EP2552630B1 - Verfahren zur herstellung von formkörpern aus aluminiumlegierungen - Google Patents
Verfahren zur herstellung von formkörpern aus aluminiumlegierungen Download PDFInfo
- Publication number
- EP2552630B1 EP2552630B1 EP11720714.2A EP11720714A EP2552630B1 EP 2552630 B1 EP2552630 B1 EP 2552630B1 EP 11720714 A EP11720714 A EP 11720714A EP 2552630 B1 EP2552630 B1 EP 2552630B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- binder
- debinding
- aluminum
- thermal debinding
- carried out
- 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.)
- Not-in-force
Links
- 229910000838 Al alloy Inorganic materials 0.000 title claims description 12
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 239000011230 binding agent Substances 0.000 claims description 58
- 239000000843 powder Substances 0.000 claims description 41
- 238000005245 sintering Methods 0.000 claims description 37
- 238000000034 method Methods 0.000 claims description 36
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 33
- 229910052751 metal Inorganic materials 0.000 claims description 31
- 239000002184 metal Substances 0.000 claims description 31
- 229910052782 aluminium Inorganic materials 0.000 claims description 25
- 229910045601 alloy Inorganic materials 0.000 claims description 21
- 239000000956 alloy Substances 0.000 claims description 21
- 230000003197 catalytic effect Effects 0.000 claims description 21
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 claims description 17
- 239000001301 oxygen Substances 0.000 claims description 17
- 229910052760 oxygen Inorganic materials 0.000 claims description 17
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 16
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 15
- 238000001746 injection moulding Methods 0.000 claims description 15
- 239000011777 magnesium Substances 0.000 claims description 13
- 229910052749 magnesium Inorganic materials 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 11
- 150000002739 metals Chemical class 0.000 claims description 10
- 229920006324 polyoxymethylene Polymers 0.000 claims description 10
- 239000002904 solvent Substances 0.000 claims description 8
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 claims description 6
- 229930182556 Polyacetal Natural products 0.000 claims description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 239000010949 copper Substances 0.000 claims description 5
- 239000007791 liquid phase Substances 0.000 claims description 5
- 235000006408 oxalic acid Nutrition 0.000 claims description 5
- 229910052710 silicon Inorganic materials 0.000 claims description 5
- 239000010703 silicon Substances 0.000 claims description 5
- 229930040373 Paraformaldehyde Natural products 0.000 claims description 4
- 239000002253 acid Substances 0.000 claims description 4
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 claims description 4
- -1 polyoxymethylene Polymers 0.000 claims description 3
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 claims description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 claims description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 2
- 235000011054 acetic acid Nutrition 0.000 claims description 2
- 235000019253 formic acid Nutrition 0.000 claims description 2
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- 229910017604 nitric acid Inorganic materials 0.000 claims description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims 1
- 229910052748 manganese Inorganic materials 0.000 claims 1
- 239000011572 manganese Substances 0.000 claims 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 16
- 239000000203 mixture Substances 0.000 description 14
- 230000004580 weight loss Effects 0.000 description 9
- 229910052757 nitrogen Inorganic materials 0.000 description 8
- 239000000463 material Substances 0.000 description 7
- 238000000465 moulding Methods 0.000 description 7
- 239000004033 plastic Substances 0.000 description 7
- 229920003023 plastic Polymers 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 6
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 6
- 239000004435 Oxo alcohol Substances 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 6
- 238000002844 melting Methods 0.000 description 6
- 230000008018 melting Effects 0.000 description 6
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 6
- 239000004926 polymethyl methacrylate Substances 0.000 description 6
- 239000004094 surface-active agent Substances 0.000 description 6
- JSPLKZUTYZBBKA-UHFFFAOYSA-N trioxidane Chemical compound OOO JSPLKZUTYZBBKA-UHFFFAOYSA-N 0.000 description 6
- 238000005275 alloying Methods 0.000 description 5
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 3
- 229910052786 argon Inorganic materials 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 241001522319 Chloris chloris Species 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 229910002065 alloy metal Inorganic materials 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 235000021355 Stearic acid Nutrition 0.000 description 1
- 229910004349 Ti-Al Inorganic materials 0.000 description 1
- 229910004692 Ti—Al Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 238000004378 air conditioning Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000004870 electrical engineering Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000011089 mechanical engineering Methods 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002516 radical scavenger Substances 0.000 description 1
- 238000007086 side reaction Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 239000011877 solvent mixture Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910000634 wood's metal Inorganic materials 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Images
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
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
-
- 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
- B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
-
- 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
- B22F3/12—Both compacting and sintering
-
- 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
- B22F3/1017—Multiple heating or additional steps
- B22F3/1021—Removal of binder or filler
-
- 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
-
- 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
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
- B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
-
- 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
- B22F3/24—After-treatment of workpieces or articles
-
- 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
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
Definitions
- a feedstock is prepared in the form of a sprayable granulate of metal powder and a plastic component comprising at least two intensively mixed polymer components.
- This feedstock is then sprayed into molded parts in plastic injection molding machines.
- This so-called “green body” or “green body” usually contains about 40% by volume of plastic binder, which is removed in the subsequent step, the so-called debindering, for the most part. There remains only a residual component of the binder, the so-called. "Backbone”, which ensures the residual strength of the unbent body.
- Debinding can be done in a variety of ways, e.g.
- EP 329,475 A2 describes the processing of various metal powders, ceramics or alloys into moldings using a special organic binder mixture.
- Aluminum is mentioned as one of many possible starting materials, which should be sinterable with the binder system there.
- Suitable atmospheres for debinding include oxidizing, reducing and inert atmospheres - under low, normal or overpressure - and thus all conceivable options.
- Carbides were also found in the sintered bodies, the presence of which is attributed to contamination with carbon from the furnace, but which is much more likely to result from incomplete debindering and hence the logical presence of organic carbon in the brown compact. Consequently, it is stated that debinding should be done in a vacuum and not in air.
- a particular difficulty in the processing of aluminum in the manner described above is also the relatively low melting point of aluminum (660 ° C) produced by the addition of alloying elements, e.g. Tin, still lowered.
- alloying elements e.g. Tin
- the resulting problem is that the debinding of the plastic component must be completed at very low temperatures, which often makes the available process window too small to ensure complete removal.
- undesirable reactions of residual organic constituents with the metallic components can occur, hindering sintering and thus impairing the mechanical properties that can be achieved.
- the object of the invention was, in this context, the development of a metal powder injection molding process, by the moldings of aluminum materials with good mechanical properties can be produced in a simpler and reproducible manner.
- the aluminum alloy contains, besides aluminum, one or more other metals which are not specifically limited.
- the alloying partners are selected from the group consisting of magnesium, copper, silicon and manganese, and are more preferably contained in a respective proportion of 0.5 to 25% by weight to obtain molded articles having desirable properties.
- Significantly lower melting metals, such as bismuth, tin, lead, indium, or even zinc, or alloys such as Wood's metal, sometimes called sintering aids for lowering serve the temperature of the onset of melting, are not required according to the present invention, but can still be added as alloying partners, if desired, to obtain sintered bodies of the corresponding alloys.
- the other metals are used as alloys with aluminum, ie as master alloy or so-called master alloy powder.
- binders which are known to be removable at low temperatures, more preferably polyacetal-based binders, for example polyoxymethylene (POM) binders, for example those described by BASF in US Pat EP 413,231 .
- POM polyoxymethylene
- WO 94/25205 and especially EP 446,708 disclosed and sold under the brand name Catamold ® In order to promote rapid and complete removability at low temperatures and in the presence of oxygen, a high polyacetal content is desirable in the binder, and therefore, the binder is preferably 50 to 95%, more preferably 80 to 90%, of polyacetal.
- binder systems can be used which are based on wax polymer-based and in which the main component wax by previous Wegsentbind réelle, ie prior to the inventive implementation of the thermal debinding in the presence of oxygen, is removed.
- Debinding in step c) of the process of the invention may involve a single step of thermal debinding in the presence of oxygen, in which the entire binder is removed.
- one or more preceding debinding steps may be performed to remove the bulk of the binder, followed by the thermal debinding step of the present invention to remove the residual binder in the presence of oxygen.
- a previous debinding step may also be a thermal debindering - in the absence or also in the presence of oxygen. That is, as debindering can also be a multi-stage thermal debindering at different process parameters, such as different temperature or atmosphere, eg without and with oxygen or with air and pure oxygen, etc.
- the bulk of the binder is already removed from the composition, so that in the subsequent thermal debinding preferably only the "backbone" component needs to be removed.
- the catalytic debinding is carried out preferably in the presence of at least one acid selected from nitric acid, oxalic acid, formic acid and acetic acid, since these acids accelerate the complete removal of the preferred polyacetal binder by acidolysis, without leading to undesirable side reactions with the alloying partners.
- the bulk of the binder is obtained by extraction with a suitable solvent or solvent mixture, e.g. Acetone, n-heptane, water etc., removed.
- a catalytic debindering with sublimed oxalic acid is particularly preferred according to the present invention.
- the thermal debinding to remove the residual binder in step c) is carried out at a relatively low temperature in order to suppress oxidation reactions, especially of the aluminum in the powder mixture.
- a relatively low temperature herein is meant a temperature well below the melting point of aluminum, preferably below 500 ° C, more preferably between 100 and 420 ° C.
- an empirically optimized temperature profile for the respective powder mixture is set, which preferably provides a heating rate of not more than 5 K / min, more preferably not more than 1 to 2 K / min.
- the sintering step d) of the process of the present invention is not specifically limited except for the requirement that the binder must be completely removed beforehand. Preferably, however, is sintered to form a liquid phase, as will be explained in more detail below.
- Embodiments according to the invention are therefore preferred in which the completely debinded browning material is sintered in step d) to form a liquid phase.
- This liquid phase which in the view of the inventors - without wishing to be bound to a particular theory - to a part intermediary, but predominantly stationary, ie in thermodynamic equilibrium with the solid Al phase, is present over microcracks, pores or the like "Openings" in the oxide skins of the metal powder particles and infiltration of the oxide skins forth the required contact between the metals in the powder mixture ago and thus supports the formation of a high-density sintered body from the completely unbonded B Hurnling.
- the sintering in step d) is carried out at a temperature between the solidus and the liquidus temperature of the respective aluminum alloy, so that at any time during the sintering process only a controllable by the choice of a corresponding temperature profile proportion of the alloy metals in liquid Phase exists, which effectively prevents loss of dimensional and dimensional stability.
- the composition of the particular atmosphere in the individual steps of the process according to the invention is not particularly limited except for the presence of the oxygen in the thermal debinding in step c), and the person skilled in the art can select in each individual step the most suitable atmosphere for the respective powder mixture , whereby also vacuum is possible.
- the sintering step d) is preferably carried out in an extremely dry nitrogen-containing atmosphere, i. in pure nitrogen, under normal pressure or reduced pressure ("partial pressure sintering"), or in a mixture of nitrogen and pure inert gas (helium, argon), preferably with a dew point ⁇ -40 ° C, since the presence of nitrogen with the wettability of the powder the resulting molten metal significantly supported.
- sintering may be followed by a suitable after-treatment, by means of which the finished molded parts are obtained in the desired shape.
- a suitable after-treatment for example, the known method of hot isostatic pressing (HIP) can be used to bring the moldings to the desired final density.
- HIP hot isostatic pressing
- residual pores remaining after sintering are pressed by the simultaneous action of external gas pressure and temperature, and the pore walls are welded together.
- feedstocks prepared in the examples below were homogenized in a heated kneader at 190 ° C. From these feedstocks, tensile test bars or hollow cylinders were molded by means of injection molding in accordance with ISO 2740, the method according to the invention being used as follows. To produce the green parts, a hydraulic injection molding machine (Battenfeld HM 600/130) with PIM equipment was used.
- the feedstock was first filled into a funnel of the injection molding machine.
- the powder injection molding for the production of the green parts was carried out in the following steps:
- the prepared feed material was plasticized and pre-dosed by means of a heated injection cylinder in which a screw rotates according to preset setting parameters (such as, for example, rotational speed, metering volume, dynamic pressure, etc.).
- preset setting parameters such as, for example, rotational speed, metering volume, dynamic pressure, etc.
- the pre-dosed quantity was injected into a suitably tempered tool.
- the plasticizing temperature in the injection cylinder was between 120 and 220 ° C, while in the tool between 25 and 140 ° C prevailed.
- the injection mold was opened and the green part ejected from the tool and removed with a handling.
- Example 1 Tension rods: Solution debonding / thermal debinding
- a commercially available metal powder mixture (Alumix ® 231 of Ecka) consisting of aluminum, with 14 wt .-% of silicon, 2.5 wt .-% copper and 0.6 wt .-% magnesium, was with a group consisting of wax / thermoplastic Solvent binder carefully mixed into a feedstock.
- Feedstock component Proportion (% by weight)
- Solvent binder wax content 14.8
- Solvent binder thermoplastic content 8.2 stearic acid 2.2 100.0 *
- This feedstock was first debinded by solvent extraction in a 60 L oven with acetone at a temperature of 45 ° C over 12 h.
- the Bhoffnling thus obtained contained a residual binder content of about 14.5 wt .-%, which then by thermal debinding according to the invention by means of a temperature profile of 150 ° C to 320 ° C for 1 h and then from 320 to 420 ° C for 1.5 h was removed at a heating rate of 3 K / min under a pure oxygen-containing atmosphere.
- the thus completely unbonded B syndromenling was then sintered at 560 ° C within 1 h in pure nitrogen (dew point: -50 ° C).
- Example 2 Tension rods: thermal debindering in one step
- Feedstock component Proportion (% by weight) aluminum powder 67.1 Master Alloy Powder * 4.3 POM Binder 25.8
- PMMA polymethylmethacrylate
- the sintering was carried out at a furnace setting temperature of 665 ° C, which corresponds to a temperature within the furnace of about 630 ° C, during 1 h in pure nitrogen.
- a first thermal debinding was carried out in a 50 l oven in 500 l / h of air at 180 ° C for 14 h. Weight loss: 27.0%.
- Example 3 a thermal debindering to 420 ° C under pure oxygen within 1 h, after which it was again sintered at a Ofeneinstelltemperatur of 665 ° C for 1 h under nitrogen.
- Example 4 a catalytic debinding was carried out analogously to Example 4, but using 80 g of anhydrous oxalic acid on a Sublimierschale instead of HNO 3 at 140 ° C for 24 h. Weight loss: 23.0%. Due to the use of oxalic acid, no outgrowths appeared on the surface. Subsequently, thermal debinding and sintering were also carried out analogously to Example 4.
- Feedstock component Proportion (% by weight) Alumix 231 powder * 70.8 POM Binder * 25.6 surfactant ** 3.6 100.0 * Commercially available metal powder mixture of aluminum with 14% by weight of silicon, 2.5% by weight of copper and 0.6% by weight of magnesium (from Ecka) ** Ethoxylated C 13 -C 15 oxo alcohol with 7 EO units
- Example 5 a catalytic debinding was carried out analogously to Example 5. Weight loss: 25.2%. Subsequently, thermal debinding and sintering were carried out analogously to Example 4, but at a Ofeneinstelltemperatur of 560 ° C.
- Feedstock component Proportion (% by weight) aluminum powder 68.0 Master Alloy Powder * 4.3 POM Binder 24.0 surfactant ** 3.7 100.0 * Master alloy of aluminum and magnesium in the ratio 50:50 ** Ethoxylated C 13 -C 15 oxo alcohol with 7 EO units
- Example 5 a catalytic Entbindtation analogous to Example 5. Weight loss: 23.2%. Subsequently, thermal debinding and sintering were carried out analogously to Example 4.
- Example 8 Hollow Cylinder: Catalytic / Thermal Debinding
- Feedstock component Proportion (% by weight) aluminum powder 68.0 Master Alloy Powder * 4.3 POM Binder 24.0 surfactant ** 3.7 100.0 * Master alloy of aluminum and magnesium in the ratio 50:50 ** Ethoxylated C 13 -C 15 oxo alcohol with 7 EO units
- Example 5 a catalytic debinding was carried out analogously to Example 5. Weight loss: 23.7%. Subsequently, thermal debinding and sintering were carried out analogously to Example 4.
- Example 5 a catalytic debinding analogous to Example 5. Weight loss: 25.7%. Subsequently, thermal debinding and sintering were carried out analogously to Example 4.
- Example 10 Hollow Cylinder: Catalytic / Thermal Debinding
- Feedstock component Proportion (% by weight) aluminum powder 67.1 Master Alloy Powder * 4.3 POM Binder 25.8
- PMMA polymethylmethacrylate
- Example 5 a catalytic debinding analogous to Example 5. Weight loss: 25.6%. Subsequently, thermal debinding and sintering were carried out analogously to Example 4.
- sintered bodies of aluminum alloys can be provided by means of injection molding, which are suitable for practical use in many fields, e.g. in the transport sector, construction, mechanical engineering, packaging, iron and steel, electrical engineering, household appliances, etc., for example for heat dissipation in electronic devices ("heat sinks") or as components of air conditioning systems.
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PCT/AT2011/000157 WO2011120066A1 (de) | 2010-04-01 | 2011-03-31 | Verfahren zur herstellung von formkörpern aus aluminiumlegierungen |
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JP5709856B2 (ja) | 2009-06-25 | 2015-04-30 | ビーエーエスエフ ソシエタス・ヨーロピアBasf Se | 熱可塑性成型組成物を用いて射出成型、押出成型またはプレスで製造された金属製及び/又はセラミック製成型物からバインダーを連続的に熱的に除去する方法 |
CN104057089A (zh) * | 2013-03-20 | 2014-09-24 | 江苏天一超细金属粉末有限公司 | 制造金属、陶瓷制品的金属、陶瓷粉末与聚合物混融物及聚合物从成型品中酸催化脱除方法 |
CN104057090A (zh) * | 2013-03-20 | 2014-09-24 | 江苏天一超细金属粉末有限公司 | 打印金属、陶瓷制品的金属、陶瓷粉末与聚合物混融材料及聚合物在成型品中的脱除方法 |
GB2513869B (en) * | 2013-05-07 | 2015-12-30 | Charles Grant Purnell | Aluminium alloy products, and methods of making such alloy products |
CN104227002A (zh) * | 2013-06-19 | 2014-12-24 | 东莞市事通达机电科技有限公司 | 一种铝粉冶金注射成型工艺 |
CN103769587A (zh) * | 2013-11-28 | 2014-05-07 | 王利民 | 一种金属3d打印法产品生产方法及设备 |
TWI669330B (zh) * | 2018-05-23 | 2019-08-21 | 晟銘電子科技股份有限公司 | 金屬射出成型射料組合物、成型體及其製備方法 |
CN108889950A (zh) * | 2018-06-21 | 2018-11-27 | 深圳市富优驰科技有限公司 | 一种中空散热器的制备方法及中空散热器 |
US11219960B2 (en) | 2019-05-29 | 2022-01-11 | The Boeing Company | Flash-removal tool |
US11229951B2 (en) | 2019-05-29 | 2022-01-25 | The Boeing Company | Monolithic precursor test coupons for testing material properties of metal-injection-molded components and methods and apparatuses for making such coupons |
US10724932B1 (en) * | 2019-05-29 | 2020-07-28 | The Boeing Company | Monolithic precursor test coupons for testing material properties of metal-injection-molded components |
CN113878116A (zh) * | 2021-10-11 | 2022-01-04 | 深圳艾利佳材料科技有限公司 | 一种基于仿形治具的薄壁长条零部件的烧结方法 |
CN114131021B (zh) * | 2021-12-01 | 2025-04-08 | 湖南英捷高科技有限责任公司 | 一种Al-Si-Mg系铝合金的金属注射成形方法 |
US20250135532A1 (en) | 2022-02-18 | 2025-05-01 | Basf Se | A process for the treatment of at least one three-dimensional green body |
CN118832158A (zh) * | 2024-09-24 | 2024-10-25 | 成都增谊科技有限公司 | 一种3d打印回收不锈钢粉末的热解酸洗复合方法 |
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EP0329475B1 (en) * | 1988-02-18 | 1994-01-26 | Sanyo Chemical Industries Ltd. | Mouldable composition |
JP3128130B2 (ja) | 1989-08-16 | 2001-01-29 | ビーエーエスエフ アクチェンゲゼルシャフト | 無機焼結成形体の製造方法 |
EP0436952B1 (en) * | 1989-12-29 | 1997-04-02 | Showa Denko Kabushiki Kaisha | Aluminium-alloy powder, sintered aluminium-alloy, and method for producing the sintered aluminum-alloy |
DE4007345A1 (de) | 1990-03-08 | 1991-09-12 | Basf Ag | Thermoplastische massen fuer die herstellung metallischer formkoerper |
JPH06192706A (ja) * | 1992-12-25 | 1994-07-12 | Sanyo Chem Ind Ltd | 焼結性粉末成形体の脱脂方法 |
DE4314694C1 (de) | 1993-05-04 | 1994-05-11 | Basf Ag | Verfahren zur Herstellung von Sinterformteilen |
CA2133387A1 (en) * | 1993-10-01 | 1995-04-02 | Basf K&F Corporation | Process for improving the debinding rate of ceramic and metal injection molded products |
JPH0820803A (ja) * | 1993-11-22 | 1996-01-23 | Sanyo Chem Ind Ltd | 焼結体の製造方法 |
EP0701875B1 (de) * | 1994-09-15 | 2000-06-07 | Basf Aktiengesellschaft | Verfahren zur Herstellung metallischer Formteile durch Pulverspritzguss |
JP2000017304A (ja) * | 1998-06-29 | 2000-01-18 | Olympus Optical Co Ltd | 無機粉末焼結体の製造方法及び無機粉末焼結体 |
JP2000063903A (ja) * | 1998-08-13 | 2000-02-29 | Citizen Watch Co Ltd | 粉末射出成形部品の製造方法 |
US6376585B1 (en) * | 2000-06-26 | 2002-04-23 | Apex Advanced Technologies, Llc | Binder system and method for particulate material with debind rate control additive |
US7691174B2 (en) * | 2004-03-08 | 2010-04-06 | Battelle Memorial Institute | Feedstock composition and method of using same for powder metallurgy forming a reactive metals |
JP2010500469A (ja) * | 2006-08-07 | 2010-01-07 | ザ ユニバーシティー オブ クイーンズランド | 金属射出成形方法 |
KR20080027171A (ko) * | 2006-09-22 | 2008-03-26 | 세이코 엡슨 가부시키가이샤 | 소결체의 제조방법 및 소결체 |
JP5709856B2 (ja) * | 2009-06-25 | 2015-04-30 | ビーエーエスエフ ソシエタス・ヨーロピアBasf Se | 熱可塑性成型組成物を用いて射出成型、押出成型またはプレスで製造された金属製及び/又はセラミック製成型物からバインダーを連続的に熱的に除去する方法 |
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JP2013524006A (ja) | 2013-06-17 |
AT509613B1 (de) | 2017-05-15 |
HUE035814T2 (en) | 2018-05-28 |
AT509613A1 (de) | 2011-10-15 |
KR20130079373A (ko) | 2013-07-10 |
US20130101456A1 (en) | 2013-04-25 |
ES2639134T3 (es) | 2017-10-25 |
JP5956419B2 (ja) | 2016-07-27 |
DK2552630T3 (en) | 2017-09-25 |
WO2011120066A1 (de) | 2011-10-06 |
CN103038006A (zh) | 2013-04-10 |
PL2552630T3 (pl) | 2018-05-30 |
EP2552630A1 (de) | 2013-02-06 |
SG184423A1 (en) | 2012-10-30 |
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