JP2015508446A - Method for producing a member from MMC (metal matrix composite) with melt sprayed powder in an inert gas atmosphere - Google Patents

Method for producing a member from MMC (metal matrix composite) with melt sprayed powder in an inert gas atmosphere Download PDF

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JP2015508446A
JP2015508446A JP2014531266A JP2014531266A JP2015508446A JP 2015508446 A JP2015508446 A JP 2015508446A JP 2014531266 A JP2014531266 A JP 2014531266A JP 2014531266 A JP2014531266 A JP 2014531266A JP 2015508446 A JP2015508446 A JP 2015508446A
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ディックマン トーマス
ディックマン トーマス
コマンドゥール ベアント
コマンドゥール ベアント
クロークマン ディアク
クロークマン ディアク
シンハ ジェロ
シンハ ジェロ
ペルマー ラルフ
ペルマー ラルフ
ナーゲル クラウディア
ナーゲル クラウディア
シュトアツ アンドレアス
シュトアツ アンドレアス
ヴァイス ホルガー
ヴァイス ホルガー
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Peak Werkstoff GmbH
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02Compacting only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/105Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12Both compacting and sintering
    • B22F3/14Both compacting and sintering simultaneously
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/026Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/04Making non-ferrous alloys by powder metallurgy
    • C22C1/0408Light metal alloys
    • C22C1/0416Aluminium-based alloys
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/10Alloys containing non-metals
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/10Alloys containing non-metals
    • C22C1/1036Alloys containing non-metals starting from a melt
    • C22C1/1042Alloys containing non-metals starting from a melt by atomising
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/02Braking members; Mounting thereof
    • F16D65/12Discs; Drums for disc brakes
    • F16D65/125Discs; Drums for disc brakes characterised by the material used for the disc body
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C49/00Alloys containing metallic or non-metallic fibres or filaments
    • C22C49/14Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00Materials; Production methods therefor
    • F16D2200/0004Materials; Production methods therefor metallic
    • F16D2200/0026Non-ferro
    • F16D2200/003Light metals, e.g. aluminium
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00Materials; Production methods therefor
    • F16D2200/0082Production methods therefor

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Powder Metallurgy (AREA)
  • Braking Arrangements (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Forging (AREA)

Abstract

本発明は一体化された硬質材料を有するアルミニウムまたはAl合金、特にMMC(金属マトリックス複合材)から、不活性ガス雰囲気下で溶融噴霧された粉末を用いて部材を製造する方法に関し、その際溶融かつ噴霧された金属、特にアルミニウムまたはアルミニウム合金に、噴霧工程の間、またはこれに引き続いて補強粒子を添加し、かつその後部材または半製品を製造するために前記粉末粒子をSPS方法を用いて圧縮する。The present invention relates to a method for producing a component from powders melted and sprayed in an inert gas atmosphere from aluminum or an Al alloy having an integrated hard material, in particular MMC (metal matrix composite), And reinforcing particles are added to the sprayed metal, in particular aluminum or aluminum alloy, during or subsequent to the spraying process, and the powder particles are then compressed using the SPS method to produce parts or semi-finished products To do.

Description

本発明は、一体化された硬質材料を有するアルミニウムまたはAl合金、特にMMC(金属マトリックス複合材)から不活性ガス雰囲気下で溶融噴霧された粉末を用いて部材を製造する方法、および前記方法により製造された部材または半製品に関する。   The present invention relates to a method for producing a member using powder having been melt sprayed in an inert gas atmosphere from aluminum or an Al alloy having an integrated hard material, in particular, MMC (metal matrix composite), and the above method. It relates to manufactured parts or semi-finished products.

噴霧圧縮によりアルミニウム(Al)またはAl合金のような金属から部材を製造することは公知である。噴霧圧縮の際に溶融物は不活性ガス雰囲気(例えば窒素)中で噴霧され、かつターゲットに堆積される。この方法の利点は、非常に高い冷却速度であり、かつ過共晶合金をも製造することが可能であることである。このような方法は、例えばEP0198613、EP0200349、EP0574458およびEP0517882に記載されている。   It is known to produce parts from metals such as aluminum (Al) or Al alloys by spray compression. During spray compression, the melt is sprayed in an inert gas atmosphere (eg, nitrogen) and deposited on the target. The advantage of this method is that it has a very high cooling rate and can also produce hypereutectic alloys. Such methods are described for example in EP0198613, EP0200349, EP0574458 and EP0517882.

これらの方法においては、そのようなMMC半製品を生産するため、補強のためにSiC、BCまたはAlのようなセラミック粒子を加えることが同様に公知である。そのように生産された組織内で成分(例えばSiCとAl)の粒子は密接に結合して存在する。 In these methods it is likewise known to add ceramic particles such as SiC, B 4 C or Al 2 O 3 for reinforcement in order to produce such MMC semi-finished products. Within the tissue so produced, the particles of the components (eg SiC and Al) are in close association.

この方法においては、半製品のほかにいわゆる工程に再び供給することのできる(再圧入)、または副生成物としてさらに処理することのできるスプレーしぶきが発生する。   In this way, in addition to the semi-finished product, a spray spray that can be fed back into the so-called process (reinjection) or can be further processed as a by-product is generated.

代替的にMMC粒子は、鋳造体の鋳造中に液状のAl溶融物に導入される(Duralcan方法)。   Alternatively, MMC particles are introduced into the liquid Al melt during casting of the casting (Duralcan method).

同様に公知のSPS(放電プラズマ焼結)方法においては、粉末または粉末混合体は圧縮され、そのことにより使用目的に対して、理想的には好適な粒子の組織密度が、生産された未完成製品または半製品において達成される。   Similarly, in the known SPS (Discharge Plasma Sintering) method, the powder or powder mixture is compressed, so that an ideally suitable particle structure density for the intended use is produced. Achieved in products or semi-finished products.

従来技術(粉末混合体)における欠点は、一方では補強粒子とマトリックスの間の結合が不完全であること、他方では混合体の完全な均質性が保証されないことである。両欠点は該混合物で生産された部材、例えばブレーキディスクの機械的耐負荷能力に不利な結果をもたらす。この際工程によって条件付けられた残留気孔率を下げ、かつ安定した特性値を設定し、それゆえに安定した機械的特性値を設定するためにさらに、後からの圧密(例えば圧延、鍛造または押出)という工程が追加的に必要である。   The disadvantage in the prior art (powder mixture) is that on the one hand, the bond between the reinforcing particles and the matrix is incomplete, and on the other hand the complete homogeneity of the mixture is not guaranteed. Both disadvantages have a disadvantageous effect on the mechanical load-bearing capacity of components produced with the mixture, for example brake discs. In this case, in order to lower the residual porosity conditioned by the process and to set a stable characteristic value, and therefore to set a stable mechanical characteristic value, it is further referred to as subsequent compaction (eg rolling, forging or extrusion) Additional steps are required.

EP 0198613EP 0986613 EP 0200349EP 0003439 EP 0574458EP 0574458 EP 0517882EP 0517882

従って本発明の課題は、部材または半製品が製造され、補強粒子が溶融噴霧によって生産される球状粉末粒子中に強固にかつ均質に結合しており、かつ後からの圧密工程(例えば圧延、鍛造または押出)を必要としない方法を提供することに基づいている。   Therefore, the object of the present invention is to produce a member or a semi-finished product, in which reinforcing particles are firmly and uniformly bonded in spherical powder particles produced by melt spraying, and a subsequent compaction process (eg rolling, forging). Or providing a method that does not require extrusion.

前記課題は本発明によれば、溶融され、かつ噴霧された金属、特にアルミニウムまたはAl合金に、噴霧工程の間、またはこれに引き続いて強化粒子を添加することにより解決される。   The object is solved according to the invention by adding reinforcing particles to a molten and sprayed metal, in particular aluminum or an Al alloy, during or following the spraying process.

噴霧の間に、補強粒子が強固にかつ均質に結合されている金属(特にAl)MMC粉末粒子が生産される。   During spraying, metal (especially Al) MMC powder particles are produced in which the reinforcing particles are firmly and homogeneously bound.

MMC粒子を後から添加する変法の際に、あらかじめ溶融噴霧により発生されるアルミニウムまたはAl合金の粉末に、篩過後MMC粒子が加えられ、かつ粉末と均質に混合される。   In a modified method in which MMC particles are added later, the MMC particles are added to the aluminum or Al alloy powder generated beforehand by melt spraying after sieving and are mixed homogeneously with the powder.

全変法において、前記粉末粒子は引き続き部材または半製品の生産のためにSPS法を用いて圧縮される。   In all variants, the powder particles are subsequently compressed using the SPS method for the production of parts or semi-finished products.

それによって同様にそれから生産される部材において、MMC硬質材料分布は極めて均質であり、このことはこの部材または半製品の組織構造および機械的性質に実質的に肯定的に作用する。   Thereby in the parts produced therefrom as well, the MMC hard material distribution is very homogeneous, which has a substantially positive effect on the structural structure and mechanical properties of this part or semi-finished product.

このことは本発明により、噴霧の後に続く、高い組織密度(同時に極めて低い粒径の際に)を可能にするSPS工程によって補強される。生産される部材または半製品を後から圧密(例えば圧延、鍛造または押出)する工程はここではもはや必要ない。   This is reinforced by the present invention by an SPS process that allows high tissue density (at the same time very low particle size) following spraying. The process of later compacting (eg rolling, forging or extruding) the produced part or semi-finished product is no longer necessary here.

スプレーしぶきからの金属粒子を使用する場合、これらは補強粒子との混合の前に篩過によって250μm未満の粒子スペクトルに設定される。   If metal particles from spray splash are used, they are set to a particle spectrum of less than 250 μm by sieving prior to mixing with the reinforcing particles.

補強粒子が導入される前記金属合金もしくはアルミニウムまたはAl合金は、例えばケイ素割合5〜25質量%、鉄割合2〜10質量%、ニッケル割合2〜5質量%、マンガン割合0〜3質量%およびマグネシウム割合0〜1質量%を有し、残分はアルミニウムである過共晶アルミニウム合金からなる。   The metal alloy or aluminum or Al alloy into which the reinforcing particles are introduced is, for example, a silicon ratio of 5 to 25 mass%, an iron ratio of 2 to 10 mass%, a nickel ratio of 2 to 5 mass%, a manganese ratio of 0 to 3 mass%, and magnesium. It has a proportion of 0 to 1% by mass, and the balance is a hypereutectic aluminum alloy that is aluminum.

使用されるMMC粒子、もしくは硬質材料粒子は有利には1〜50μmの大きさを有する。SPS工程におけるさらなる加工のために、前述した方法で生産される250μm以下の大きさを有するMMC粉末粒子が使用される。   The MMC particles or hard material particles used preferably have a size of 1 to 50 μm. For further processing in the SPS process, MMC powder particles having a size of 250 μm or less produced by the method described above are used.

本発明は前述した方法と前記方法で最終寸法に近い大きさで生産される部材または半製品、特に高い機械的応力および/または熱応力に耐えられねばならないものに関する。このような部材は、例えば有利には本発明による前記方法で製造することができる乗り物のためのブレーキディスクまたは摩擦リングである。そのようなブレーキディスクまたは摩擦リングは、ソリッドディスク(Monoscheibe)、インサート(Einleger)またはスライダ(Schieber)により生産されたベンチレーテッドディスク(belueftete Scheibe)、または複数部材によって構成されたベンチレーテッドディスクである。   The present invention relates to the above-described method and parts or semi-finished products produced with the method close to the final dimensions, in particular those which have to withstand high mechanical and / or thermal stresses. Such a member is, for example, a brake disc or a friction ring for a vehicle that can advantageously be produced by the method according to the invention. Such a brake disc or friction ring can be a solid disc (Monoschebe), a ventilated disc produced by an insert (Einleger) or a slider (Schieber), or a ventilated disc composed of multiple members. is there.

同様に応力に相当する組織構成におけるそのようなブレーキディスクまたは摩擦リングにおいては、軸方向および/または半径方向に濃度勾配が変化している、すなわち組成はMMC割合に関して製造の間、図1に示すように、部材横断面にわたって応力にふさわしく分散している。   Similarly, in such a brake disc or friction ring in a tissue configuration corresponding to stress, the concentration gradient varies axially and / or radially, ie the composition is shown in FIG. As described above, the stress is appropriately distributed over the member cross section.

濃度勾配変化は同様に、キャリヤーとしての均質な基体上に、追加的に応力にふさわしいMMC粉末を図2に示すようにSPS方法によって機能層として設けることによって達成することができる。   Concentration gradient changes can also be achieved by providing additional functionally suitable MMC powder as a functional layer by SPS method as shown in FIG. 2 on a homogeneous substrate as a carrier.

組成がMMC割合に関して、製造の間に部材横断面にわたって応力にふさわしく分散していることを示す図である。FIG. 4 shows that the composition is properly distributed in stress across the member cross-section during manufacture with respect to the MMC proportion. 濃度勾配変化が、応力にふさわしいMMC粉末を機能層として設けることによって達成されることを示す図である。It is a figure which shows that a concentration gradient change is achieved by providing MMC powder suitable for stress as a functional layer.

Claims (6)

一体化された硬質材料を有するアルミニウムまたはAl合金、特にMMC(金属マトリックス複合材)から、不活性ガス雰囲気下で溶融噴霧された粉末を用いて部材を製造する方法において、溶融かつ噴霧された金属、特にアルミニウムまたはアルミニウム合金に、噴霧工程の間、またはこれに引き続いて補強粒子を添加し、かつその後部材または半製品を製造するために前記粉末粒子をSPS方法を用いて圧縮することを特徴とする製造方法。   Molten and sprayed metal in a method for producing parts from powders melted and sprayed under an inert gas atmosphere from aluminum or an Al alloy having an integrated hard material, in particular MMC (metal matrix composite) Characterized by adding reinforcing particles, particularly to aluminum or aluminum alloy, during or subsequent to the spraying process, and then compressing said powder particles using the SPS method to produce parts or semi-finished products Manufacturing method. 前記MMC粒子が導入される金属割合もしくはAl割合は、主としてケイ素割合5〜25質量%、鉄割合2〜10質量%、ニッケル割合2〜5質量%、マンガン割合0〜3質量%およびマグネシウム割合0〜1質量%を有し、残分はアルミニウムである過共晶アルミニウム合金からなることを特徴とする、請求項1に記載の方法。   The metal ratio or Al ratio into which the MMC particles are introduced is mainly 5-25 mass% of silicon, 2-10 mass% of iron, 2-5 mass% of nickel, 0-3 mass% of manganese, and 0% of magnesium. The process according to claim 1, characterized in that it consists of a hypereutectic aluminum alloy with -1 mass%, the balance being aluminum. 前記球状MMC粒子もしくは硬質材料粒子が1〜30μmの大きさを有することを特徴とする、請求項1または2に記載の方法。   The method according to claim 1, wherein the spherical MMC particles or hard material particles have a size of 1 to 30 μm. 補強粒子の割合が5〜70質量%であることを特徴とする、請求項1から3のいずれかに記載の方法。   The method according to claim 1, wherein the proportion of reinforcing particles is 5 to 70% by mass. 追加的に前記金属にさらなる補強粒子、例えば炭素短繊維を、そのように製造された原材料もしくは部材または半製品の機械的特性をさらに改善するために、噴霧の際または混合により導入することを特徴とする、請求項1から4のいずれかに記載の方法。   In addition, further reinforcing particles, for example carbon short fibers, are introduced into the metal during spraying or by mixing in order to further improve the mechanical properties of the raw materials or components or semi-finished products so produced The method according to claim 1, wherein: 請求項1から5のいずれかに記載の方法により製造されることを特徴とする、部材、特にブレーキディスクまたは摩擦リング。   6. A member, in particular a brake disc or a friction ring, manufactured by the method according to claim 1.
JP2014531266A 2011-09-22 2012-09-24 Method for producing a member from MMC (metal matrix composite) with melt sprayed powder in an inert gas atmosphere Pending JP2015508446A (en)

Applications Claiming Priority (3)

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