EP2143809A1 - Aluminium alloy for metal foams, its use and method for its manufacture - Google Patents
Aluminium alloy for metal foams, its use and method for its manufacture Download PDFInfo
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- EP2143809A1 EP2143809A1 EP09007574A EP09007574A EP2143809A1 EP 2143809 A1 EP2143809 A1 EP 2143809A1 EP 09007574 A EP09007574 A EP 09007574A EP 09007574 A EP09007574 A EP 09007574A EP 2143809 A1 EP2143809 A1 EP 2143809A1
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- 238000000034 method Methods 0.000 title claims abstract description 32
- 239000006262 metallic foam Substances 0.000 title claims abstract description 20
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 14
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 14
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 65
- 239000000956 alloy Substances 0.000 claims abstract description 65
- 239000000843 powder Substances 0.000 claims abstract description 32
- 239000000203 mixture Substances 0.000 claims abstract description 27
- 229910052751 metal Inorganic materials 0.000 claims abstract description 21
- 239000002184 metal Substances 0.000 claims abstract description 21
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 15
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 10
- 239000006260 foam Substances 0.000 claims description 21
- 238000005187 foaming Methods 0.000 claims description 15
- 239000011162 core material Substances 0.000 claims description 13
- 239000012792 core layer Substances 0.000 claims description 11
- 229910052710 silicon Inorganic materials 0.000 claims description 10
- 239000004604 Blowing Agent Substances 0.000 claims description 9
- 239000011265 semifinished product Substances 0.000 claims description 8
- 239000002131 composite material Substances 0.000 claims description 7
- 238000000354 decomposition reaction Methods 0.000 claims description 7
- 239000007789 gas Substances 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 7
- 230000008018 melting Effects 0.000 claims description 7
- 239000000470 constituent Substances 0.000 claims description 5
- 239000007787 solid Substances 0.000 claims description 3
- 150000001875 compounds Chemical class 0.000 claims description 2
- 239000003795 chemical substances by application Substances 0.000 claims 1
- 239000004088 foaming agent Substances 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 6
- 239000004411 aluminium Substances 0.000 abstract 1
- 239000011148 porous material Substances 0.000 description 22
- 239000011777 magnesium Substances 0.000 description 12
- 229910052749 magnesium Inorganic materials 0.000 description 9
- 239000000155 melt Substances 0.000 description 7
- 238000009826 distribution Methods 0.000 description 6
- 239000010410 layer Substances 0.000 description 6
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 5
- 238000005275 alloying Methods 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000003380 propellant Substances 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000010309 melting process Methods 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910001111 Fine metal Inorganic materials 0.000 description 1
- 229910019018 Mg 2 Si Inorganic materials 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 210000002421 cell wall Anatomy 0.000 description 1
- 230000005465 channeling Effects 0.000 description 1
- 238000011496 digital image analysis Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
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Classifications
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- 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
- C22C1/08—Alloys with open or closed pores
-
- 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
- B22F3/1134—Inorganic fillers
-
- 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
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
- B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
- B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
Definitions
- the invention relates to an aluminum alloy for metal foams, a product thereof and a method for its production.
- the prior art generally discloses the production of metal foams in a powder-metallurgical manner by first compacting a mixture of metal powder and blowing agent and then partially or completely melting it and cooling it again after pore formation has taken place. In the molten state, the gas released by the blowing agent forms the pores in the melt.
- Such a method is for example in DE 101 15 230 A1 described.
- the production of a metal foam of the alloy AA6060 (AlMgSi) is given.
- metal foam sandwiches in which a metal foam core is arranged between two outer cover layers closing off to the outside.
- Sandwich structures of this type can be produced by bonding the cover layer to the foam core layer, but also by metallically bonding the unfoamed core material to the cover layers by applying pressure in one method step (see, for example, US Pat EP 0 997 215 A2 ) and only then foamed by means of thermally activated blowing agent.
- the choice of materials for the metal foam core and for the cover layers is particularly important because the foaming process requires special temperature conditions.
- DE 101 36 370 A1 The composite blank is formed into a semi-finished product and foamed by heating to a temperature which is simultaneously above the Ausgastemperatur of the blowing agent powder and within the solidus-liquidus region of the metal powder, to form a component. It is stated that in the case where both the core layer and the cover layers have the same material, e.g. As aluminum is used, different melting temperatures can be adjusted by different alloying additives in powder and cover materials.
- the object of the invention is now to provide an aluminum alloy for metal foams of the type AlMgSi and a use of this alloy, wherein the metal foam should have a fine pore structure with high expansion capacity, good mechanical properties and good corrosion resistance.
- the object is further to provide a method for producing a product of this aluminum alloy.
- the aluminum alloy of the AlMgSi type is the alloy AlMg4 ( ⁇ 1) Si8 ( ⁇ 1), stated in% by weight.
- the improved properties can also be attributed to the particular melting behavior of the alloy according to the invention, which is characterized by the function of the liquid volume fraction as a function of the temperature of the melt.
- the alloy isothermally produces a proportion of about 50% ternary-eutectic melt at 560 ° C. and has a liquidus temperature of about 600 ° C., which enables precise setting of an optimum toughness of the melt for foam expansion.
- the claimed alloy is used as a foamed core material in aluminum foam sandwiches.
- a metal powder mixture for the alloy AlMg4 ( ⁇ 1) Si8 ( ⁇ 1) is first prepared and compacted to form a foamable semifinished product, and then this semifinished product is foamed by known means.
- a metal powder mixture for the alloy AlMg4 ( ⁇ 1) Si8 ( ⁇ 1) is first produced and compacted into a foamable core layer, after which this core layer is placed between two cover plates of a 6000 alloy and these Assembly is transferred to a solid metallic composite, then this composite is heated to a temperature slightly lower than the solidus temperature of the 6000 alloy and, upon reaching the desired thickness of the foamed core material, the foaming process is stopped by cooling below the solidus temperature of the core material.
- the metal powder mixtures in the context of the invention mean mixtures of alloy powders, i. Powders of such materials that make up the proposed alloy, and in such proportions by weight of the individual components that lead to this alloy. It is irrelevant whether powder of the three alloying components individually or z. For example, powders already containing two alloy components to which the missing constituents are added can also be used.
- a mixture of the individual alloy constituents is used as the metal powder mixture for the alloy AlMg4 ( ⁇ 1) Si8 ( ⁇ 1), in particular in the composition 50 wt.% AlMg8, 8 wt.% Si and 41 Wt.% Al or in elemental composition 88 wt% Al, 4 wt% Mg and 8 wt% Si.
- Another embodiment provides a metal powder mixture of 8% by weight of the two-component alloy powder AlMg50, 8% by weight of Si and 84% by weight of Al.
- the use of an alloy powder mixture has the advantage that the unwanted burnup of the Mg content in the production and in the foaming process of the alloy according to the invention is prevented.
- the optionally provided exclusion or removal of foreign gases (for example oxygen) and their compounds with the metal powders during the production of the foamable semifinished product or of the foamable core layer also prevents the unwanted burning off of the Mg fraction.
- a propellant it is provided that the decomposition temperature of the propellant and the melting temperature of the metal powder mixture are as close as possible to each other, i. a few degrees below the decomposition temperature, so that a high-viscosity large amount of melt is available at the decomposition temperature.
- the use of a blowing agent has the advantage that the foaming process is easy to control, in particular via the temperature, and thus runs very cleanly.
- a powder mixture of 1 wt.% TiH 2 , 8 wt.% Si, 4 wt.% Mg and 87 wt.% Al is produced. This is then uniaxially compressed at a temperature of 400 ° C, a pressing pressure of 195 MPa and 300 s pressing time to a tablet-shaped semi-finished product, which is then heated in a cylindrical steel sheet mold until the metal powder mixture is completely melted. During this process, the alloy AlMg4Si8 forms from the individual metal powders.
- the foaming process takes place in a known manner by the decomposition of the blowing agent TiH 2 , whereby gas bubbles are formed in the semifinished product. Once the foam has filled the cylindrical sheet steel mold, it is removed from the oven. The foaming process stops by cooling the mold below the solidus temperature of the melt.
- the cylindrical AlMg4Si8 alloy component has a low density and a homogeneous pore structure as well as a good corrosion resistance and high ductility.
- a metal powder mixture of 50 wt.% Of the aluminum alloy AlMg8, 8 wt.% Si and 41 wt.% Aluminum is produced and then compacted to a core layer.
- This core situation will be discussed in a next step Cover plates of a 6000 series hardenable alloy converted into a solid, metallic composite. This can be done by way of example by means of roll-plating or another known method.
- This composite is then heated until a minimum lower temperature, here 590 ° C, than the solidus temperature of the cover plates, which is at about 600 ° C is reached, and thereby the foaming process starts.
- the aluminum alloy AlMg4Si8 forms in the foam core layer.
- these aluminum foam sandwiches have a high degree of expansion of the foam core layer as well as good mechanical properties and good corrosion resistance.
- FIG. 5 is schematically the foam quality, which results from the expansion and the pore size distribution, shown as a function of the concentration of the alloying elements magnesium and silicon.
- the foam quality shows a maximum. Even slight deviations from the composition of the alloy according to the invention lead to a noticeable loss of foam quality due to a decrease in the expansion and / or coarsening of the pore structure.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Composite Materials (AREA)
- Powder Metallurgy (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
Die Erfindung betrifft eine Aluminiumlegierung für Metallschäume, ein Produkt daraus und ein Verfahren zu seiner Herstellung.The invention relates to an aluminum alloy for metal foams, a product thereof and a method for its production.
Dem Stand der Technik nach allgemein bekannt ist die Herstellung von Metallschäumen auf pulvermetallurgische Weise, indem eine Mischung aus Metallpulver und Treibmittel zunächst verdichtet und dann teilweise oder vollständig aufgeschmolzen und nach erfolgter Porenbildung wieder abgekühlt wird. Im aufgeschmolzenen Zustand bildet das vom Treibmittel freigesetzte Gas die Poren in der Schmelze.The prior art generally discloses the production of metal foams in a powder-metallurgical manner by first compacting a mixture of metal powder and blowing agent and then partially or completely melting it and cooling it again after pore formation has taken place. In the molten state, the gas released by the blowing agent forms the pores in the melt.
Ein derartiges Verfahren ist beispielsweise in
Auf der Homepage des Fraunhofer Instituts Werkzeugmaschinen und Umformtechnik (http://www.iwu.fraunhofer.de/schaumzentrum/produkte.htm) sind weitere Aluminiumlegierungen, wie beispielsweise AlSi10 und auch eine 6000er Aluminiumlegierung, nämlich AlMg1Si0,5, angegeben.The homepage of the Fraunhofer Institute for Machine Tools and Forming Technology ( http://www.iwu.fraunhofer.de/schaumzentrum/produkte.htm ) lists further aluminum alloys, such as AlSi10 and also a 6000 aluminum alloy, namely AlMg1Si0.5.
Die bisher dem Stand der Technik nach bekannten und wissenschaftlich untersuchten 6000er AlMgSi-Legierungen, die in geringen Mengen (bis etwa 2 %) Si und Mg enthalten, lieferten für die Herstellung von Metallschäumen keine befriedigenden Ergebnisse hinsichtlich des Erhalts einer feinen Porenstruktur bei hohem Expansionsvermögen, guten mechanischen Eigenschaften und guter Korrosionsbeständigkeit.The prior art known and scientifically investigated 6000 AlMgSi alloys, which contain Si and Mg in small amounts (up to about 2%), did not give satisfactory results in terms of obtaining a fine metal foam Pore structure with high expansion capacity, good mechanical properties and good corrosion resistance.
Andere derzeit für Metallschäume verwendete technische Aluminiumlegierungen sind die Gusslegierung AlSi7 oder die Legierung AlSi6Cu6 (s. Homepage der Firma alm GmbH am 03.06.08: http://www.alm-gmbh.de/html/produkte.html).Other technical aluminum alloys currently used for metal foams are the cast alloy AlSi7 or the alloy AlSi6Cu6 (see homepage of alm GmbH on 03.06.08: http://www.alm-gmbh.de/html/produkte.html ).
Weitere Anstrengungen wurden unternommen zur Erzielung der gewünschten Eigenschaften von Aluminiumschäumen durch Variation des Si- und/oder Cu-Gehaltes.Further efforts have been made to achieve the desired properties of aluminum foams by varying the Si and / or Cu content.
Zwar haben sich die letztgenannten AlSi-(beispielsweise AlSi6) und AlSiCu-Gusslegierungen (teilweise mit modifiziertem Cu-Gehalt) etabliert, jedoch wurden auch mit diesen Legierungen die erwünschten und oben erwähnten Eigenschaften bisher nicht erreicht. Hier wird vermutet, dass die genannten Gusslegierungen viel zu geringe Mg- und Si-Gehalte haben, um eine ausreichend große Schmelzmenge zu Beginn des Schmelzvorganges zu erzielen. Zudem ist das Entstehen kleiner Schmelzmengen zu Anfang des Prozesses mit dem Risiko der Kanalbildung im Halbzeug und dem damit verbundenen Treibgasverlust zu Beginn des Aufschmelzens verbunden.Although the latter AlSi (for example AlSi6) and AlSiCu casting alloys (partially with modified Cu content) have become established, the desired and above-mentioned properties have not yet been achieved with these alloys. Here it is assumed that the mentioned casting alloys have far too low Mg and Si contents in order to achieve a sufficiently large melt quantity at the beginning of the melting process. In addition, the formation of small amounts of melt at the beginning of the process is associated with the risk of channeling in the semifinished product and the associated loss of propellant gas at the start of the melting process.
Dem Stand der Technik nach allgemein bekannt sind auch Metallschaum-Sandwichs, bei denen zwischen zwei nach außen abschließenden Decklagen ein Metallschaumkern angeordnet ist.Also well known in the art are metal foam sandwiches in which a metal foam core is arranged between two outer cover layers closing off to the outside.
Derartige Sandwich-Strukturen können durch Verkleben der Decklage mit der Schaumkernschicht hergestellt werden, aber auch, indem das unaufgeschäumte Kernmaterial mit den Decklagen durch Druckeinwirkung in einem Verfahrensschritt metallisch verbunden (s. beispielsweise
Für das letztgenannte Verfahren zur Herstellung von Metallschaum-Sandwichs ist die Wahl der Materialien für den Metallschaumkern und für die Decklagen besonders wichtig, da der Aufschäumprozess besondere Temperaturverhältnisse erfordert. In
Allgemein ist festzustellen, dass der Beginn des Schmelztemperaturbereiches der dem Stand der Technik nach bekannten Metallschaumlegierungen deutlich oberhalb der Zersetzungstemperatur des üblicherweise verwendeten Treibmittels TiH2 liegt.In general, it should be noted that the beginning of the melting temperature range of the known prior art metal foam alloys is well above the decomposition temperature of the commonly used blowing agent TiH 2 .
Aufgabe der Erfindung ist es nun, eine Aluminiumlegierung für Metallschäume vom Typ AlMgSi und eine Verwendung dieser Legierung anzugeben, wobei der Metallschaum eine feine Porenstruktur bei hohem Expansionsvermögen, gute mechanische Eigenschaften und gute Korrosionsbeständigkeit aufweisen soll. Die Aufgabe besteht weiterhin darin, ein Verfahren zur Herstellung eines Produktes aus dieser Aluminiumlegierung anzugeben.The object of the invention is now to provide an aluminum alloy for metal foams of the type AlMgSi and a use of this alloy, wherein the metal foam should have a fine pore structure with high expansion capacity, good mechanical properties and good corrosion resistance. The object is further to provide a method for producing a product of this aluminum alloy.
Die Aufgabe wird erfindungsgemäß dadurch gelöst, dass die Aluminiumlegierung vom Typ AlMgSi die Legierung AlMg4(±1)Si8(±1) - Angabe erfolgt in Gew.% - ist.The object is achieved according to the invention in that the aluminum alloy of the AlMgSi type is the alloy AlMg4 (± 1) Si8 (± 1), stated in% by weight.
Es hat sich gezeigt, dass die bisher technologisch irrelevante AlMg4Si8-Legierung innerhalb der durch die Pulvermischung technisch realisierbaren Toleranz von ± 1 % hervorragende Schäumeigenschaften und der entstehende Metallschaum eine im Vergleich zum Stand der Technik deutlich feinere Porenstruktur aufweist.It has been shown that the previously technologically irrelevant AlMg4Si8 alloy within the technically feasible by the powder mixture Tolerance of ± 1% excellent foaming properties and the resulting metal foam has a much finer pore structure compared to the prior art.
Zurückgeführt werden kann dies auf positive Auswirkungen des enthaltenen Mg, wie die Verringerung der Oberflächenspannung der Schmelze und seine starke Oxidationsneigung - da eine schnelle Oxid bildung die Zellwände der entstehenden Poren stabilisiert - und die Erhöhung der Schmelzviskosität, die Drainage verringert wird und ebenfalls zur Stabilität der Porenstruktur im flüssigen Bereich beiträgt.This can be attributed to positive effects of the Mg contained, such as the reduction of the surface tension of the melt and its strong tendency to oxidation - as a rapid oxide stabilizes the cell walls of the resulting pores - and increasing the melt viscosity, the drainage is reduced and also to the stability of the Contributes pore structure in the liquid region.
Die verbesserten Eigenschaften können auch auf das besondere Schmelzverhalten der erfindungsgemäßen Legierung zurückgeführt werden, welches charakterisiert wird durch die Funktion des Flüssigvolumentanteils in Abhängigkeit von der Temperatur der Schmelze. Die Legierung erzeugt während des Aufschäumprozesses bei 560 °C isotherm einen Anteil von etwa 50 % ternär-eutektischer Schmelze und hat eine Liquidustemperatur von ca. 600 °C, wodurch die präzise Einstellung einer für die Schaumexpansion optimalen Zähigkeit der Schmelze ermöglicht wird.The improved properties can also be attributed to the particular melting behavior of the alloy according to the invention, which is characterized by the function of the liquid volume fraction as a function of the temperature of the melt. During the foaming process, the alloy isothermally produces a proportion of about 50% ternary-eutectic melt at 560 ° C. and has a liquidus temperature of about 600 ° C., which enables precise setting of an optimum toughness of the melt for foam expansion.
Gegenüber den oben im Stand der Technik erwähnten Cu-haltigen Legierungen besteht zudem der Vorteil höherer Duktilität und besserer Korrosionsbeständigkeit des fertigen Produkts.Compared to the Cu-containing alloys mentioned above in the prior art, there is also the advantage of higher ductility and better corrosion resistance of the finished product.
Erfindungsgemäß wird die beanspruchte Legierung als geschäumtes Kernmaterial in Aluminiumschaum-Sandwichs verwendet.According to the invention, the claimed alloy is used as a foamed core material in aluminum foam sandwiches.
Bei dem Verfahren zur Herstellung des Metallschaumes aus der beanspruchten Legierung wird zunächst eine Metallpulvermischung für die Legierung AlMg4(±1)Si8(±1) hergestellt und zu einem schäumbaren Halbzeug verdichtet und anschließend dieses Halbzeug mit bekannten Mitteln aufgeschäumt.In the process for producing the metal foam from the claimed alloy, a metal powder mixture for the alloy AlMg4 (± 1) Si8 (± 1) is first prepared and compacted to form a foamable semifinished product, and then this semifinished product is foamed by known means.
Bei dem erfindungsgemäßen Verfahren zur Herstellung des Kernmaterials aus der beanspruchten Legierung wird zunächst eine Metallpulvermischung für die Legierung AlMg4(±1)Si8(±1) erzeugt und zu einer schäumbaren Kernlage verdichtet, danach wird diese Kernlage zwischen zwei Deckbleche einer 6000er Legierung angeordnet und diese Anordnung in einen festen metallischen Verbund überführt, anschließend wird dieser Verbund bis auf eine Temperatur, die geringfügig niedriger ist als die Solidustemperatur der 6000er Legierung, erhitzt und bei Erreichen der gewünschten Dicke des geschäumten Kernmaterials der Aufschäumprozess durch Kühlen unter die Solidustemperatur des Kernmaterials gestoppt.In the method according to the invention for producing the core material from the claimed alloy, a metal powder mixture for the alloy AlMg4 (± 1) Si8 (± 1) is first produced and compacted into a foamable core layer, after which this core layer is placed between two cover plates of a 6000 alloy and these Assembly is transferred to a solid metallic composite, then this composite is heated to a temperature slightly lower than the solidus temperature of the 6000 alloy and, upon reaching the desired thickness of the foamed core material, the foaming process is stopped by cooling below the solidus temperature of the core material.
Die Metallpulvermischungen bedeuten im Zusammenhang mit der Erfindung Mischungen aus Legierungspulvern, d.h. Pulvern aus solchen Materialien, aus denen die vorgeschlagene Legierung besteht, und in solchen Gewichtsanteilen der einzelnen Komponenten, die zu dieser Legierung führen. Dabei ist es unerheblich, ob Pulver aus den drei Legierungsbestandteilen einzeln oder z. B. auch bereits zwei Legierungskomponenten enthaltende Pulver, denen die fehlenden Bestandteile zugemischt werden, verwendet werden.The metal powder mixtures in the context of the invention mean mixtures of alloy powders, i. Powders of such materials that make up the proposed alloy, and in such proportions by weight of the individual components that lead to this alloy. It is irrelevant whether powder of the three alloying components individually or z. For example, powders already containing two alloy components to which the missing constituents are added can also be used.
In Ausführungsformen der Erfindung ist deshalb beispielhaft vorgesehen, dass als Metallpulvermischung für die Legierung AlMg4(±1)Si8(±1) eine Mischung der einzelnen Legierungsbestandteile verwendet wird, insbesondere in der Zusammensetzung 50 Gew.% AlMg8, 8 Gew.% Si und 41 Gew.% Al bzw. in Elementarzusammensetzung 88 Gew% Al, 4 Gew% Mg und 8 Gew% Si. Eine andere Ausführungsform sieht eine Metallpulvermischung aus 8 Gew% des zweikomponentigen Legierungspulvers AlMg50, 8 Gew% Si und 84 Gew% Al vor.In embodiments of the invention, it is therefore provided by way of example that a mixture of the individual alloy constituents is used as the metal powder mixture for the alloy AlMg4 (± 1) Si8 (± 1), in particular in the
Die Verwendung einer Legierungspulvermischung hat den Vorteil, dass der unerwünschte Abbrand des Mg-Anteils im Herstellungs- und im Schäumprozess der erfindungsgemäßen Legierung verhindert wird.The use of an alloy powder mixture has the advantage that the unwanted burnup of the Mg content in the production and in the foaming process of the alloy according to the invention is prevented.
Auch das optional vorgesehene Ausschließen bzw. Entfernen von Fremdgasen (z.B. Sauerstoff) und deren Verbindungen mit den Metallpulvern bei der Herstellung des schäumbaren Halbzeuges oder der schäumbaren Kernlage verhindert den unerwünschten Abbrand des Mg-Anteils.The optionally provided exclusion or removal of foreign gases (for example oxygen) and their compounds with the metal powders during the production of the foamable semifinished product or of the foamable core layer also prevents the unwanted burning off of the Mg fraction.
Es wurde festgestellt, dass der Aufschäumprozess für die erfindungsgemäße Legierung sowohl mit als auch ohne Treibmittel erfolgreich verläuft.It has been found that the foaming process for the alloy according to the invention is successful both with and without blowing agent.
Wird - wie in einer weiteren Ausführungsform - ein Treibmittel verwendet, so ist vorgesehen, die Zersetzungstemperatur des Treibmittels und die Schmelztemperatur der Metallpulvermischung möglichst nahe zueinander, d.h. wenige Grade unterhalb der Zersetzungstemperatur, einzustellen, damit eine hochviskose große Schmelzmenge bei der Zersetzungstemperatur zur Verfügung steht. Der Verwendung eines Treibmittels hat den Vorteil, dass der Schäumprozess insbesondere über die Temperatur gut steuerbar ist und damit sehr sauber abläuft.If, as in a further embodiment, a propellant is used, it is provided that the decomposition temperature of the propellant and the melting temperature of the metal powder mixture are as close as possible to each other, i. a few degrees below the decomposition temperature, so that a high-viscosity large amount of melt is available at the decomposition temperature. The use of a blowing agent has the advantage that the foaming process is easy to control, in particular via the temperature, and thus runs very cleanly.
Die Erfindung wird in folgenden Ausführungsbeispielen veranschaulicht.The invention is illustrated in the following exemplary embodiments.
Die Figuren zeigen:
- Fig. 1 bis 3:
- die Porengrößenverteilung der bekannten Legierungen AlMg6Si6 und AlSi6 im Vergleich zur erfindungsgemäßen Legierung AlMg4Si8 entsprechend;
- Fig. 4 :
- die gemessene Expansion bei verschiedenen Heizleistungen für die erfindungsgemäße Legierung und die bekannten Legierungen AlMg6Si6 und AlSi6;
- Fig. 5:
- Schaumqualität der Legierung AlMg4Si8 in Abhängigkeit der Konzentration der Legierungselemente Magnesium und Silizium.
- 1 to 3:
- the pore size distribution of the known alloys AlMg6Si6 and AlSi6 compared to the alloy according to the invention AlMg4Si8 accordingly;
- 4:
- the measured expansion at different heating powers for the alloy according to the invention and the known alloys AlMg6Si6 and AlSi6;
- Fig. 5:
- Foam quality of the alloy AlMg4Si8 as a function of the concentration of the alloying elements magnesium and silicon.
Für die Herstellung eines zylindrischen Bauteils aus Aluminiumschaum der erfindungsgemäßen Legierung wird zunächst eine Pulvermischung aus 1 Gew.% TiH2, 8 Gew.% Si, 4 Gew.% Mg und 87 Gew.% Al hergestellt. Diese wird dann bei einer Temperatur von 400 °C, einem Pressdruck von 195 MPa und 300 s Presszeit uniaxial zu einem tablettenförmigen Halbzeug verdichtet, was anschließend in einer zylindrischen Stahlblechform so lange erhitzt wird, bis die Metallpulvermischung vollständig aufgeschmolzen ist. Während dieses Prozesses bildet sich aus den einzelnen Metallpulvern die Legierung AlMg4Si8. Der Aufschäumprozess erfolgt in bekannter Weise durch die Zersetzung des Treibmittels TiH2, wodurch Gasblasen im Halbzeug gebildet werden. Hat der Schaum die zylindrische Stahlblechform ausgefüllt, wird sie dem Ofen entnommen. Der Schäumprozess stoppt durch das Abkühlen der Form unter die Solidustemperatur der Schmelze.For the production of a cylindrical component of aluminum foam of the alloy according to the invention, first a powder mixture of 1 wt.% TiH 2 , 8 wt.% Si, 4 wt.% Mg and 87 wt.% Al is produced. This is then uniaxially compressed at a temperature of 400 ° C, a pressing pressure of 195 MPa and 300 s pressing time to a tablet-shaped semi-finished product, which is then heated in a cylindrical steel sheet mold until the metal powder mixture is completely melted. During this process, the alloy AlMg4Si8 forms from the individual metal powders. The foaming process takes place in a known manner by the decomposition of the blowing agent TiH 2 , whereby gas bubbles are formed in the semifinished product. Once the foam has filled the cylindrical sheet steel mold, it is removed from the oven. The foaming process stops by cooling the mold below the solidus temperature of the melt.
Das zylindrische Bauteil aus der Legierung AlMg4Si8 weist neben einer geringen Dichte und einer homogenen Porenstruktur ebenso eine gute Korrosionsbeständigkeit und hohe Duktilität auf.The cylindrical AlMg4Si8 alloy component has a low density and a homogeneous pore structure as well as a good corrosion resistance and high ductility.
Für die Herstellung eines Aluminiumschaum-Sandwichs wird zunächst eine Metallpulvermischung aus 50 Gew.% der Aluminiumlegierung AlMg8, 8 Gew.% Si und 41 Gew.% Aluminium hergestellt und anschließend zu einer Kernlage verdichtet. Diese Kernlage wird in einem nächsten Schritt mit Deckblechen einer aushärtbaren Legierung der Serie 6000 in einen festen, metallischen Verbund überführt. Dies kann beilspielsweise mittels Walzplattierens oder eines anderen bekannten Verfahrens erfolgen. Dieser Verbund wird nun so lange erhitzt, bis eine minimal niedrigere Temperatur, hier 590 °C, als die Solidustemperatur der Deckbleche, die bei ca. 600 °C liegt, erreicht ist, und dadurch der Aufschäumprozess startet. Während des Aufschäumens bildet sich die Aluminiumlegierung AlMg4Si8 in der Schaumkernlage.For the production of an aluminum foam sandwich, first a metal powder mixture of 50 wt.% Of the aluminum alloy AlMg8, 8 wt.% Si and 41 wt.% Aluminum is produced and then compacted to a core layer. This core situation will be discussed in a next step Cover plates of a 6000 series hardenable alloy converted into a solid, metallic composite. This can be done by way of example by means of roll-plating or another known method. This composite is then heated until a minimum lower temperature, here 590 ° C, than the solidus temperature of the cover plates, which is at about 600 ° C is reached, and thereby the foaming process starts. During foaming, the aluminum alloy AlMg4Si8 forms in the foam core layer.
Bei Erreichen der gewünschten Schaumschichtdicke wird der Aufschäumprozess durch Kühlen unter die Solidustemperatur der Schaumkernlegierung, beispielsweise bis auf eine Temperatur zwischen 555 °C und 560 °C gestoppt. Nun kann bei Bedarf direkt im Anschluss oder zu einem späteren Zeitpunkt eine Wärmebehandlung des erzeugten Aluminiumschaum-Sandwichs erfolgen.Upon reaching the desired foam layer thickness of the foaming process is stopped by cooling below the solidus temperature of the foam core alloy, for example, to a temperature between 555 ° C and 560 ° C. Now, if required, a heat treatment of the produced aluminum foam sandwich can take place directly afterwards or at a later time.
Auch diese Aluminiumschaum-Sandwichs weisen einen hohen Expansionsgrad der Schaumkernlage sowie gute mechanische Eigenschaften und eine gute Korrosionsbeständigkeit auf.Also, these aluminum foam sandwiches have a high degree of expansion of the foam core layer as well as good mechanical properties and good corrosion resistance.
Die gute Qualität des aus der erfindungsgemäßen Legierung erzeugten Metallschaumes soll nun anhand der beiden Parameter Porengrößenverteilung und erreichte Expansionshöhe im Vergleich zu den bekannten Legierungen AlSi6 und AlMg6Si6 gezeigt werden.The good quality of the metal foam produced from the alloy according to the invention is now to be shown on the basis of the two parameters pore size distribution and achieved expansion height in comparison to the known alloys AlSi6 and AlMg6Si6.
In den
In den in
Die in
Wie bereits oben erwähnt ist festgestellt worden, dass es für eine gute Qualität - nämlich eine hohe Expansion und eine feinporige Struktur - des Metallschaumes von Vorteil ist, wenn eine zum Einschließen des frei gesetzten Gases ausreichende Schmelzmenge bei konstanter Temperatur erzeugt wird, da die Treibmittelzersetzung ohne gleichzeitigen Temperaturanstieg nur sehr langsam verläuft und somit Gasverluste durch beim Anschmelzen gebildete Kanäle vermieden werden. Diese darf allerdings nicht zu groß sein, da die verbliebenen ungeschmolzenen Bestandteile der Schmelze durch die hohe Viskosität im 2-Phasengebiet der Legierung unerwünschte Effekte (Drainage, Schaumkollaps) vermeiden. In der Praxis hat sich gezeigt, dass bei binären AlSi-Legierungen die Menge der isotherm entstehenden Schmelze ca. 50 % beträgt.As already mentioned above, it has been found that it is advantageous for a good quality - namely, a high expansion and a fine-pored structure - of the metal foam, if a sufficient amount of melt for the inclusion of the released gas is generated at a constant temperature, since the propellant decomposition without simultaneous increase in temperature is very slow and thus gas losses are avoided by channels formed during melting. However, this must not be too large, since the remaining unmelted components of the melt due to the high viscosity in the 2-phase region of the alloy avoid unwanted effects (drainage, foam collapse). In practice, it has been shown that in binary AlSi alloys, the amount of isothermally produced melt is about 50%.
Bei der erfindungsgemäßen Legierung AlMg4Si8 ist es nun möglich, diesen Anteil durch das ternäre Eutektikum Schmelze ↔ Al + Mg2Si + Si zu erzeugen, was sowohl zu einer feinen Porenstruktur als auch zu einer hohen Expansion - und damit zu einer besseren Schaumqualität im Vergleich zu den dem Stand der Technik nach bekannten Legierungen - führt.In the case of the AlMg4Si8 alloy according to the invention, it is now possible to produce this fraction through the ternary eutectic melt ↔ Al +
In
Claims (11)
dadurch gekennzeichnet, dass
diese Aluminiumlegierung AlMg4(±1)Si8(±1), angegeben in Gew.%, ist.Aluminum alloy for metal foams,
characterized in that
this aluminum alloy is AlMg4 (± 1) Si8 (± 1), expressed in weight%.
als geschäumtes Kernmaterial für die Herstellung von Aluminiumschaum-Sandwichs.Use of the alloy according to claim 1
as a foamed core material for the production of aluminum foam sandwiches.
dadurch gekennzeichnet,
dass als Metallpulvermischung eine Mischung der Legierungsbestandteile verwendet wird.Method according to claim 3 or 4,
characterized,
in that a mixture of the alloy constituents is used as metal powder mixture.
dadurch gekennzeichnet,
dass die Metallpulvermischung die folgenden Legierungsbestandteile aufweist: 50 Gew.% AlMg8, 8 Gew.% Si und 41 Gew.% Al.Method according to claim 5,
characterized,
that the metal powder mixture having the following alloy constituents:... 50% by weight AlMg8, 8 wt% Si and 41 wt% Al.
dadurch gekennzeichnet,
dass die Metallpulvermischung die Legierungsbestandteile in der Elementarzusammensetzung 88 Gew% Al, 4 Gew% Mg und 8 Gew% Si aufweist.Method according to claim 5,
characterized,
in that the metal powder mixture has the alloy constituents in the elemental composition of 88% by weight Al, 4% by weight Mg and 8% by weight Si.
dadurch gekennzeichnet,
dass die Metallpulvermischung aus 8 Gew% des zweikomponentigen Legierungspulvers AlMg50, 8 Gew% Si und 84 Gew% Al gebildet wird.Method according to claim 5,
characterized,
that the metal powder mixture of 8% by weight of the two-component alloy powder AlMg50, 8 wt% of Si and formed 84 wt% Al.
dadurch gekennzeichnet,
dass Fremdgase und deren Verbindungen mit den Metallpulvern bei der Herstellung des schäumbaren Halbzeuges oder der schäumbaren Kernlage ausgeschlossen oder entfernt werden.Method according to claim 3,
characterized,
that foreign gases and their compounds with the metal powders are excluded or removed in the production of the foamable semifinished product or the foamable core layer.
dadurch gekennzeichnet,
dass für den Aufschäumprozess ein Treibmittel verwendet wird.Method according to claim 3 or 4,
characterized,
that a foaming agent is used for the foaming process.
dadurch gekennzeichnet,
dass die Schmelztemperatur der Metallpulvermischung wenige Grad unterhalb der Zersetzungstemperatur des Treibmittels eingestellt wird.Method according to claim 10,
characterized,
that the melting temperature of the metal powder mixture is set a few degrees below the decomposition temperature of the blowing agent.
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AT (1) | ATE524569T1 (en) |
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Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0884123A2 (en) * | 1997-06-10 | 1998-12-16 | Th. Goldschmidt AG | Foamble metal body |
EP0997215A2 (en) | 1998-10-28 | 2000-05-03 | Schunk Sintermetalltechnik Gmbh | Process for manufacturing metallic composite material with foamed core |
DE10115230A1 (en) | 2000-03-28 | 2001-11-08 | Fraunhofer Ges Forschung | Production of porous metal body comprises compacting mixture of powdered metallic material containing metal (alloy) and gas-splitting propellant-containing powder |
DE10136370A1 (en) | 2001-07-26 | 2003-03-06 | Schwingel Dirk | Composite material and component made from it, consisting of a foamed metal core and solid cover plates, as well as manufacturing methods |
Family Cites Families (2)
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JP2721912B2 (en) * | 1989-06-09 | 1998-03-04 | 東洋アルミニウム株式会社 | Powder brazing filler metal for aluminum |
DE19852277C2 (en) * | 1998-11-13 | 2000-12-14 | Schunk Sintermetalltechnik Gmb | Process for the production of a metallic composite material and semi-finished product for such |
-
2008
- 2008-06-11 DE DE102008027798A patent/DE102008027798A1/en not_active Ceased
-
2009
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Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0884123A2 (en) * | 1997-06-10 | 1998-12-16 | Th. Goldschmidt AG | Foamble metal body |
EP0997215A2 (en) | 1998-10-28 | 2000-05-03 | Schunk Sintermetalltechnik Gmbh | Process for manufacturing metallic composite material with foamed core |
DE10115230A1 (en) | 2000-03-28 | 2001-11-08 | Fraunhofer Ges Forschung | Production of porous metal body comprises compacting mixture of powdered metallic material containing metal (alloy) and gas-splitting propellant-containing powder |
DE10136370A1 (en) | 2001-07-26 | 2003-03-06 | Schwingel Dirk | Composite material and component made from it, consisting of a foamed metal core and solid cover plates, as well as manufacturing methods |
Non-Patent Citations (2)
Title |
---|
SEVOSTIANOV I ET AL: "Elastic and electric properties of closed-cell aluminum foams", MATERIALS SCIENCE AND ENGINEERING A: STRUCTURAL MATERIALS:PROPERTIES, MICROSTRUCTURE & PROCESSING, LAUSANNE, CH, vol. 420, no. 1-2, 25 March 2006 (2006-03-25), pages 87 - 99, XP025098269, ISSN: 0921-5093, [retrieved on 20060325] * |
WANG Z ET AL: "Studies on the dynamic compressive properties of open-cell aluminum alloy foams", SCRIPTA MATERIALIA, ELSEVIER, AMSTERDAM, NL, vol. 54, no. 1, 1 January 2006 (2006-01-01), pages 83 - 87, XP025028346, ISSN: 1359-6462, [retrieved on 20060101] * |
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ES2378840T3 (en) | 2012-04-18 |
PL2143809T3 (en) | 2012-07-31 |
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