion of the coating layer or mechanical processing for surface illumination control as well as the formation of intermetallic compounds.
  • the method of preparing metal matrix composites in the invention may further comprise the step of separating the coating layer which is formed in the coating step from the substrate and thus there can be provided a metal matrix composite bulk comprising the metal matrix composite alone.
  • the invention provides a metal matrix composite coating layer characterized in that it is prepared by the method of preparing metal matrix composite described above.
  • the thickness of the coating layer is preferably 10 um to 1 mm If it is too thin, wear resistance is decreased and if it is thick, it will be expensive to prepare a coating layer, and peeling or heat stress by thermal expansion may be generated.
  • the invention provides a metal matrix composite bulk characterized in that it is prepared from the metal matrix composite coating layer prepared by the method of preparing metal matrix composite described above by further comprising the step of separating the coating layer formed in the coating step from the substrate.
  • the wear-resistant metal matrix composite coating layer or bulk obtained from the method of the invention improves mechanical properties of the substrate, coating or bulk.
  • the wear resistance of the members can be improved by containing in- termetallic compounds and ceramic particles with high hardness in the coating layer or bulk.
  • the coating layer or bulk prepared by the invention enhances the fatigue properties of the coated parts.
  • strong binding between the coating layer and the substrate inhibits crack from being generated and as the coating layer possesses the characteristics of metal matrix composite, its fine structure reduces the generation of crack and its propagation rate and therefore, fatigue properties are enhanced.
  • it helps the parts have high resistance against thermal fatigue destruction.
  • One of the main causes for the generation and propagation of crack in parts used in heat resistant engines such as gas turbines is heat stress due to local temperature difference. In engine blocks, a portion close to the cylinder has high temperature and a portion far from the cylinder has low temperature due to combustion of the engine. Such temperature difference generates heat stress, which causes crack on the engine block surfaces.
  • the thermal conductivity properties of the member can be enhanced by preparing the coating layer using particles having high thermal conductivity such as aluminum or aluminum alloys as a metal and SiC as a ceramic.
  • the improvement of the thermal conductivity properties reduces temperature difference present in the parts thereby resulting in improvement in the heat fatigue destruction properties of the parts.
  • the formation of composite can reduce difference in thermal expansion coefficient from the substrate, heat stress occurring during heating can be reduced and the peeling and crack generation of the coating layers can be minimized.
  • the prepared coating was subject to thermal treatment for four hours at about 450 °C, 500 °C and 550 °C.
  • the thermal treatment was carried out under nitrogen atmosphere.
  • Fig. 10 Al-10%Ni
  • Fig. 11 Al-25%Ni
  • the prepared coating was subject to thermal treatment for four hours at about 450 °C, 500 °C, 550 °C and 630 °C.
  • the thermal treatment was carried out under nitrogen atmosphere.
  • Fig. 14 Al-10%Ti
  • Fig. 15 Al-25%Ti
  • the invention can be applied to prepare members with excellent mechanical strength and also, it can be used to dispersion reinforce the surface of the existing members. In particular, as it is carried out at low thermal treatment temperatures, there is a slight possibility of exercising bad influence on the properties of the members upon surface hardening.
  • the invention enables the processing under the environments of the thermal treatment temperature of relatively low temperature, low injection pressure of mixed powders and low transportation gas temperature, it can be manufactured with low costs and it is easy to mass production.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

L'invention concerne un procédé de préparation d'un composé de matrice métallique, d'une couche de revêtement et le mélange ainsi obtenu, plus particulièrement, elle concerne un procédé de préparation d'un composite de matrice métallique comprenant les étapes suivantes: fournir un substrat; préparer une poudre mélangée contenant (i) une première poudre métallique contenant un métal, un alliage ou leur particule de mélange, (ii) une seconde poudre métallique contenant un composé intermétallique formant une particule métallique qui constitue, à son tour, un composé intermétallique avec le métal ou l'élément d'alliage de l'alliage et (iii) une poudre céramique contenant une céramique ou sa particule de mélange; injecter la poudre mélangée obtenue auparavant dans une buse de vaporisation en vue d'un revêtement; recouvrir la surface du substrat avec la poudre mélangée par accélération de cette poudre à l'état de non fusion à une vitesse comprise entre 300 et 1 200 m/s au moyen de l'écoulement de gaz de transport dans la buse de vaporisation; et former le composé intermétallique par traitement thermique de la couche de revêtement appliquée, d'une couche de revêtement et du mélange ainsi obtenu, la couche de revêtement et le mélange faisant preuve d'une forte résistance à l'usure et d'une excellente résistance à la cassure de fatigue sur la surface sans causer de dommages, tels que la contrainte thermique sur le substrat pendant la préparation de la couche de revêtement.
EP06732828A 2005-04-15 2006-04-06 Procede de preparation d'un composite de matrice metallique, couche de revetement et melange ainsi obtenu Withdrawn EP1877594A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR1020050031509A KR100802329B1 (ko) 2005-04-15 2005-04-15 금속기지 복합체 형성방법 및 이를 이용하여 제조된 코팅층및 벌크
PCT/KR2006/001267 WO2006109956A1 (fr) 2005-04-15 2006-04-06 Procede de preparation d'un composite de matrice metallique, couche de revetement et melange ainsi obtenu

Publications (2)

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EP1877594A1 true EP1877594A1 (fr) 2008-01-16
EP1877594A4 EP1877594A4 (fr) 2010-04-28

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EP06732828A Withdrawn EP1877594A4 (fr) 2005-04-15 2006-04-06 Procede de preparation d'un composite de matrice metallique, couche de revetement et melange ainsi obtenu

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US (1) US20090120539A1 (fr)
EP (1) EP1877594A4 (fr)
JP (1) JP2008538385A (fr)
KR (1) KR100802329B1 (fr)
CN (1) CN101160417B (fr)
TW (1) TW200700567A (fr)
WO (1) WO2006109956A1 (fr)

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KR20060109179A (ko) 2006-10-19
JP2008538385A (ja) 2008-10-23
CN101160417B (zh) 2010-05-19
WO2006109956A1 (fr) 2006-10-19
US20090120539A1 (en) 2009-05-14
CN101160417A (zh) 2008-04-09
KR100802329B1 (ko) 2008-02-13
EP1877594A4 (fr) 2010-04-28
TW200700567A (en) 2007-01-01

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