EP3083105B1 - Continuous composite metal foam production and method and device for stirring particle reinforced composite metal - Google Patents

Continuous composite metal foam production and method and device for stirring particle reinforced composite metal Download PDF

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EP3083105B1
EP3083105B1 EP14835731.2A EP14835731A EP3083105B1 EP 3083105 B1 EP3083105 B1 EP 3083105B1 EP 14835731 A EP14835731 A EP 14835731A EP 3083105 B1 EP3083105 B1 EP 3083105B1
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Prior art keywords
metal
stirring
mixture
composite metal
temperature
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German (de)
French (fr)
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EP3083105A2 (en
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Nilhan Urkmez TASKIN
Vedat TASKIN
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams

Definitions

  • This invention is related to a method and a device that performs said method in order to carry out in one go, the production of closed cell, and continuous form composite metal foam production without the necessity to perform pre-processes thereon; to increase the quality and strength of the material, to distribute the reinforcement and/or foam material homogenously within the material, to be able to produce foam material having the desired density and to provide a homogenous inner structure, moreover, to be able to mix homogenously at the desired ratios, the reinforcement material and the matrix material during the production of particle reinforced composite metal, to distribute the ceramic particles used as reinforcement material into the material homogenously and in order for the material to be wetted better by the matrix material and in order to increase the quality of the material.
  • Metal foams can be used in several fields from mechanical applications to thermal applications due to their perfect durability /weight ratios [1-4,13,15]. Metal foams, form interesting physical and mechanical characteristics when high durability is combined with very low specific gravity or high gas permeability is combined with heat treatment conduction.
  • Cell size and distribution control can be relatively carried out in metal foams that have been produced by first forming a preform by means of sintering and then heating in a furnace or in limited volumes; however the product sizes and numbers obtained with these kind of methods are limited ( WO2010127668 and WO201010106883 ). Moreover the sintering procedure is quite long. The precautions taken in order to prevent these kinds of disadvantages also increase process costs. [10,11].
  • the method and device, developed by means of the present invention, in order to produce a continuous composite metal foam or particle reinforced composite metal overcomes the disadvantages mentioned above and the method and device developed according to the present invention is characterized by the following:
  • MMC Metal Matrix Composites
  • the present invention is a new method and device used in composite metal foam production; wherein the developed device comprises the following characteristics.
  • the device that has been developed in order to produce metal foam comprises three sections which are the front heating section (1), the stirring section (2) and the foaming section (3). All sections are heated with separate resistance groups (7). The temperature control of the sections is carried out separately.
  • the temperatures of the furnace front heating (1) section are temperatures that are below 40 - 60 °C, of the molting temperatures of the metal or metal alloy that is to be foamed.
  • the temperatures of the foaming section (3) are temperatures that are 50 - 70 °C higher than the molten temperature of the metal or metal alloy that is to be foamed.
  • the temperatures of the stirring section (2) are 100 - 300 °C higher than the molten temperatures of the metal or metal alloy that is to be foamed.
  • the movable molds (8) and the reinforcement powders at the front heating section are tried to be brought to process temperatures.
  • the stirring section (2) comprises a crucible (11), metal or metal alloy material inlet (23) that is to be foamed, reinforcement powder inlet (25), foaming powder inlet (22), protective gas inlet (14) and top stirring cover (6), kneading and stirring apparatus (18) and a stirring mechanism (27).
  • Protective gas N 2 or argon is continuously sprayed on a crucible (11).
  • Reinforcement material, foaming metal or metal alloy (matrix material), foaming powder and powder inputs are poured through the inlets located on said stirring section (2).
  • the reinforcement and matrix material and foaming powder inputs are provided by the automatic control unit according to the information obtained from the sensors (19 and 20).
  • the material inside the metal or metal alloy (matrix material) vessel (24) that is to be foamed, is divided into parts. Said material, can be processed by preparing it in particle or powder form from metal plate, ingot or recycled materials.
  • the materials can be formed of aluminum, copper, titanium, nickel or other metals.
  • the stirring process with kneading and stirring apparatus (18) is again carried out through the top stirring cover located at again the top alignment of the crucible. Moreover the gas used as protective atmosphere (N 2 or argon) is also blown onto the crucible from this cover section.
  • N 2 or argon gas used as protective atmosphere
  • the kneading and mixing apparatus (18) are operated by the kneading and stirring mechanism (27).
  • the pressure sensor (20) and the temperature sensor can be located within the stirring mechanism (27). Besides this the temperature sensor (19) can also be located in the crucible (19).
  • the stirring procedures are carried out by controlling the viscosity/consistency and temperature information obtained from the pressure and temperature sensors (19 and 20).
  • One of the most important aspects of the invention is to keep the mixture at a semi solid state during the whole of the stirring process. If the viscosity is low (at the phase of being semi solid to being liquid) the viscosity is increased by adding foaming metal or metal alloy to the mixture.
  • the stirring procedure is continued without adding metal to the mixture.
  • the mixture is checked to see if it is at a semi solid state by means of the pressure and temperature sensors (19 and 20) which are controlled by the control unit and the addition of metal is provided by commands submitted to the stirrer by the control unit.
  • the pressure sensor (20) of the stirring mechanism (27) submits the pressure (viscosity) information that enables to control the up and down movement of the stirrer at the pressure value, to the automatic control unit.
  • the temperature sensor (19) which measures the temperature inside the crucible (11) submits the temperature information which enables the movement of the stirrer by ensuring that the mixture is kept at a certain temperature, to the automatic control unit.
  • the stirring mechanism (27) is a system that can operate in connection with a tool changer such that it can provide the changing of different stirrers and that can ensure that the required stirrer at the stirring section is chosen and attached. After the stirrer is attached the down and up (27b) and rotational (27a) movement is carried out.
  • the stirring durations, the selection of stirrers, their attachment or dismantling is controlled by an electronic system.
  • the end parts of the kneading and stirring apparatus (18) connected to the stirring mechanism (27) can be flat, spiral or could have holes inside it.
  • the holes within the kneading and stirring apparatus with holes can be circular, elliptical, or can have a square shapes or a polygonal geometrical shapes, and the holes could each be the same size or could be in different sizes.
  • the kneading and stirring apparatus (18) can be resistant to high temperatures and can have different diameters depending on the crucible diameter. In the case that the bottom of the crucible has a different geometry, the kneading and stirring apparatus (18) can also have different geometries and sizes compliant to the geometry of the crucible.
  • the material of the stirrers (18) can be made of graphite or said stirrers could be coated with high temperature resistant materials such as ceramic. Besides this, the surface of the apparatus (18) can be coated with a mixture comprising silicium carbide powder and colloidal silica. By this means, the life span of the stirrer is also extended.
  • More than one crucible (11) can be used which can be moved in sequence in order to provide a mixture that is continuously at a semi solid state.
  • the crucible (11) which is empty is pushed outside of the stirring section (2) by moving it forward and a new crucible (11) is pushed in place to replace the preceding crucible.
  • the next crucible with a mixture prepared inside is brought to an alignment with the movable crucibles and this procedure is repeated constantly to provide a ready mixed mixture.
  • the bottom parts of the crucibles (11) are open and the front part of the movable mold also functions as a crucible bottom (25) and is at a closed position during the stirring procedures.
  • the movable molds move along the mold bearing (9) made of firebrick that extends from the cover (4) of the movable mold to the mold outlet cover.
  • the material of the crucible (11) can be SiC, Al 2 O 3 , graphite etc.
  • the crucible bottom (12) is made of high temperature resistant and heat conducting material.
  • graphite is used to form crucible bottoms (12).
  • the vessel (13) is made of high temperature resistant and low heat conductive material such as gas, concrete, ceramic foam etc.
  • a fan (16) mechanism is present on the mold outlet cover so that the foam material exiting out of the furnace can be cooled.
  • the continuous metal foam production or particle reinforced composite metal production method developed according to the present invention has been listed below:
  • the method developed according to the present invention can also be used during the stirring phase of the particle reinforced composite metal production.
  • the steps of the particle reinforced composite metal stirring method have been listed below.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Description

    Technical Field of the Invention
  • This invention is related to a method and a device that performs said method in order to carry out in one go, the production of closed cell, and continuous form composite metal foam production without the necessity to perform pre-processes thereon; to increase the quality and strength of the material, to distribute the reinforcement and/or foam material homogenously within the material, to be able to produce foam material having the desired density and to provide a homogenous inner structure, moreover, to be able to mix homogenously at the desired ratios, the reinforcement material and the matrix material during the production of particle reinforced composite metal, to distribute the ceramic particles used as reinforcement material into the material homogenously and in order for the material to be wetted better by the matrix material and in order to increase the quality of the material.
    • Prior Art related to the art of metal foams
  • The publications (articles and thesis) within the known state of the art related to the method and device for producing continuous composite metal foam have been listed below.
    1. [1] Ashby, M. F., Evans, A., Fleck, N. A., Gibson, L. J., Hutchinson, J. W. and Wadley, H. N. G., "Metal Foams: A Design Guide", Butterworth-Heinemann Woburn, USA,ISBN 0-7506-7219-6,2000
    2. [2] Wassim Elias Azzi, "A Systematic Study On The Mechanical And Thermal Properties Of Open Cell Metal Foams For Aerospace Applications" Ph.D. Thesis, North Carolina State University, Raleigh, ,2004.
    3. [3] John Banhart, "Manufacture, Characterization and Application of Cellular Metals and Metal Foams" John Banhart & Denis Weaire, "On the road again: Metal foams find favor". Physics Today, 2002.
    4. [4] H.P. Degischer, Handbook of Cellular Materials - Production, Processing, Applications,H.P. Degischer y B. Kriszt (Eds.), Wiley-VCH, Weinheim, pp. 5-7.,2000
    5. [5] Matijasevic-Lux, B. (2006). Characterization and optimization of blowing agent for making improved metal foams, Doctor Eng. Science thesis, Technical University of Berlin
    6. [6] S. Elbir, S. Yilmaz, A. K. Toksoy, M. Guden "SiC-Particulate Aluminum Composite Foams Produced By Powder Compacts: Foaming And Compression Behavior" Journal Of Materials Science 38,4745-4755,2003
    7. [7] S. Esmaeelzadeh A, A. Simchi, "Foamability And Compressive Properties Of AISi7-3 Vol.% SiC-0.5 Wt.% TiH2 Powder Compact", Materials Letters, 2008
    8. [8] Wang Deqing, Shi Ziyuan, "Effect Of Ceramic Particles On Cell Size And Wall Thickness Of Aluminum Foam", Materials Science And Engineering A361,45-49,2003
    9. [9] F. Simancik, L. Lucan And J.Jerz, "Reinforced Aluminium Foams" Institute Of Materials And Machine Mechanics, Sas, Bratislava, Slovak Republic
    10. [10] B.P.Neville,A.Rabiei,"Comp. Metal Foams Processed Through Powder Metallurgy", Mat. And Des.29-388-396,2008
    11. [11] Rabiei, A.T. O'neill, "A Study On Processing Of A Composite Metal Foam Via Casting", Materials Science And Engineering A 404,159-164,2005
    12. [12] Lakshmi J. Vendra, Afsaneh Rabiei, "A Study On Aluminum-Steel Composite Metal Foam Processed By Casting" Materials Science And Engineering A 465,59-67,2007
    13. [13] Banhart, J., Fleck, N. and Mortensen, A., "Cellular Metals: Manufacture, Properties, Applications", Verlag Metall Innovation Technologie MIT Berlin, Germany,ISBN 3-935538-12-X,2003
    14. [14] Ashby,M.F.,"Materials Selection in Mechanical Design",Butterworth-Heinemann Oxford,UK,
    15. [15] Stadler, C., Hosnedl, S. and Lasova, V., "Organ Features Incorporating Metal Foams-their Properties and their Relationships and Evaluation", Proc.of the 4th Int. Conf. on Porous Metals and Metal Foaming Tech.-MetFoam05,, Japan, 2005.
    16. [16] John Banhart, Manufacture, "Characterization And Application Of Cellular Metals And Metal Foams", Progress In Materials Science, 46, 559-632, 2001
    17. [17] Esmaeelzadeh,S., Simchi, A., Lehmhus, D., "Effect of Ceramic Particle Addition on the Foaming Behavior, Cell Structure and Mechanical Properties of P/M AISi7 Foam", Materials Science and Engineering, A424, 290-299,2006
    18. [18] Yu, S., Luo, Y., Liu, J., "Effects of Strain Rate and SiC Particle on the Compressive Property of SiCp/AlSi9Mg Composite Foams", Materials Science and Engineering, 487, 394-399,2008
    19. [19] Gui, M.C., Wang, D.B., Wu, J.J., Yuan, G.J., Li, C.G., "Deformation and Damping Behaviors of Foamed Al-Si-SiCp Composite", Materials Science and Engineering, A286, 282-288,2000
    20. [20] Esmaeelzadeh, S., Simchi, A., "Foamability and Compressive Properties of AISi7 - 3 Vol.% SiC- 0.5 Wt.% Tih2 Powder Compact", Materials Letters, 62, 1561-1564,2008
    21. [21] Jeon, Y.P., Kang,C.G., Lee, S.M., "Effects of Cell Size on Compression and Bending Strength of Aluminum-Foamed Material by Complex Stirring in Induction Heating", Journal of Materials Processing Technology, 2 0 9, 435-444,2009
    22. [22] Luo, Y., Yu, S., Li, W., Liu, J., Wei, M., "Compressive Behavior of SiCp/Alsi9Mg Composite Foams", Journal of Alloys and Compounds, 460, 294-298,2009
    23. [23] Yu, C.J., Banhart, J., "Mechanical Properties of Metallic Foams", Fraunhofer USA Metal Foam Symposium, 37-48,1997
    24. [24] Haesche, M., Weise, J., Garcia-Moreno, F., Banhart, J., "Influence of Particle Additions on The Foaming Behaviour of AlSi11/TiH2 Composites Made by Semi-Solid Processing", Materials Science And Engineering, 480, 283-288,2007
    25. [25] Taskin, V., Taskin, N. U., Demirhan, P. A., Mutlu, I., "Manufacturing Of Composite Metal Foam By Directly Foaming At Semi Solid Temperature", Proceedings UNITECH'10 Gabrovo, II-193-II-196, 2010
  • Metal foams (Metal Foam) can be used in several fields from mechanical applications to thermal applications due to their perfect durability /weight ratios [1-4,13,15]. Metal foams, form interesting physical and mechanical characteristics when high durability is combined with very low specific gravity or high gas permeability is combined with heat treatment conduction.
  • They are characterized with cell topologies, structurally, or by the fact that they are open or closed cells, according to their specific intensities, to their cell sizes, cell shapes, and anisotropies. They can be produced from different materials such as aluminum, titanium and nickel. As a result the field of application determines the type of material from which the metal foam should be produced from. [4,13].
  • Due to their low densities, perfect specific durability, noise insulation, and impact and flame damping characteristics, studies that have increased recently especially regarding closed cell Metal Foams in sectors such as space, aviation, and automotives attract attention [3,4]
  • Mainly two methods are used to produce Metal Foam's which are the liquid phase and the solid phase. The structural and durability characteristics show difference in connection with the production method. There are several studies related to the problems that arise during production. [5-9,16,18-23].
  • The main problems that are faced during the production of metal foams that are produced using liquid phase methods, are not being able to provide sufficient resistance in the cell walls, not being able to control cell sizes and distribution, combining of cells, and the obligation to perform heat treatment on powders that are used as foaming agents [11-13,21]. In the patent publications numbered US2005161188 , HU0800736 , WO2006021082 , it has been explained that reinforcement material is added into liquid metal prior to the foaming process in order to increase resistance and foam stability and to thicken the walls of cells. This application has been described in the publication numbered WO2008003290 .
  • It is said that that in these studies where composite foam production is carried out, the matrix and reinforcement materials are in contact with each other for a long time and due to this reason unwanted brittle phases occur in inter surfaces, and that homogenously distributing the reinforcement material within the liquid phase is a difficult task on which studies are still being carried out. [6,8-12,17,18].
  • Although production is possible using liquid phase production methods, due to weak resistance characteristics they have limited usage in structural applications [5,7,8,and 9].
  • Cell size and distribution control can be relatively carried out in metal foams that have been produced by first forming a preform by means of sintering and then heating in a furnace or in limited volumes; however the product sizes and numbers obtained with these kind of methods are limited ( WO2010127668 and WO201010106883 ). Moreover the sintering procedure is quite long. The precautions taken in order to prevent these kinds of disadvantages also increase process costs. [10,11].
  • The method and device, developed by means of the present invention, in order to produce a continuous composite metal foam or particle reinforced composite metal overcomes the disadvantages mentioned above and the method and device developed according to the present invention is characterized by the following:
    • Closed cell composite foam materials reinforced with ceramic particles added in different ratios can be directly produced using the semi solid production method,
    • Ceramic particles and foaming powders are mixed into the semi solid metal or metal alloys,
    • The stirring procedure is carried out when the material is semi solid by means of stirrers having different profiles, prepared from graphite rods,
    • The semi solid mixture is added to movable molds by means of a piston after the stirring process has been completed,
    • The size of the product is determined by the section of the mold and the volume of the crucible,
    • Following the foaming procedure that has been carried out inside a furnace the product is taken out of the furnace by means of a pushing mechanism,
    • It is quickly cooled by a cooling system located outside of the furnace, and as a result the metal foam production having the desired characteristics is produced.
    KNOWN STATE OF THE ART RELATED TO PARTICLE REINFORCED COMPOSITE METAL
  • The publications (articles and thesis studies) within the known state of the art related to the method and device for particle reinforced composite metal stirring developed by means of this invention have been listed below.
    1. [1] Naher,S., Brabazon,D., Looney,L, "Development and assessment of a new quick quench stir caster design for the production of metal matrix composites", Journal of Material Processing Technology, 166,430-439.,2004
    2. [2] Zhou, W. and Xu, Z.M., "Casting of SiC reinforced metal matrix composites", J. of Mat. Proc.Tech., 63, 358-363.,1997
    3. [3] D.O.D., "Department of Defense Handbook", Comp. Mat. Handbook, Metal Matrix Composites, Vol.4.,1999
    4. [4] Kaczmar, J.W., Pietrzak, K., Wlosinski, W., "The production and application of metal matrix composite materials", Journal of Materials Processing Technology 106, 58-67,2000
    5. [5] William, C., Harrigan, Jr.,"Commercial processing of metal matrix composites", Mat. Sci. and Eng. A244,75-79,1998
    6. [6] Evans, A., San Marchi, C., Mortensen, A., "Metal Matrix Composites in Industry, An Introduction and a Survey", 440 p., Hardcover, ISBN: 978-1-4020-7521-6,2003
    7. [7] O'Donnell, G., Looney, L., "Production of Aluminium Matrix Composite Components Using Conventional PM Technology", Materials Science and Engineering A303,292-301,2001
    8. [8] Hashim, J. Looney, L., Hashmi, M.S.J,. "The Wettability of SiC Particles by Molten Aluminium Alloy", Journal of Materials Processing Technology 119, 324-328,2001
    9. [9] Hashim, J., Looney,L., Hashmi, M.S.J., "Particle distribution in cast metal matrix composites-Part I", Journal of Materials Processing Technology 123, 251-257,2002
    10. [10] Hashim, J., Looney,L., Hashmi, M.S.J., "Particle distribution in cast metal matrix composites-Part II", Journal of Materials Processing Technology,123 ,258-263,2002
    11. [11] Shi, Z., Ochiai, S. , Gu, M., Hojo, M. and Lee, J.C., "The formation and thermostability of MgO and MgAl2O4 nanoparticles in oxidized SiC particle-reinforced Al-Mg composites", Applied Physics A: Materials·Science & Processing Springer Berlin / Heidelberg, 74, 97-104,2002
    12. [12] Contreras, A., Bedolla, E. , Perez, R., "Interfacial phenomena in wettability of TiC by Al-Mg alloys", Acta Materialia ,52 985-994,2004
    13. [13] Vaucher, S., Beffort, O., "Bonding and interface formation in Metal Matrix Composites", Vol. 9, EMPA Swiss Federal Laboratories for Materials Testing and Research Thun Switzerland,2000
    14. [14] Tham, L.M., Gupta, M. and Cheng, L., "Effect Of Limited Matrix-Reinforcement Interfacial Reaction On Enhancing The Mechanical Properties Of Aluminium-Silicon Carbide Composites", Acta mate., 49 3243-3253,2001
    15. [15] Kevorkijan, V.M. , Sustarsic, B., "A New Production Technology for Discontinuously Reinforced Al-SiC Composites", Key Engineering Materials (Volumes 127 - 131),471-478,1997
    16. [16] Naher, S., Brabazon D., Looney L., "Simulation of The Stir Casting Process, Journal of Materials Processing Technology", 143-144 ,567-571,2003
    17. [17] Yarandi, F.M. , Rohatgi, P.K. , Ray, S., Settling, "Casting Fluidity and Solidification Behavior of Aluminum-SiC Particle Composite", Journal Key Engineering Materials (Volumes 79 - 80), 91-104,1993
    18. [18] J. Hashim, L. Looney* and M. S. J. Hashmi, Metal matrix composites: production by the stir casting method", Journal of Materials Processing Technology,Volumes 92-93, Pages 1-7,1999
    19. [19] Balasivanandha S. P.,, Karunamoorthy, L., Kathiresan, S., Mohan, B., "Influence of stirring speed and stirring time on distribution of particles in cast metal matrix composite", Journal of Materials Processing Technology,Volume 171,
    20. [20] A. Ourdjini, K.C. Chew, B.T. Khoo, "Settling of silicon carbide particles in cast metal matrix composite", J. Mater. Process. Technol. 116,72-76.,2001
    21. [21] Aklaghi, F., Lajevardi, A., Maghanaki, H.M., "Effect of Casting Temperature On The Microstructure And Wear Resistance of Compocast A356/SiCp Composites:A Comparison Between SS and SL Routes", J. Mat. Proc. Tech,2004
    22. [22] Hallen, J.M. , Balmori, H.M. , Jaramillo-Vigueras, D. , Estrada, J.L., González J.L. , Manzano-Ramírez, A., "Influence of Mg and Stirring on the Strength of an Aluminium Matrix Composite Obtained by Compocasting", Journal Key Engineering Materials (Volumes 127 - 131), 495-502,1997
    23. [23] Wang,H., 2007, In-Situ Si/Al "Composite Produced by Semisolid Metal Processing, Materials and Manufacturing Processes", 22, 696 - 699,2007
    24. [24] Qin, Q.D., Zhao, , Y.G., Cong, P.J. W. Zhou and Xu, B., "Semisolid microstructure of Mg2Si/Al composite by cooling slope cast and its evolution during partial remelting process", Materials Science and Engineering: A, 444, 99-103,2007
    25. [25] Ghomashchi,M.R.,Vikhrov,A.,"Squeeze casting: an overview",J. of Materials Processing Technology 101,1-9,2000
    26. [26] Vijayaram, T.R., Sulaiman, S., Hamouda, A.M.S. and Ahmad, M.H.M., "Fabrication of fiber reinforced metal matrix composites by squeeze casting technology". Journal of Materials Processing Technology,178,34-38,2006
    27. [27] Yong, M. S. and Clegg, A. J., "Process optimization for a squeeze cast magnesium alloy", J. of Mat. Proc. Tech., 145, 134-141,2004
    28. [28] Zheng,M., Wu, K., Yao, C., "Characterization of interfacial reaction in squeeze cast SiCw/Mg composites", Materials Letters,47, 118-124,2001
    29. [29] Reihani, S.M.S., "Processing of squeeze cast Al6061-30vol% SiC composites and their characterization". Materials and Design,27, 216-222,2006
    30. [30] Long, S., Beffort, O., Cayron, C., Bonjour C., "Microstructure and mechanical properties of a high volume fraction SiC particle reinforced AlCu4MgAg squeeze casting", Mat. Sci. and Eng. A269 175-185,1999
    31. [31] Vicens,J., Chédru, M., Chermant, J. L., "New Al-AlN composites fabricated by squeeze casting: interfacial phenomena", Composites Part A: Applied Science and Manufacturing, Volume 33,Issue10,2, Pages 1421-1423,2002
    32. [32] Spencer, K., Corbin, S.F., Lloyd, D.J., "The Influence of Iron Content on the Plane Strain Fracture Behaviour of
    33. [33] Valdez,S., Campillo,B., Pérez,R., Martínez,L., García H. A., "Synthesis and microstructural characterization of Al-Mg alloy-SiC particle composite", Materials Letters, 62, 2623-2625,2008
    34. [34] Ürkmez, N., "AlMg3/SiCp Kompozitlerinin Üretimi ve Mekanik Özelliklerdeki
      Figure imgb0001
      İncelenmesi", Doktora Tezi, YTU F.B.E., İstanbul, 2004
    35. [35] Skolianos,S.M., Skolianos, S.M., Kiourtsidis, G. and Xatzifotiou, T. "Effect of Applied Pressure on the Microstructure and Mechanical Properties of Squeeze-Cast aluminium AA6061 alloy",Material Sci. and Engineering A231,17-24,1997
  • Various methods are used during the production of Metal Matrix Composites (MMC), depending on the type of reinforcement and its geometry. [1]. These methods are liquid, solid and double phase methods. [2-4]. Each method has its own advantages and disadvantages during its application [1,5-7].
  • Quite a high amount of resistance, homogenous reinforcement distribution, and controlled inter surface reactions can be provided as a result of solid phase production methods in especially particle reinforced metal matrix composite (PRMMC) materials. However the procedure is difficult and quite costly due to additional processes. The particle sizes that can be obtained are limited.[1]
  • As liquid phase production methods are relatively cheaper, easier and more adaptable they are commercially preferred. During the production of PRMMC materials with liquid phase methods, problems that are difficult to overcome occur at the stirring and solidification processes[4, 8-10]. Some of the main problems that can occur are, not being able to homogenously distribute the reinforcement material into the liquid phase, not being wetted by the matrix material, being pushed beyond the mixture, flocculation, accumulation, occurrence of unwanted chemical reactions between the matrix and reinforcement material, inter surface problems and formation of pores [11-14].
  • There are several studies that research for solutions of the present problems in literature. Reinforcement pre processes and metallurgical procedures that increase wetting are carried out in order to improve the inter surface connection between the reinforcement and the matrix[15].
  • Different stirring profiles, stirring speed and durations have been tried in order to overcome problems such as the reinforcement being pushed out of the mixture, flocculation and sedimentation [19,20]. Although these solutions provide homogenous reinforcement, unwanted inter surface reactions are also faced as stirring duration is extended in high temperatures and the rate of pore formation is also increased. [2, 12, 15-20].
  • The methods using double phase for production are being preferred by investigators recently. These methods have several advantages that can be explained with the ticsotropic behavior of metal materials. Main advantages of said method can be listed as: (a) Lower energy consumption relative to other liquid stirring methods due to short time stirring procedures in low temperatures; (b) reducing chemical waste in the reinforcement material from the alloy (c) longer mold life; (d) laminar flow of the viscose semi solid material; (e) lower solidification shrinkage; (f) lower tendency to hot tearing; (g) faster process conversion; (h) less formation of reaction products that reduce the resistance of composite material; (j) reducing abrasion in the stirrers, and reducing the unwanted elements inside the mixture; (k) less porous inner structure as the gas intake rate from the environment is reduced; (I) solid phase formation having co axial particles which are not dentritic [21-22]. The main disadvantages of the semi solid production methods are; stirring difficulty due to high viscosity and trying to ensure that the procedure parameters are kept fixed (temperature, shear stresses etc.) [21-24].
  • A method and device for the method of particle reinforced composite metal stirring developed according to the present invention can overcome the disadvantages mentioned above and the characteristics of the method and device developed according to the present invention is as follows:
    • Ceramic particles with different ratios are added directly into metal matrix material using the semi solid stirring method,
    • Ceramic particles are homogenously distributed into metal or metal alloys which are semi solid,
    • The stirring procedure is carried out by means of stirrers having different profiles, prepared from graphite rods when the material is at a semi solid state,
    • When the stirring procedure is completed the semi solid mixture is transferred into molds either at a semi solid state or under high temperatures,
    • Particle reinforced composite metal production can be performed using the desired casting or production method,
    • The product sizes are determined by the mold section and the volume of the crucible; and as a result the particle reinforced composite metal production having the desired characteristics can be carried out.
    Description of the Drawings
  • The figures that have been drawn in order to further explain the method and device for the production of continuous composite metal foam and particle reinforced composite metal stirring method have been attached to this document. The definitions of the figures are given below.
    • Figure 1 Process line sectional view
    • Figure 2 Process line mold movement view
    • Figure 3 The view of the crucible and the crucible bottom
    • Figure 4 Schematic view of the furnace
    • Figure 5 The schematic view of the kneading and stirring apparatus and the stirring system
    • Figure 6 Schematic view of the bottom of the crucible
    • Figure 7 View of the aluminum composite foam that has been prepared by adding %25 SiCp reinforcement
    • Figure 8 SiC reinforcement rate-linear expansion change graphic
    • Figure 9 View of the non reinforced, %10 SiC reinforced and %20 SiC reinforced samples that have been produced with 5754 alloy
    • Figure 10 View of the aluminum foam samples that have been produced using TiH2 powders having different particle sizes,
    • Figure 11 View of %1 TiH2 and %20 SiC reinforced 5754 alloy that has been foamed at different durations
    • Figure 12 Resistance graphic according to heat treatment application of composite foam produced with 7075 Aluminum alloy
    • Figure 13 Resistance graphic of 15% SiC reinforced composite foam not treated with heat and resistance graphic of 20% SiC reinforced composite foam treated with heat Figure 14 Resistance graphics of 15% SiC reinforced composite foam treated with heat
    • Figure 15 Resistance graphics of composite foam with variable densities but whose aluminum 5754 aluminum materials and reinforcement rates are the same
    • Figure 16 Resistance graphics of composite foam whose 5083 aluminum materials and reinforcement rates are the same but whose densities are variable
    • Figure 17 Resistance graphics of composite foam whose 7075 aluminum materials and reinforcement rates are the same but whose densities are variable
    • Figure 18 Surface images that have been obtained as a result of SEM examinations
    • Figure 19 Micro rigidity test results of naturally aged and heat treated composite foam samples
    • Figure 20 View of the characteristic curves of furnace sections
    • Figure 21 The inner structure sectional view of the composite foam obtained as a result of a graphite mold foaming procedure
    • Figure 22 The inner structure sectional view of the composite foam obtained as a result of a gas concrete foaming procedure.
    • Figure 23 The inner structure sectional view of the composite foam produced in a continuous form foam production device
    Descriptions of the parts shown in the figures
  • The components (parts, elements) within the drawings (figures) that have been prepared in order to further describe the method and device developed by means of the invention for continuous composite metal foam production and particle reinforced composite metal stirring have each been numbered. The descriptions of each number have been listed below.
    • 1 Front heating section
    • 2 Stirring section
    • 3 Foaming section
    • 4 Mold entrance cover
    • 5 Mold exit cover
    • 6 Top stirring cover
    • 7 Resistance groups
    • 8 Moving molds (Material resistant to high temperatures and having low heat transfer)
    • 9 Mold bed
    • 11 Crucible
    • 12 Crucible bottom (Material resistant to high temperatures and having low heat transfer)
    • 13 Reinforcement powder oxidization vessel
    • 14 Protective gas inlet (N2 or argon)
    • 15 Pushrod
    • 16 Fan
    • 17 Piston
    • 18 Kneading and stirring apparatus
    • 19 Heat sensor
    • 20 Pressure sensor
    • 21 Foaming powder vessel (TiH2 or CaCO3)
    • 22 Foaming powder inlet.
    • 23 Matrix material inlet (Particle or powder form)
    • 24 Matrix material vessel
    • 25 Reinforcement powder inlet (SiC, TiC,B4C or Al2O3)
    • 26 Reinforcement powder vessel
    • 27 Stirring mechanism
    • 27a Stirring mechanism rotating means
    • 27b Up and down movement of stirring mechanism means
    Detailed description of the Invention
  • The present invention is a new method and device used in composite metal foam production; wherein the developed device comprises the following characteristics.
  • The device that has been developed in order to produce metal foam comprises three sections which are the front heating section (1), the stirring section (2) and the foaming section (3). All sections are heated with separate resistance groups (7). The temperature control of the sections is carried out separately.
  • The temperatures of the furnace front heating (1) section are temperatures that are below 40 - 60 °C, of the molting temperatures of the metal or metal alloy that is to be foamed.
  • The temperatures of the foaming section (3) are temperatures that are 50 - 70 °C higher than the molten temperature of the metal or metal alloy that is to be foamed.
  • The temperatures of the stirring section (2) are 100 - 300 °C higher than the molten temperatures of the metal or metal alloy that is to be foamed.
  • The movable molds (8) and the reinforcement powders at the front heating section are tried to be brought to process temperatures.
  • The stirring section (2) comprises a crucible (11), metal or metal alloy material inlet (23) that is to be foamed, reinforcement powder inlet (25), foaming powder inlet (22), protective gas inlet (14) and top stirring cover (6), kneading and stirring apparatus (18) and a stirring mechanism (27). Protective gas (N2 or argon) is continuously sprayed on a crucible (11).
  • Reinforcement material, foaming metal or metal alloy (matrix material), foaming powder and powder inputs (25,23,22,and 14) are poured through the inlets located on said stirring section (2).
  • Protective gas (N2 or argon) are present all the time in the environment and the protective gas is continuously sprayed on the crucible (11). The reinforcement and matrix material and foaming powder inputs (25,23 and 22) are provided by the automatic control unit according to the information obtained from the sensors (19 and 20). The material inside the metal or metal alloy (matrix material) vessel (24) that is to be foamed, is divided into parts. Said material, can be processed by preparing it in particle or powder form from metal plate, ingot or recycled materials. The materials can be formed of aluminum, copper, titanium, nickel or other metals.
  • The stirring process with kneading and stirring apparatus (18) is again carried out through the top stirring cover located at again the top alignment of the crucible. Moreover the gas used as protective atmosphere (N2 or argon) is also blown onto the crucible from this cover section.
  • The kneading and mixing apparatus (18) are operated by the kneading and stirring mechanism (27). The pressure sensor (20) and the temperature sensor can be located within the stirring mechanism (27). Besides this the temperature sensor (19) can also be located in the crucible (19). The stirring procedures are carried out by controlling the viscosity/consistency and temperature information obtained from the pressure and temperature sensors (19 and 20). One of the most important aspects of the invention is to keep the mixture at a semi solid state during the whole of the stirring process. If the viscosity is low (at the phase of being semi solid to being liquid) the viscosity is increased by adding foaming metal or metal alloy to the mixture. If the viscosity is high (at the phase from being semi solid to solid) the stirring procedure is continued without adding metal to the mixture. The mixture is checked to see if it is at a semi solid state by means of the pressure and temperature sensors (19 and 20) which are controlled by the control unit and the addition of metal is provided by commands submitted to the stirrer by the control unit.
  • The pressure sensor (20) of the stirring mechanism (27), submits the pressure (viscosity) information that enables to control the up and down movement of the stirrer at the pressure value, to the automatic control unit.
  • The temperature sensor (19) which measures the temperature inside the crucible (11) submits the temperature information which enables the movement of the stirrer by ensuring that the mixture is kept at a certain temperature, to the automatic control unit.
  • The stirring mechanism (27) is a system that can operate in connection with a tool changer such that it can provide the changing of different stirrers and that can ensure that the required stirrer at the stirring section is chosen and attached. After the stirrer is attached the down and up (27b) and rotational (27a) movement is carried out. The stirring durations, the selection of stirrers, their attachment or dismantling is controlled by an electronic system.
  • The end parts of the kneading and stirring apparatus (18) connected to the stirring mechanism (27) can be flat, spiral or could have holes inside it. The holes within the kneading and stirring apparatus with holes, can be circular, elliptical, or can have a square shapes or a polygonal geometrical shapes, and the holes could each be the same size or could be in different sizes.
  • The kneading and stirring apparatus (18) can be resistant to high temperatures and can have different diameters depending on the crucible diameter. In the case that the bottom of the crucible has a different geometry, the kneading and stirring apparatus (18) can also have different geometries and sizes compliant to the geometry of the crucible.
  • The material of the stirrers (18) can be made of graphite or said stirrers could be coated with high temperature resistant materials such as ceramic. Besides this, the surface of the apparatus (18) can be coated with a mixture comprising silicium carbide powder and colloidal silica. By this means, the life span of the stirrer is also extended.
  • More than one crucible (11) can be used which can be moved in sequence in order to provide a mixture that is continuously at a semi solid state. The crucible (11) which is empty is pushed outside of the stirring section (2) by moving it forward and a new crucible (11) is pushed in place to replace the preceding crucible. The next crucible with a mixture prepared inside is brought to an alignment with the movable crucibles and this procedure is repeated constantly to provide a ready mixed mixture.
  • The bottom parts of the crucibles (11) are open and the front part of the movable mold also functions as a crucible bottom (25) and is at a closed position during the stirring procedures. The movable molds move along the mold bearing (9) made of firebrick that extends from the cover (4) of the movable mold to the mold outlet cover.
  • The material of the crucible (11) can be SiC, Al2O3, graphite etc. The crucible bottom (12) is made of high temperature resistant and heat conducting material. Preferably graphite is used to form crucible bottoms (12). The vessel (13) is made of high temperature resistant and low heat conductive material such as gas, concrete, ceramic foam etc.
  • A fan (16) mechanism is present on the mold outlet cover so that the foam material exiting out of the furnace can be cooled.
  • The continuous metal foam production or particle reinforced composite metal production method developed according to the present invention, has been listed below:
    1. 1- The movable molds (8) and reinforcement powders at the front part of the furnace (1) is subjected to pre-heating and are brought to process temperatures. Reinforcement powders can be SiC, B4C, Al2O3, TiC, and other carbides, oxides, nitrides and ceramic powders.
    2. 2- The pre heating section (1) of the furnace is brought to a temperature approximately below 40-60 °C of the metal or metal alloy melting temperature which is to be turned into foam. The temperature of the foaming section (3) is brought to a temperature 50 - 70 °C higher than the melting temperature of the metal or metal alloy that is to be foamed.
    3. 3- The crucible (11) containing metal or metal alloy that is to be turned into foam, is taken into the stirring section (2) of the pre-heating section (1) of the furnace. The temperature of the stirring section (2) is 100 - 300 °C higher than the metal or metal alloy melting temperature that is to be turned into foam.
    4. 4- The metal or metal alloy (matrix material) present inside the stirring section (2) of the crucible (11) is kept until the temperature of said mixture rises to the temperature range in which said mixture is at a semi solid state.
    5. 5- The movable molds (8) are inserted into the pre-heating section (1) from the mold entry cover (4) and is brought to the temperature of the pre-heating section (1)
    6. 6- When the material inside the crucible (11) is softened and begins to be crushed, the reinforcement material that has been pre-heated, is added into the crucible (11) through the reinforcement material inlet (25).
    7. 7- The metal or metal alloy (matrix material) that is to be turned into foam is poured in from the crucible inlet (11) in order to ensure that the material stays between the semi solid temperature ranges, when the temperature exceeds the semi solid state temperature range. Metal or metal alloy addition, is carried out by the automatic control unit according to the information obtained from the pressure sensors (20). The viscosity of the mixture is controlled by means of adding metal or metal alloy in accordance with the information obtained from the pressure and temperature sensors (19 and 20). At this point the aim is to ensure that the mixture is kept at a semi solid state. The aim or the mixture to be kept at a semi solid state is to ensure that the material does not flocculate or sedimentation is not created when the reinforcement material is added, and to ensure that the reinforcement material is homogenously distributed into the mixture. If the viscosity of the mixture is low (at the phase from being at a semi solid state to being liquid), the viscosity is increased by adding metal or metal alloy that is to be converted into foam in order to keep the mixture at a semi solid state. If the viscosity of the mixture is high (at the phase from being at a semi solid state to becoming solid) the stirring procedure is continued without adding metal to the mixture. When the temperature of the mixture increases, and when the viscosity is low, reinforcement material is not added to the mixture and only metal or metal alloy is added.
    8. 8- The mixture is checked if it is at a semi solid state or not by determining by means of the pressure and temperature sensors (19 and 20) controlled by the control unit, and again the semi solid state is ensured by the commands submitted to the stirrer and metal addition mechanism.
    9. 9- After the reinforcement material is added, kneading and mixing procedures are carried out together until the material is homogenously mixed. The stirring process is carried out by the up and down movement of the stirrer(s) depending on the viscosity/stability (or in other words depending on the mixture being at a semi solid state or not) of the material found inside the crucible (11). Besides this the stirrer(s) (18) also change orbits by zig zag or elliptical or radial movement inside the crucible (11).
    10. 10- After the mixture is prepared at the desired amount, the foaming powder inside (TiH2 and CaCO3 and compounds comprising gas) the foaming powder vessel (21) is added to the mixture through the foaming powder inlet (22) and the quick stirring procedure is repeated. At this moment metal or alloy is continued to be added to the mixture.
    11. 11- After the mixture is prepared at the desired amounts, the foaming powder inside the foaming powder vessel (21) is added to the mixture from the foaming powder inlet (22) and the quick stirring process is continued. During this time metal or alloy is continued to be added to the mixture.
    12. 12- When a homogenous mixture is obtained, the movable mold is shifted and the bottom of the crucible (11) is opened, the mixture is transferred into the mold cavity (8) from the bottom of the crucible (11) by means of a thrusting piston (17).
    13. 13- Whilst the mixture is being pushed by the piston (17) the movable mold is moved at a constant speed on the mold bed (9) by means of a pushrod (15) and the mixture fills the cavity of the movable mold.
    14. 14- The movable mold (8) is taken into the foaming section (3) having a temperature which is 50 - 70 °C higher than the melting temperature of the metal or metal alloy that is to be foamed.
    15. 15- When the waiting period depending on the mixture amount, is completed the mold (8) is taken out of the furnace by means of the pushrod (15), after the mold exit cover (5) is opened.
    16. 16- The foaming material inside the mold which has been taken out of the furnace is cooled quickly by means of cooling fans (16).
    TESTS CARRIED OUT FOR THE PRODUCTION METHOD DEVELOPED ACCORDING TO THE INVENTION
  • Several tests have been carried out regarding the continuous composite metal foam production developed according to the invention or method developed for the production of metal foam using the particle reinforced metal production method and device developed for the continuous production of metal foam. The tests that have been conducted for the product that was produced using the method subject to the invention have been listed below.
    1- Determining the reinforcement powder ratios that could be added into the semi solid material. (Up to 25% reinforcement powder can be added into semi solid material) (Figure 7).
    2- Determining the effect of the foaming powder amount to linear expansion (The linear expansion rate is 5-8 when the foaming powder is added at a percentage of 1-2%) (Figure 8)
    3- Examining the effect of the reinforcement rate to the formation of foam. The effects of SiC powders to the formation of foam have been mentioned below. When the SiC reinforcement amount increased;
    • Linear expansion increased
    • Homogenous pore distribution was provided
    • Drainage formation was prevented
    • The thickness of the cell walls increased
    • The resistance of the cell walls increased and pore combining was prevented
    The effects mentioned above are performed by the selection of the foam formation temperature distinctive to the material. When the waiting period at a high temperature has been exceeded, combining of the pores, thinning of the cell walls and sedimentation occurs.
    4- Examining the effect of the foaming powder size to the formation of foam. (when foaming powder having particle sizes larger than ∼40 µm was used it was harder for a homogenous inner structure to be obtained. The test results are shown in Figure 10).
    5- Examining the effect of the type of foaming powder used to the production of foam. Similar results have been obtained with tests carried out with TiH2 and CaCO3 powders. The process parameters change for such procedures.
    6- Examining the effect of the foaming duration to the foam structure. As the duration for the foaming procedure increased the cell sizes increased, and the cells are combined with each other and a non homogenous inner structure is obtained. The pore structure in stirring and foaming procedures carried out under protective gas by means of the metal foam production apparatus passes through different phases depending on time. The time also changes depending on material. The %1 TiH2 and %20 SiC reinforced 5754 alloy foam which have been foamed in different durations can be seen in Figure 11.
    7- Measuring the densities of the products that have been produced. Aluminum composite foam materials having a density between 0.3 gr/cm3 to 0.8 gr/cm3 have been obtained. The results of the tests carried out in relation to specific weight and relative densities (EN AW 5754) have been given in the table below.
    Test name Condensation (g/cm3) Relative densities Test Name Condensation (g/cm3) Relative densities
    TiH21SiC2 TB44µmKS 8min-heat tr 0,588 0,220 TiH21SiC20TB30µmKS12min-heat tr 0,379 0,141
    TiH21SiC20TB44µmKS10min -heat tr 0,399 0,149 TiH21 SiC10TB4µm KS 8min 0,618 0,231
    TiH21SiC20TB44µmKS12min -heat tr 0,388 0,145 TiH21SiC10TB4µm KS 10min 0,652 0,244
    TiH21SiC0TB44µmKS8min-heat tr 0,497 0,186 TiH21 SiC10TB4µmKS 12min 0,550 0,205
    TiH21SiC0TB44µmKS10min heat tr 0,497 0,186 TiH21SiC10TB4µmKS8min-heat tr 0,769 0,288
    TiH21SiC0TB44µmKS12min-heat tr 0,410 0,153 TiH21SiC10TB4µmKS10min heat tr 0,662 0,247
    TiH21SiC0TB44µmKS 10min 0,389 0,145 TiH21 SiC10 TB4µmKS 12min-heat tr 0,683 0,255
    TiH21 SiC20TB44µm KS 8min 0,324 0,121 TiH2 1 SiC 20 TB4µm 8min 0,613 0,229
    TiH21 SiC20TB44µm KS 10min 0,380 0,142 TiH21SiC20TB4µmKS 10min 0,773 0,289
    TiH21SiC20TB44µm KS 12min 0,311 0,116 TiH21 SiC 20TB4µmKS 12min 0,960 0,359
    TiH21SiC10TB44µmKS8min-heat tr. 0,704 0,263 TiH21SiC10TB100µmKS 8min 0,648 0,242
    TiH21SiC10TB44µmKS10min -heat tr. 0,683 0,255 TiH21SiC10TB100µmKS10mi n 0,521 0,195
    TiH21SiC10TB44µmKS12min -heat tr. 0,482 0,180 TiH21SiC10TB100µmKS 12min 0,499 0,186
    TiH21SiC10 TB44µm KS8min 0,473 0,177 TiH21SiC20TB100µmKS 8min 0,334 0,125
    TiH21 SiC10 TB44µm KS10min 0,380 0,142 TiH21SiC20TB100µm KS10min 0,371 0,138
    TiH21 SiC10TB44µm KS 12min 0,413 0,154 TiH21SiC20TB100µmKS 12min 0,450 0,168
    TiH2 1SiC20TB44µmKS8min 800°C 0,900 0,337 TiH21SiC10TB100µm KS 8min-heat tr. 0,493 0,184
    TiH2 1SiC20TB44µmKS10min 800 °C 0,665 0,249 TiH21SiC10TB100µmKS10mi n-heat tr. 0,260 0,097
    TiH2 1SiC20TB44µmKS12min 800 °C 0,616 0,230 TiH21SiC10TB100µmKS12mi n-heat tr.- 0,290 0,108
    TiH21 SiC10TB30µmKS 8min-heat tr. 0,564 0,211 TiH21SiC20TB100µm KS 8min-heat tr.- 0,408 0,152
    TiH21SiC10TB30µmKS10min -heat tr. 0,365 0,136 TiH21SiC20TB100µmKS10mi n-heat tr.- 0,772 0,289
    TiH21SiC10TB30µmKS12min -heat tr. 0,418 0,156 TiH21SiC20TB100µmKS12mi n -heat tr. 0,575 0,215
    TiH2 1SiC 10 TB30µm KS 8min 0,300 0,112 TiH20,5SiC20TB44µm KS 8min 0,424 0,158
    TiH21SiC10TB30µm KS 10min 0,249 0,093 TiH20,5SiC20TB44µmKS10mi n 0,301 0,112
    TiH21SiC10 TB30µmKS 12min 0,346 0,129 TiH20,5SiC20TB44µmKS12mi n 0,378 0,141
    TiH2 SiC 20 TB30µm KS 8min 0,482 0,180 TiH2SiC20TB44µm KS 8min 0,456 0,170
    TiH21SiC 20TB30µmKS 10min 0,590 0,22 TiH22 SiC20TB44µm KS10min 0,355 0,132
    TiH21SiC20TB30µm KS 12min 0,550 0,205 TiH22SiC20TB44µmKS 12min 0,368 0,137
    TiH21SiC20TB30µmKS 8min-heat tr. 0,480 0,179 TiH20,5 SiC 5 TB44µm KS10min 0,572 0,214
    TiH21SiC20TB30µmKS10min -heat tr. 0,643 0,240 TiH20,5 SiC 10 TB44µm KS10min 0,689 0,258
    TiH2 1 SiC 20 TB30µm KS(Foaming Time) 10min-heat tr.-T800 °C → %1 TiH2-%20 SiC-30µm Particle Size-10 minutes Foaming Time- heat tr. Heat Treatment TiH2 - T800Furnace temperature- All tests besides T800 have been carried out at a furnace temperature of 750 °C).

    8- Determining the compressive strengths of the obtained products (Aluminum composite foam materials between the range of 5 MPa- 35 MPa have been produced.
    Figure 12, shows that the resistances of the composite foam produced with 7075 aluminum alloy can be increased by means of heat treatment.
    Figure 13, shows that the resistance of the composite foam produced using heat treated %20 SiC reinforcement is much higher than non heat treated %15 SiC reinforced composite foam.
    Figure 14, shows the effect of the reinforcement rate on resistance. It shows that the composite foam which has been subjected to heat treatment having a higher reinforcement rate is more resistant.
    Figure 15, 16 and 17, shows that the resistance of the composite foams with higher density is more resistant in comparison to composite foams having the same material and reinforcement rate but having different densities.
    9- The surface images obtained as a result of SEM examinations are shown in Figure 18.
    10- The results of the micro rigidity tests have been shown in Figure 19. TESTS CARRIED OUT ON THE DEVICE ON WHICH THE PRODUCTION METHOD DEVELOPED ACCORDING TO THE INVENTION IS APPLIED:
  • The tests related to the device on which the continuous composite metal foam production or particle reinforced composite metal production method developed according to the invention is carried out have been listed below.
    1. 1- Forming the temperature characteristic curves of furnace sections: As it can be seen in Figure 20, the furnace sections rise up to 750°C temperature in 3 hours. The characteristics of the device used for measurements are described below.
    Technical features of the AFM05 device
    • Maximum temperature: 1200 °C
    • Constant usage temperature: 750 °C
    • Temperature deviation: + 3 °C
    • Inner dimensions: 2x (30x30x60) + (40x40x70) (cm)
    • Heating means: Kanthal (d=2mm) On the ceramic rod, on the side walls of the partitions
    • Temperature control devices: 3x (PC 442/6, Dual Display,PID.6 step programming)
    Energy distribution
    • Pre-heating section: 3.85 kW,
    • Stirring Section: 7.7 kW,
    • Retention section: 3.85 kW
    • Total 15.4 kW
    • Atmosphere: Gas metal protection environment (Nitrogen gas)
    • 2- It has been noted that during the foaming procedures carried out using graphite and gas concrete blocks in tests determining the foam mold materials, low heat conducting material needs to be used as mold material. The inner structure sectional views of the composite foams obtained in tests have been shown in Figures 21 and 22. Heterogeneous pores are present and drainage sections are established inside the inner structure of the composite foam produced in graphite molds. Pores which are homogenous and do not have drainage sections are formed inside the inner structure of the composite foam foamed with gas concrete molds.
    The inner structure sectional view of the composite foam in constant from obtained by means of the AFM05 device has been shown in Figure 23. The important issue here is for the composite foam to be produced continuously. The inner structure and density of the foam is controlled by selecting suitable parameters (such as waiting time, TiH2 size, SiC amount/rate).
  • The method developed according to the present invention can also be used during the stirring phase of the particle reinforced composite metal production. The steps of the particle reinforced composite metal stirring method have been listed below.
    1. 1- The reinforcement powders at the pre heating part of the furnace (1) are subjected to pre-heating and are brought to process temperatures. Reinforcement powders can be SiC, B4C, Al2O3, TiC, and other carbides, oxides, nitrides and ceramic powders.
    2. 2- The pre heating section (1) of the furnace is brought to a temperature approximately below 40-60 °C of the metal or metal alloy melting temperature which is to be turned into particle reinforced composite metal.
    3. 3- The crucible (11) containing metal or metal alloy that is to be turned into particle reinforced composite metal, is taken into the stirring section (2) of the pre-heating section (1) of the furnace. The temperature of the stirring section (2) is 100 - 300 °C higher than the metal or metal alloy melting temperature that is to be turned into particle reinforced composite metal.
    4. 4- The metal or metal alloy used to produce composite metal production inside the crucible (11) located at the stirring section (2) is kept until the temperature thereof is increased to the temperature range wherein said metal or metal alloy is at a semi solid state,
    5. 5- When the material inside the crucible (11) is softened and begins to be crushed, the reinforcement material that has been pre-heated, is added into the crucible (11) through the reinforcement material inlet (25).
    6. 6- The metal or metal alloy (matrix material) that is to be turned into composite metal production is poured in from the crucible inlet (11) in order to ensure that the material stays between the semi solid temperature range, when the temperature exceeds the semi solid state temperature range. Metal or metal alloy addition, is carried out by the automatic control unit according to the information obtained from the pressure sensors (20). The viscosity of the mixture is controlled by means of adding metal or metal alloy in accordance with the information obtained from the pressure and temperature sensors (19 and 20). At this point the aim is to ensure that the mixture is kept at a semi solid state. The aim or the mixture to be kept at a semi solid state is to ensure that the material does not flocculate or sedimentation is not created when the reinforcement material is added, and to ensure that the reinforcement material is homogenously distributed into the mixture. If the viscosity of the mixture is low (at the phase from being at a semi solid state to being liquid), the viscosity is increased by adding metal or metal alloy that is to be converted into foam in order to keep the mixture at a semi solid state. If the viscosity of the mixture is high (at the phase from being at a semi solid state to becoming solid) the stirring procedure is continued without adding metal to the mixture. When the temperature of the mixture increases, and when the viscosity is low, reinforcement material is not added to the mixture and only metal or metal alloy is added.
    7. 7- The mixture is checked if it is at a semi solid state or not by determining by means of the pressure and temperature sensors (19 and 20) controlled by the control unit, and again the semi solid state is ensured by the commands submitted to the stirrer and metal addition mechanism.
    8. 8- After the reinforcement material is added, kneading and mixing procedures are carried out together until the material is homogenously mixed. The stirring process is carried out by the up and down movement of the stirrer(s) depending on the viscosity/stability (or in other words depending on the mixture being at a semi solid state or not) of the material found inside the crucible (11). Besides this the stirrer(s) (18) also change orbits by zig zag or elliptical or radial movement inside the crucible (11).
    9. 9- When a homogenous mixture is obtained, the composite mixture inside the crucible (11) is taken out and poured into molds thereby a particle reinforced composite material production is obtained by means of a casting or production method.

Claims (26)

  1. A continuous composite metal foam production method, characterized in that it comprises the following steps,
    • The movable molds (8) and reinforcement powders, are subjected to preheating at the pre heating section (1) of the furnace having a temperature 40 - 60 °C below the melting temperature of the metal or metal alloy that is to be converted into foam,
    • The crucible (11) containing metal or metal alloy used to produce foam, is delivered to the stirring section (2) having a temperature 100 - 300 °C higher than the melting temperature of the metal or metal alloy that is to be turned into foamed and the metal or metal alloy to be foamed is added into said crucible,
    • Waiting for the temperature of the metal or metal alloy that is to be turned into foam present inside the crucible (11) to increase and reach the temperature range where the metal or metal alloy becomes semi solid,
    • Taking the movable molds (8) from the mold inlet cover (4) and moving them to the pre-heating section (1) and bringing the temperature to the pre heating section's (1) temperature,
    • When the material inside the crucible (11) is softened and crushed, the reinforced material that has been passed through preheating is added into the crucible (11) via the reinforced material inlet (25),
    • In order to ensure that the metal or metal alloy that is to be foamed, inside the crucible (11) is kept at a semi solid temperature range, if the viscosity of the mixture (from being a semi solid to being liquid) is low according to the information obtained from the pressure and temperature sensors (19 and 20) metal or metal alloy to be foamed is added to the mixture in order to increase the viscosity of the mixture, during this time, no more reinforcement material is added; and if the viscosity is high the stirring procedure is continued without adding metal or metal alloy to the mixture, thereby keeping the mixture at a semi solid state and continuing this process until the addition of reinforcement material is finished.
    • After the mixture is prepared at the desired amount, the foaming powder found inside the foaming powder vessel (21) is added into the mixture through the foaming powder inlet (22) and the stirring procedure is carried out quickly and at this moment, metal or metal alloy is continue to be added into the mixture,
    • When a homogenous mixture has been provided, the movable mold is shifted and the bottom of the crucible (11) is opened, and the mixture is pushed by a pushing piston (17) from the bottom of the crucible (11) and transferred to the cavity of the movable mold (8),
    • When the mixture is pushed by the piston (17) the mixture is moved at a constant quick speed in the mold bearing (9) by means of a pushrod (15) and the mixture fills the cavity of the movable mold,
    • The movable mold (8) is taken into the foaming section (3) having a temperature 50 - 70 °C higher than the melting temperature of the metal or metal alloy that is to be foamed,
    • When the waiting time depending on the amount of the mixture is fulfilled the pushrod (15) pushes the outlet cover (5) of the mold (8) and the mixture is taken out of the furnace,
    • The foam material inside the mold is quickly cooled by means of cooling fans (16).
  2. A particle reinforced composite metal stirring method; characterized in that;
    • The reinforcement powders are pre heated at the pre heating (1) section and are brought to process temperatures,
    • The pre heating section (1) of the furnace is brought to a temperature 40 - 60 °C below the melting temperature of the metal or metal alloy that is to be turned into particle reinforced composite metal,
    • The crucible (11) containing metal or metal alloy used to produce particle reinforced composite metal production is taken to the stirring section (2) of the furnace and the temperature of the stirring section (2) is 100 - 300 °C higher than the melting temperature of the metal or metal alloy used to produce composite metal production,
    • The metal or metal alloy used to produce composite metal production inside the crucible (11) located at the stirring section (2) is kept until the temperature thereof is increased to the temperature range wherein said metal or metal alloy is at a semi solid state,
    • When the material inside the crucible (11) is softened and crushed, the reinforced material that has been passed through preheating is added into the crucible (11) via the reinforced material inlet (25),
    • In order to ensure that the material, inside the crucible is kept at a semi solid temperature range, when the temperature exceeds the semi solid temperature, the metal or metal alloy that is used to produce composite metal is added to the crucible (11) or the addition of the metal or metal alloy, is performed by an automatic control unit according to the information obtained from the pressure sensors (20), the viscosity of the mixture is controlled by adding metal or metal alloy according to the information obtained from the pressure and temperature sensors (19 and 20), in order to keep the mixture at a semi solid state, if the viscosity of the mixture is low metal or metal alloy used to produce composite metal is added to the mixture in order to increase the viscosity of the mixture, and if the viscosity of the mixture is high the stirring procedure is continued without adding metal to the mixture, and if the temperature of the mixture increases but the viscosity decreases, reinforcement material is not added to the mixture but only metal or metal alloy is added.
    • The mixture is checked if it is at a semi solid state or not by determining by means of the pressure and temperature sensors (19 and 20) controlled by the control unit, and again the semi solid state is ensured by the commands submitted to the stirrer and metal addition mechanism.
    • After reinforcement material is added the stirring procedure is carried out by moving the stirrers up and down and at the same time the stirrers move inside the crucible (11) radially or elliptically or in zig zag shape by changing place on the orbit in order to carry out the kneading and stirring procedure together until the material is homogenously mixed by means of stirrers following the addition of reinforcement material,
    • When a homogenous mixture is obtained, the composite mixture inside the crucible (11) is taken out and poured into molds thereby a particle reinforced composite material production is obtained by means of a casting or production method.
  3. A method according claim 1 and 2 characterized in that; the reinforcement material is SiC, B4C, Al2O3, TiC, and other carbides, oxides, nitrides and ceramic.
  4. A method according to claims 1 or 2, characterized in that the kneading and stirring apparatus (18) which carries out the kneading and stirring procedure at the same time with the homogenously mixing of the material, is moved up and down, and at the same time, radially, elliptically within the crucible (11) or changes place on a zig zag orbit.
  5. A continuous composite metal foam production method according to claim 1, characterized in that the foaming powder is TiH2 and CaCO3.
  6. A device for producing composite metal or for performing particle reinforced composite metal stirring, characterized in that; it comprises three sections, which are the pre heating section (1), stirring section (2) and foaming section (3), each section (1,2,3) being heated with separate resistance groups (7); wherein temperature controls can be carried out separately; and wherein the temperature of the pre heating (1)section of the furnace is at a temperature lower than 40 - 60 °C, the temperature of the foaming section(3) is at temperature which is higher than 50 - 70 °C of the melting temperature of the metal or metal alloy that is to be foamed, and wherein the temperature of the stirring section (2) is 100 - 300 °C higher than the melting temperature of the metal or metal alloy that is to be foamed.
  7. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6, characterized in that; the stirring section (2) comprises a crucible (2), inlet (23) for the metal or metal alloy material that is to be foamed, matrix material vessel (24), reinforcement material inlet (25), foaming powder inlet (22), protective gas inlet (14) and a stirring mechanism (27) together with a top stirring cover (6), kneading and stirring apparatus (18); wherein protective gas (N2 or argon) is continuously sprayed onto the crucible (11).
  8. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the reinforcement material, matrix material and foaming powder additions (25,23, and 22) are provided by the automatic control unit, according to the information obtained from the sensors (19 and 20).
  9. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the material inside the metal or metal alloy vessel (24) that is to be foamed or turned into particle reinforced composite, is divided into small pieces.
  10. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the material inside the metal or metal alloy vessel (24) that is to be foamed or turned into particle reinforced composite is prepared and processed in particle or powder form made from metal plate, ingot or recycled materials.
  11. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the metal or metal alloy material that is to be foamed or turned into particle reinforced composite, can be comprised of aluminum, copper, titanium, nickel or other metals.
  12. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the kneading and stirring apparatus (18) are operated by the kneading stirring mechanism (27), the pressure sensors (20) and the temperature sensors (19) are located inside the stirring mechanism (27), that the stirring procedure is carried out by the automatic control unit in a controlled manner according to the viscosity/stability and temperature information obtained from the pressure and temperature sensors (19 and 20).
  13. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the mixture is kept at a semi solid state during the stirring period, and if the viscosity is low (from being a semi solid to being liquid) the viscosity is increased by adding metal or metal alloy to be foamed, and if the viscosity is high no additional metal is added to the mixture but the stirring process is continued and the pressure and temperature sensors (19 and 20) controlled by the control unit are used to determine if the mixture is at a semi solid state and the stirring process is carried out again by the commands sent to the stirrer and metal addition mechanism by the control unit.
  14. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the kneading and stirring apparatus (18) connected to the stirring mechanism (27) carries out an up and down (27b) motion and a radial (27a) movement and the stirring times and selection of stirring rods, their attachment and dismantling are controlled by the electronic system.
  15. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the ends of the kneading and stirring apparatus (18) connected to the stirring mechanism (27) can be flat, spiral or perforated.
  16. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the holes in the perforated kneading and stirring apparatus (18) ends can have round, square, elliptical, rectangular, or polygonal geometrical shapes and each hole can be of the same size or can be in different sizes.
  17. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the material of the kneading and stirring apparatus (18) is coated with high temperature resistant material such as graphite or ceramic.
  18. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the surface of the kneading and stirring apparatus (18) is coated with a mixture prepared from silicium, carbide powder and colloidal silica.
  19. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that it comprises a plurality of crucibles (11) which can be moved such that they can be used in sequence in order to provide a semi solid ready mixture constantly, that the empty crucible (11) is pushed forward out of the stirring section (2), a new crucible (11) is pushed in place, the next crucible loaded with the mixture is pushed into queue to be aligned with the molds and that this procedure is repeated to provide ready mixtures continuously.
  20. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the bottom parts of the crucibles (11) are open, that the front section of the movable mold also functions as the crucible bottom (25), and that said bottom part is at a closed position during the stirring processes.
  21. A device for producing composite metal or for performing particle reinforced composite metal stirring according to claim 6 or 7, characterized in that; the movable molds are moved on a mold bed (9) made of firebricks that extend from the inlet cover (4) of the mold to the outlet cover of the mold.
  22. A device to produce composite metal foam and for stirring particle reinforced composite metal according to claim 6 or 7, characterized in that the crucible (11) material is SiC, Al2O3 or graphite.
  23. A device to produce composite metal foam and for stirring particle reinforced composite metal according to claim 6 or 7, characterized in that the bottom of the crucible (12) is made of high temperature resistant and high heat conductive material, preferably graphite.
  24. A device to produce composite metal foam and for stirring particle reinforced composite metal according to claim 6 or 7, characterized in that the vessel (13) is made of high temperature resistant and low heat conductive material.
  25. A device to produce composite metal foam and for stirring particle reinforced composite metal according to claim 6 and 7, characterized in that the vessel (13) is gas concrete or ceramic foam.
  26. A device to produce composite metal foam or for stirring particle reinforced composite metal according to claim 6, characterized in that, a fan (16) mechanism is present on the mold exit cover so that the foam material taken out of the furnace can be cooled down.
EP14835731.2A 2013-12-17 2014-12-10 Continuous composite metal foam production and method and device for stirring particle reinforced composite metal Not-in-force EP3083105B1 (en)

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TR201314802 2013-12-17
PCT/TR2014/000497 WO2015094139A2 (en) 2013-12-17 2014-12-10 Continuous composite metal foam production and method and device for stirring particle reinforced composite metal

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EP3083105B1 true EP3083105B1 (en) 2017-11-15

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CN110145910B (en) * 2019-05-20 2021-09-03 江苏瑞安特重型机械有限公司 High-efficiency cooling machine
CN110756777B (en) * 2019-12-03 2023-10-27 元泰达新材料股份有限公司 Foamed aluminum production process line and production process thereof
CN116103521B (en) * 2023-02-15 2024-02-02 重庆大学 Preparation method of metal titanium particle reinforced magnesium-based composite material

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JPS5017298B1 (en) * 1971-04-19 1975-06-19
US5281251A (en) * 1992-11-04 1994-01-25 Alcan International Limited Process for shape casting of particle stabilized metal foam
DE4326982C1 (en) * 1993-08-11 1995-02-09 Alcan Gmbh Process and apparatus for manufacturing formed (shaped, moulded) parts from metal foam
DE60301947T2 (en) * 2002-02-01 2006-07-13 Cymat Corp., Mississauga Use of Neuregulin-ß as Indicator and / or Target
DE102006031213B3 (en) * 2006-07-03 2007-09-06 Hahn-Meitner-Institut Berlin Gmbh Process to produce metal foam by introduction of sub-microscopic or nanoparticles into molten metal mix

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