EP2552630B1 - Verfahren zur herstellung von formkörpern aus aluminiumlegierungen - Google Patents

Verfahren zur herstellung von formkörpern aus aluminiumlegierungen Download PDF

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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
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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
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EP11720714.2A
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German (de)
English (en)
French (fr)
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EP2552630A1 (de
Inventor
Herbert Danninger
Christian Gierl
Branislav Zlatkov
Johan Ter Maat
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.)
Technische Universitaet Wien
Rupert Fertinger GmbH
BASF SE
Original Assignee
Technische Universitaet Wien
Rupert Fertinger GmbH
BASF SE
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Publication date
Application filed by Technische Universitaet Wien, Rupert Fertinger GmbH, BASF SE filed Critical Technische Universitaet Wien
Priority to PL11720714T priority Critical patent/PL2552630T3/pl
Publication of EP2552630A1 publication Critical patent/EP2552630A1/de
Application granted granted Critical
Publication of EP2552630B1 publication Critical patent/EP2552630B1/de
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22Manufacture 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12Both compacting and sintering
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/1017Multiple heating or additional steps
    • B22F3/1021Removal of binder or filler
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22Manufacture 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
    • B22F3/225Manufacture 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24After-treatment of workpieces or articles
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/04Making non-ferrous alloys by powder metallurgy
    • C22C1/0408Light metal alloys
    • C22C1/0416Aluminium-based alloys
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/06Alloys 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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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
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EP11720714.2A 2010-04-01 2011-03-31 Verfahren zur herstellung von formkörpern aus aluminiumlegierungen Not-in-force EP2552630B1 (de)

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Application Number Priority Date Filing Date Title
PL11720714T PL2552630T3 (pl) 2010-04-01 2011-03-31 Sposób wytwarzania elementów kształtowych ze stopów aluminium

Applications Claiming Priority (2)

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ATA534/2010A AT509613B1 (de) 2010-04-01 2010-04-01 Verfahren zur herstellung von formköpern aus aluminiumlegierungen
PCT/AT2011/000157 WO2011120066A1 (de) 2010-04-01 2011-03-31 Verfahren zur herstellung von formkörpern aus aluminiumlegierungen

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EP2552630A1 EP2552630A1 (de) 2013-02-06
EP2552630B1 true EP2552630B1 (de) 2017-05-31

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US (1) US20130101456A1 (enrdf_load_stackoverflow)
EP (1) EP2552630B1 (enrdf_load_stackoverflow)
JP (1) JP5956419B2 (enrdf_load_stackoverflow)
KR (1) KR20130079373A (enrdf_load_stackoverflow)
AT (1) AT509613B1 (enrdf_load_stackoverflow)
DK (1) DK2552630T3 (enrdf_load_stackoverflow)
ES (1) ES2639134T3 (enrdf_load_stackoverflow)
HU (1) HUE035814T2 (enrdf_load_stackoverflow)
PL (1) PL2552630T3 (enrdf_load_stackoverflow)
SG (1) SG184423A1 (enrdf_load_stackoverflow)
WO (1) WO2011120066A1 (enrdf_load_stackoverflow)

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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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