EP3321383B1 - Process for producing aluminum-based metal composite, aluminum-based composite obtained by using the same, and aluminum-based structure having the aluminum-based composite - Google Patents
Process for producing aluminum-based metal composite, aluminum-based composite obtained by using the same, and aluminum-based structure having the aluminum-based composite Download PDFInfo
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- EP3321383B1 EP3321383B1 EP16198352.3A EP16198352A EP3321383B1 EP 3321383 B1 EP3321383 B1 EP 3321383B1 EP 16198352 A EP16198352 A EP 16198352A EP 3321383 B1 EP3321383 B1 EP 3321383B1
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- aluminum
- carbide
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- ceramic material
- based metal
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims description 174
- 229910052782 aluminium Inorganic materials 0.000 title claims description 163
- 239000002131 composite material Substances 0.000 title claims description 49
- 238000000034 method Methods 0.000 title claims description 36
- 239000002905 metal composite material Substances 0.000 title description 2
- 229910052751 metal Inorganic materials 0.000 claims description 48
- 239000002184 metal Substances 0.000 claims description 48
- 229910010293 ceramic material Inorganic materials 0.000 claims description 33
- 229910021538 borax Inorganic materials 0.000 claims description 26
- 239000004328 sodium tetraborate Substances 0.000 claims description 26
- 235000010339 sodium tetraborate Nutrition 0.000 claims description 26
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 18
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 18
- 239000001301 oxygen Substances 0.000 claims description 18
- 229910052760 oxygen Inorganic materials 0.000 claims description 18
- 229910052708 sodium Inorganic materials 0.000 claims description 18
- 239000011734 sodium Substances 0.000 claims description 18
- 239000000758 substrate Substances 0.000 claims description 14
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 13
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 13
- 229910000838 Al alloy Inorganic materials 0.000 claims description 12
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 9
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 9
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 claims description 8
- 229910052580 B4C Inorganic materials 0.000 claims description 8
- 229910052582 BN Inorganic materials 0.000 claims description 8
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 8
- 229910033181 TiB2 Inorganic materials 0.000 claims description 8
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 8
- 229910026551 ZrC Inorganic materials 0.000 claims description 8
- JXOOCQBAIRXOGG-UHFFFAOYSA-N [B].[B].[B].[B].[B].[B].[B].[B].[B].[B].[B].[B].[Al] Chemical compound [B].[B].[B].[B].[B].[B].[B].[B].[B].[B].[B].[B].[Al] JXOOCQBAIRXOGG-UHFFFAOYSA-N 0.000 claims description 8
- OTCHGXYCWNXDOA-UHFFFAOYSA-N [C].[Zr] Chemical compound [C].[Zr] OTCHGXYCWNXDOA-UHFFFAOYSA-N 0.000 claims description 8
- UQVOJETYKFAIRZ-UHFFFAOYSA-N beryllium carbide Chemical compound [Be][C][Be] UQVOJETYKFAIRZ-UHFFFAOYSA-N 0.000 claims description 8
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 claims description 8
- 229910003460 diamond Inorganic materials 0.000 claims description 8
- 239000010432 diamond Substances 0.000 claims description 8
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 8
- 229910052702 rhenium Inorganic materials 0.000 claims description 8
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 claims description 8
- 229910052726 zirconium Inorganic materials 0.000 claims description 8
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 5
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 5
- 239000011156 metal matrix composite Substances 0.000 description 7
- 230000003287 optical effect Effects 0.000 description 7
- 238000012360 testing method Methods 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- 238000007676 flexural strength test Methods 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 230000002411 adverse Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/14—Making alloys containing metallic or non-metallic fibres or filaments by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/20—Making alloys containing metallic or non-metallic fibres or filaments by subjecting to pressure and heat an assembly comprising at least one metal layer or sheet and one layer of fibres or filaments
Definitions
- the present invention generally relates to a process for producing aluminum-based metal composite, an aluminum-based composite obtained by using the same, and an aluminum-based structure having the said aluminum-based composite.
- Metal matrix composite is a novel composite obtained by using special process to distribute different kinds and types of ceramic and non-metallic strengthened phase uniformly in a continuous metallic substrate. It has the advantages of metallic substrate and strengthened phase, e.g. high specific strength and specific stiffness, heat-resisting, wear-resisting, good lateral property and interlaminar shear strength, high temperature and volume stability, and good design ability of material. Therefore, it was first used in aerospace industry. S.V. PRASAD, R. ASTHANA: "Aluminum metal-matrix composites for automotive applications: tribological considerations",TRIBOLOGY LETTERS, vol. 17, no.
- An object of the present invention is to provide a process for producing aluminum-based composite in order to improve the mechanical strength of an aluminum-based metal.
- Another object of the present invention is to provide an aluminum-based composite having better mechanical strength.
- Another object of the present invention is to provide an aluminum-based structure having better mechanical strength.
- the process for producing aluminum-based composite applies borax on the surface of an aluminum-based metal and heats such metal to a temperature over the melting point of borax.
- the aluminum-based metal is aluminum metal.
- the aluminum-based metal is aluminum alloy.
- borax is mixed with a ceramic material before being applied on the surface of the aluminum-based metal and heated over 743°C, wherein the ratio of the ceramic material with respect to borax is in the range between 0.01 to 90 wt%.
- the hardness of the ceramic material is greater than the hardness of aluminum.
- the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof.
- the aluminum-based composites of the present invention includes 7 to 9 atomic% of aluminum, 11 to 13 atomic% of sodium, and 79 to 81 atomic% of oxygen.
- the aluminum-based composites includes 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic% of oxygen.
- the aluminum-based composites further includes ceramic materials, wherein the content of aluminum is in the range between 2 to 3 wt%, the content of sodium is in the range between 3.5 to 5 wt%, the content of oxygen is in the range between 26 to 27 wt%, and the content of the ceramic material is in the range between 65 to 68 wt.%.
- the hardness of the ceramic material is greater than the hardness of aluminum.
- the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof.
- the aluminum-based structure includes an-aluminum based substrate formed by an aluminum-based metal and an aluminum-based composite disposed in the aluminum-based substrate.
- the aluminum-based composite includes 7 to 9 atomic% of aluminum, 11 to 13 atomic% of sodium, and 79 to 81 atomic % of oxygen.
- the aluminum-based composite includes 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic % of oxygen.
- the aluminum-based composite further includes a ceramic material, wherein the content of aluminum is in the range between 2 to 3 wt%, the content of sodium is in the range between 3.5 to 5 wt%, the content of oxygen is in the range between 26 to 27 wt%, and the content of the ceramic material is in the range between 65 to 68 wt.%.
- the hardness of the ceramic material is larger than the hardness of aluminum.
- the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, titanium oxide, boron nitride, diamond, and the combination thereof.
- the present invention of the process for producing aluminum-based composite applies borax on the surface of an aluminum-based metal and heats such metal to a temperature over the melting point of borax. More particularly, the melting point of borax is 743°C .
- the aluminum-based metal may be aluminum metal or aluminum alloy.
- borax is tiled on the aluminum-based metal consisting of aluminum metal, aluminum alloy, or the combination thereof, and such metal and borax are heated over 743°C in a high temperature environment such as a high temperature furnace to make the aluminum react with borax to form a strengthened phase.
- a high temperature environment such as a high temperature furnace
- the reaction takes place whether inert gas (e.g. Ar) exists or not.
- inert gas e.g. Ar
- the aluminum-based metal treating method of the present invention may be conducted in an aerobic environment.
- the brighter area represents the aluminum not treated by the aluminum-based metal treating method of the present invention, i.e. the aluminum matrix
- the darker area represents the aluminum treated by the aluminum-based metal treating method of the present invention, i.e. the aluminum-based composite.
- Berkovich hardness and Young's modulus tests are carried out by a nanoindenter (Nanoindenter XP, MTS Inc., USA) at the location indicated by the numbers 1, 2, 3, 4 in the brighter area and at the location indicated by the numbers 5, 6, 7, 8 in the darker area. The results are listed in Table 1. Table 1 No.
- the average Berkovich hardness and Young's modulus of aluminum are raised respectively to 7.65 and 1.68 times the original ones.
- the average Berkovich hardness and Young's modulus of 5083 aluminum alloy are raised respectively to 4.65 and 1.37 times the original ones.
- the method of the present invention is able to improve the mechanical strength of an aluminum-based metal.
- FIG. 2 illustrates an optical microscope photo of the cross section of a piece of aluminum treated by the aluminum-based metal treating method of the present invention.
- the aluminum-based metal treated by the method of the present invention bounds well with the aluminum matrix, and there isn't any obvious gap between the two. Accordingly, there exists good compatibility between the two, wherein the binding on the interface is well.
- the darker area represents the aluminum not treated by the aluminum-based metal treating method of the present invention, wherein the brighter area represents the aluminum treated by the method of the present invention.
- Results shown in FIGs. 4A-4C can be obtained by carrying out element analysis of the brighter area. It can be known respectively from FIG.4A , FIG. 4B , and FIG. 4C that the brighter area includes about 8 atomic% of aluminum, about 12 atomic% of sodium, and about 80 atomic% of oxygen.
- the aluminum-based metal treated by the method of the present invention is an aluminum-based composite having better mechanical strength.
- the aluminum-based composite includes 7 to 9 atomic% of aluminum, 11 to 13 atomic% of sodium, and 79 to 81 atomic % of oxygen.
- the aluminum-based composite includes 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic% of oxygen.
- the darker area represents the 5083 aluminum alloy not treated by the method of the present invention, wherein the brighter area represents the aluminum treated by the method of the present invention.
- Results shown in FIGs. 4E-4H can be obtained by carrying out element analysis of the brighter area. It can be known respectively from FIG.4E , FIG. 4F , FIG. 4G , and FIG. 4H that the brighter area includes about 12 atomic% of sodium, about 8 atomic% of magnesium, about 7 atomic% of aluminum, and about 73 atomic% of oxygen.
- borax is mixed with a ceramic material first and then applied on the surface of the aluminum-based metal and heated over 743°C. More particularly, ceramic material having greater strength is added into borax to increase further the mechanical strength such as Berkovich hardness and Young's modulus.
- the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof.
- the ratio of the ceramic material with respect to borax is in the range between 0.01 to 90 wt%, and is preferably 66 wt% ceramics material with respect to 33 wt% borax.
- borax is mixed with silicon carbide first, wherein the ratio is 66 wt% silicon carbide with respect to 33 wt% borax.
- Such mixture is applied on the surface of a piece of aluminum alloys and heated over 743°C.
- the brighter area represents silicon carbide, wherein the darker area represents a strengthened phase formed by the reaction between borax and aluminum. It is known that by carrying out tests to the entirety, the Berkovich hardness and Young's modulus tests of the heated metal are respectively 9.7Gpa and 140Gpa.
- high-strength ceramic material such as silicon carbide can seep into the aluminum phase to strengthen the aluminum-based metal.
- silicon carbide in 5083 aluminum composite, tungsten carbide in aluminum composite, titanium carbide in 5083 aluminum composite, titanium oxide in aluminum composite, and titanium oxide in 5083 aluminum composite are respectively shown in FIGs. 5B-5F .
- an aluminum-based composite having better mechanical strength containing ceramic material can be obtained.
- the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, titanium oxide, boron nitride, diamond, and the combination thereof.
- the ratio of the ceramic material with respect to borax is in the range between 0.01 to 90 wt%, and is preferably 66 wt% ceramics material with respect to 33 wt% borax .
- the above-described aluminum-based composite can be inserted into a aluminum-based substrate to form an aluminum-based structure.
- the aluminum-based structure includes an aluminum-based substrate formed by an aluminum-based metal and an aluminum-based composite disposed in the aluminum-based substrate.
- the aluminum-based substrate formed by an aluminum-based metal sandwiches multi-layer reinforcements.
- the aluminum-based structure has a single aluminum-based composite layer.
- the aluminum-based structure is not limited to having a single aluminum-based composite layer, and the aluminum-based composite layer is not limited to being disposed between two aluminum metal layers.
- Three-point flexural strength test is carried out respectively to a piece of aluminum metal (no layer), an aluminum-based structure having a single aluminum-based composite layer (1 layer), and an aluminum-based structure having four aluminum-based composite layers (4 layers) to evaluate their flexural strength.
- the flexural strength test is carried out by a flexural strength testing system (Instron 5900, Instron Inc., USA) under the condition of 3 ⁇ 10 4 in/s pressing speed and 6mm distance between adjacent points.
- the flexural strength of the aluminum-based structure having four aluminum-based composite layers is obviously greater than that of the aluminum metal, wherein the flexural strength of the aluminum-based structure having a single aluminum-based composite layer is also greater than that of the aluminum metal. Accordingly, the mechanical strength of the aluminum-based structure of the present invention is better than that of the aluminum metal.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
Description
- The present invention generally relates to a process for producing aluminum-based metal composite, an aluminum-based composite obtained by using the same, and an aluminum-based structure having the said aluminum-based composite.
- Metal matrix composite (MMC) is a novel composite obtained by using special process to distribute different kinds and types of ceramic and non-metallic strengthened phase uniformly in a continuous metallic substrate. It has the advantages of metallic substrate and strengthened phase, e.g. high specific strength and specific stiffness, heat-resisting, wear-resisting, good lateral property and interlaminar shear strength, high temperature and volume stability, and good design ability of material. Therefore, it was first used in aerospace industry. S.V. PRASAD, R. ASTHANA: "Aluminum metal-matrix composites for automotive applications: tribological considerations",TRIBOLOGY LETTERS, vol. 17, no. 3, 30 October 2004 (2004-10-30), pages 445-453,Springer Science describes an aluminum metal-matrix composites for automotive applications wherein reinforcement of aluminum alloys with solid lubricants, hard ceramic particles, short fibers and whiskers results in advanced metal-matrix composites (MMC) with precise balances of mechanical, physical and tribological characteristics.
- There are still some issues to be solved for the mass production and the commercialization of metal matrix composite. 1. High temperature is necessary to ensure efficient liquidity of the metallic substrate for it to adequately penetrate into the gap in the strengthened phase to form a composite, wherein adverse interface reaction sometimes takes place between the strengthened phase and the metallic substrate. 2. The compatibility between the strengthened phase and the metallic substrate is poor. 3. The strengthened phase is required to be uniformly distributed in the metallic substrate in accordance with the content and direction specified by the design.
- An object of the present invention is to provide a process for producing aluminum-based composite in order to improve the mechanical strength of an aluminum-based metal.
- Another object of the present invention is to provide an aluminum-based composite having better mechanical strength.
- Another object of the present invention is to provide an aluminum-based structure having better mechanical strength.
- The process for producing aluminum-based composite applies borax on the surface of an aluminum-based metal and heats such metal to a temperature over the melting point of borax.
- In one embodiment of the present invention, the aluminum-based metal is aluminum metal.
- In one embodiment of the present invention, the aluminum-based metal is aluminum alloy.
- In one embodiment of the present invention, borax is mixed with a ceramic material before being applied on the surface of the aluminum-based metal and heated over 743°C, wherein the ratio of the ceramic material with respect to borax is in the range between 0.01 to 90 wt%.
- In one embodiment of the present invention, the hardness of the ceramic material is greater than the hardness of aluminum.
- In one embodiment of the present invention, the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof.
- The aluminum-based composites of the present invention includes 7 to 9 atomic% of aluminum, 11 to 13 atomic% of sodium, and 79 to 81 atomic% of oxygen.
- In one embodiment of the present invention, the aluminum-based composites includes 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic% of oxygen.
- In one embodiment of the present invention, the aluminum-based composites further includes ceramic materials, wherein the content of aluminum is in the range between 2 to 3 wt%, the content of sodium is in the range between 3.5 to 5 wt%, the content of oxygen is in the range between 26 to 27 wt%, and the content of the ceramic material is in the range between 65 to 68 wt.%.
- In one embodiment of the present invention, the hardness of the ceramic material is greater than the hardness of aluminum.
- In one embodiment of the present invention, the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof.
- The aluminum-based structure includes an-aluminum based substrate formed by an aluminum-based metal and an aluminum-based composite disposed in the aluminum-based substrate. The aluminum-based composite includes 7 to 9 atomic% of aluminum, 11 to 13 atomic% of sodium, and 79 to 81 atomic % of oxygen.
- In one embodiment of the present invention, the aluminum-based composite includes 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic % of oxygen.
- In one embodiment of the present invention, the aluminum-based composite further includes a ceramic material, wherein the content of aluminum is in the range between 2 to 3 wt%, the content of sodium is in the range between 3.5 to 5 wt%, the content of oxygen is in the range between 26 to 27 wt%, and the content of the ceramic material is in the range between 65 to 68 wt.%.
- In one embodiment of the present invention, the hardness of the ceramic material is larger than the hardness of aluminum.
- In one embodiment of the present invention, the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, titanium oxide, boron nitride, diamond, and the combination thereof.
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FIG. 1 is an optical microscope photo of one embodiment of the present invention; -
FIG. 2 is an optical microscope photo of the cross section of a piece of aluminum treated by the present invention; -
FIG. 3 is a scanning electron microscope photo of one embodiment of the present invention; -
FIG. 4A illustrates the aluminum element analysis result of one embodiment of the present invention; -
FIG. 4B illustrates the sodium element analysis result of one embodiment of the present invention; -
FIG. 4C illustrates the oxygen element analysis result of one embodiment of the present invention; -
FIG. 4D is a scanning electron microscope photo of one embodiment of the present invention; -
FIG. 4E illustrates the sodium element analysis result of one embodiment of the present invention; -
FIG. 4F illustrates the magnesium element analysis result of one embodiment of the present invention; -
FIG. 4G illustrates the aluminum element analysis result of one embodiment of the present invention; -
FIG. 4H illustrates the oxygen element analysis result of one embodiment of the present invention; -
FIG. 5A is an optical microscope photo of one embodiment of the present invention; -
FIGs. 5B-5F are optical microscope photos of different embodiments of the present invention; -
FIG. 6 is a photo of an aluminum-based structure having a single aluminum-based composite layer in one embodiment of the present invention; -
FIG. 7 illustrates the flexural strength testing result of aluminum metal, an aluminum-based structure of the present invention having a single aluminum-based composite layer, and an aluminum-based structure of the present invention having four aluminum-based composite layers. - The present invention of the process for producing aluminum-based composite applies borax on the surface of an aluminum-based metal and heats such metal to a temperature over the melting point of borax. More particularly, the melting point of borax is 743°C . The aluminum-based metal may be aluminum metal or aluminum alloy.
- More particularly, borax is tiled on the aluminum-based metal consisting of aluminum metal, aluminum alloy, or the combination thereof, and such metal and borax are heated over 743°C in a high temperature environment such as a high temperature furnace to make the aluminum react with borax to form a strengthened phase. During the process, the reaction takes place whether inert gas (e.g. Ar) exists or not. In other words, the aluminum-based metal treating method of the present invention may be conducted in an aerobic environment.
- As shown in the optical microscope photo (VHX-5000, Keyence Inc., USA) of
FIG. 1 , the brighter area represents the aluminum not treated by the aluminum-based metal treating method of the present invention, i.e. the aluminum matrix, wherein the darker area represents the aluminum treated by the aluminum-based metal treating method of the present invention, i.e. the aluminum-based composite. Berkovich hardness and Young's modulus tests are carried out by a nanoindenter (Nanoindenter XP, MTS Inc., USA) at the location indicated by thenumbers numbers Table 1 No. Berkovich hardness (GPa) Young's modulus (GPa) 1 0.534 71.42 2 0.677 79.19 3 0.655 73.35 4 0.534 76.84 5 4.13 124.4 6 4.33 122.2 7 5.01 132.8 8 4.89 128.5 - As shown in Table 1, the mechanical strength of the aluminum treated by the method of the present invention is superior to that of the aluminum not treated by the aluminum based metal treating method of the present invention. More particularly, regarding the aluminum treated by the method of the the present invention, at the locations indicated by the
numbers numbers - The above Berkovich hardness and Young's modulus tests are also carried out on a 5083 aluminum alloy, wherein the results are listed in Table 2.
Table 2 No. Berkovich hardness (GPa) Young's modulus (GPa) 1 1.081 72.33 2 1.121 71.88 3 0.983 73.54 4 1.122 70.09 5 4.87 125.8 6 5.22 131.4 7 4.98 121.5 8 5.01 126.1 - As shown in Table 2, the mechanical strength of the 5083 aluminum alloy treated by the method of the present invention is superior to that of the 5083 aluminum alloy not treated by the aluminum based metal treating method of the present invention. More particularly, regarding the 5083 aluminum alloy treated by the method of the the present invention, at the locations indicated by the
numbers numbers - Accordingly, the method of the present invention is able to improve the mechanical strength of an aluminum-based metal.
- On the other hand, there exists good compatibility between the aluminum-based metal treated by the aluminum-based metal treating method of the present invention and the aluminum-based metal not treated by the aluminum-based metal treating method of the present invention.
FIG. 2 illustrates an optical microscope photo of the cross section of a piece of aluminum treated by the aluminum-based metal treating method of the present invention. As shown inFIG. 2 , the aluminum-based metal treated by the method of the present invention bounds well with the aluminum matrix, and there isn't any obvious gap between the two. Accordingly, there exists good compatibility between the two, wherein the binding on the interface is well. - As shown in the scanning electron microscope photo (Nova 230 Variable Pressure SEM (VP-SEM) (at 10 kV accelerating voltage), FEI Inc., USA) of
FIG. 3 , the darker area represents the aluminum not treated by the aluminum-based metal treating method of the present invention, wherein the brighter area represents the aluminum treated by the method of the present invention. Results shown inFIGs. 4A-4C can be obtained by carrying out element analysis of the brighter area. It can be known respectively fromFIG.4A ,FIG. 4B , andFIG. 4C that the brighter area includes about 8 atomic% of aluminum, about 12 atomic% of sodium, and about 80 atomic% of oxygen. Specifically, the aluminum-based metal treated by the method of the present invention is an aluminum-based composite having better mechanical strength. The aluminum-based composite includes 7 to 9 atomic% of aluminum, 11 to 13 atomic% of sodium, and 79 to 81 atomic % of oxygen. Preferably, the aluminum-based composite includes 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic% of oxygen. - As a different embodiment shown in the scanning electron microscope photo (Nova 230 Variable Pressure SEM (VP-SEM) (at 10 kV accelerating voltage), FEI Inc., USA) of
FIG. 4D , the darker area represents the 5083 aluminum alloy not treated by the method of the present invention, wherein the brighter area represents the aluminum treated by the method of the present invention. Results shown inFIGs. 4E-4H can be obtained by carrying out element analysis of the brighter area. It can be known respectively fromFIG.4E ,FIG. 4F ,FIG. 4G , andFIG. 4H that the brighter area includes about 12 atomic% of sodium, about 8 atomic% of magnesium, about 7 atomic% of aluminum, and about 73 atomic% of oxygen. - In a different embodiment, borax is mixed with a ceramic material first and then applied on the surface of the aluminum-based metal and heated over 743°C. More particularly, ceramic material having greater strength is added into borax to increase further the mechanical strength such as Berkovich hardness and Young's modulus. The ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof. The ratio of the ceramic material with respect to borax is in the range between 0.01 to 90 wt%, and is preferably 66 wt% ceramics material with respect to 33 wt% borax.
- In one embodiment, borax is mixed with silicon carbide first, wherein the ratio is 66 wt% silicon carbide with respect to 33 wt% borax. Such mixture is applied on the surface of a piece of aluminum alloys and heated over 743°C. As shown in the optical microscope photo (VHX-5000, Keyence Inc., USA) of
FIG. 5A , the brighter area represents silicon carbide, wherein the darker area represents a strengthened phase formed by the reaction between borax and aluminum. It is known that by carrying out tests to the entirety, the Berkovich hardness and Young's modulus tests of the heated metal are respectively 9.7Gpa and 140Gpa. Accordingly, with the aluminum-based metal treating method of the present invention, high-strength ceramic material such as silicon carbide can seep into the aluminum phase to strengthen the aluminum-based metal. In different embodiments, silicon carbide in 5083 aluminum composite, tungsten carbide in aluminum composite, titanium carbide in 5083 aluminum composite, titanium oxide in aluminum composite, and titanium oxide in 5083 aluminum composite are respectively shown inFIGs. 5B-5F . - In other words, by premixing borax with a ceramic material and applying such mixture on the surface of the aluminum-based metal and heating the said metal over 743°C, an aluminum-based composite having better mechanical strength containing ceramic material can be obtained. The ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, titanium oxide, boron nitride, diamond, and the combination thereof. The ratio of the ceramic material with respect to borax is in the range between 0.01 to 90 wt%, and is preferably 66 wt% ceramics material with respect to 33 wt% borax .
- The above-described aluminum-based composite can be inserted into a aluminum-based substrate to form an aluminum-based structure. More particularly, the aluminum-based structure includes an aluminum-based substrate formed by an aluminum-based metal and an aluminum-based composite disposed in the aluminum-based substrate. In other words, the aluminum-based substrate formed by an aluminum-based metal sandwiches multi-layer reinforcements. As an embodiment shown in
FIG. 6 , the aluminum-based structure has a single aluminum-based composite layer. In different embodiments, however, the aluminum-based structure is not limited to having a single aluminum-based composite layer, and the aluminum-based composite layer is not limited to being disposed between two aluminum metal layers. - Three-point flexural strength test is carried out respectively to a piece of aluminum metal (no layer), an aluminum-based structure having a single aluminum-based composite layer (1 layer), and an aluminum-based structure having four aluminum-based composite layers (4 layers) to evaluate their flexural strength. The flexural strength test is carried out by a flexural strength testing system (Instron 5900, Instron Inc., USA) under the condition of 3×10 4 in/s pressing speed and 6mm distance between adjacent points. As shown by the results in
FIG. 7 , the flexural strength of the aluminum-based structure having four aluminum-based composite layers is obviously greater than that of the aluminum metal, wherein the flexural strength of the aluminum-based structure having a single aluminum-based composite layer is also greater than that of the aluminum metal. Accordingly, the mechanical strength of the aluminum-based structure of the present invention is better than that of the aluminum metal. - Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims.
Claims (16)
- An process for producing aluminum-based composite, wherein the aluminum-based metal treating method applies borax on the surface of an aluminum-based metal and heats the aluminum-based metal to a temperature over the melting point of borax, wherein borax is tiled on the aluminum-based metal.
- The aluminum-based metal treating method of claim 1, wherein the aluminum-based metal is aluminum metal.
- The aluminum-based metal treating method of claim 1, wherein the aluminum-based metal is aluminum alloy.
- The aluminum-based metal treating method of claim 1, wherein borax is mixed with a ceramic material before being applied on the surface of the aluminum-based metal and the aluminum-based metal is heated over the melting point of borax, wherein the ratio of the ceramic material with respect to borax is in the range between 0.01 to 90 wt%.
- The aluminum-based metal treating method of claim 1, wherein the hardness of the ceramic material is larger than the hardness of aluminum.
- The aluminum-based metal treating method of claim 1, wherein the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof.
- An aluminum-based composite, comprising:7 to 9 atomic% of aluminum;11 to 13 atomic% of sodium; and79 to 81 atomic% of oxygen.
- The aluminum-based composite of claim 7 comprises 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic% of oxygen.
- The aluminum-based composite of claim 7 further comprises a ceramic material, wherein:the content of aluminum is in the range between 2 to 3 wt%;the content of sodium is in the range between 3.5 to 5 wt%;the content of oxygen is in the range between 26 to 27 wt%; andthe content of the ceramic material is in the range between 65 to 68 wt%.
- The aluminum-based composite of claim 7, wherein the hardness of the ceramic material is larger than the hardness of aluminum.
- The aluminum-based composite of claim 7, wherein the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, titanium oxide, boron nitride, diamond, and the combination thereof.
- An aluminum-based structure, comprising:an aluminum-based substrate formed by an aluminum-based metal;an aluminum-based composite disposed in the aluminum-based substrate, wherein the aluminum-based composite includes:7 to 9 atomic% of aluminum;11 to 13 atomic% of sodium; and79 to 81 atomic% of oxygen.
- The aluminum-based structure of claim 12, wherein the aluminum-based composite includes 8 atomic% of aluminum, 12 atomic% of sodium, and 80 atomic% of oxygen.
- The aluminum-based structure of claim 12, wherein the aluminum-based composite further includes a ceramic material, wherein:the content of aluminum is in the range between 2 to 3 wt%;the content of sodium is in the range between 3.5 to 5 wt%;the content of oxygen is in the range between 26 to 27 wt%; andthe content of the ceramic material is in the range between 65 to 68 wt.%.
- The aluminum-based structure of claim 14, wherein the hardness of the ceramic material is larger than the hardness of aluminum.
- The aluminum-based structure of claim 14, wherein the ceramic material is selected from a group consisting of silicon carbide, tungsten carbide, boron carbide, zirconium carbide, titanium carbide, beryllium carbide, zirconium boride, titanium diboride, rhenium diboride, aluminum boride, aluminum oxide, boron nitride, diamond, and the combination thereof.
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