JP5176196B2 - Method for producing high-density aluminum sintered material by metal powder injection molding method - Google Patents
Method for producing high-density aluminum sintered material by metal powder injection molding method Download PDFInfo
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- JP5176196B2 JP5176196B2 JP2006321104A JP2006321104A JP5176196B2 JP 5176196 B2 JP5176196 B2 JP 5176196B2 JP 2006321104 A JP2006321104 A JP 2006321104A JP 2006321104 A JP2006321104 A JP 2006321104A JP 5176196 B2 JP5176196 B2 JP 5176196B2
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims description 135
- 229910052782 aluminium Inorganic materials 0.000 title claims description 81
- 239000000843 powder Substances 0.000 title claims description 69
- 239000000463 material Substances 0.000 title claims description 58
- 238000004519 manufacturing process Methods 0.000 title claims description 39
- 238000001746 injection moulding Methods 0.000 title claims description 23
- 229910052751 metal Inorganic materials 0.000 title claims description 20
- 239000002184 metal Substances 0.000 title claims description 20
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 51
- 238000005245 sintering Methods 0.000 claims description 45
- 239000002245 particle Substances 0.000 claims description 44
- 239000011863 silicon-based powder Substances 0.000 claims description 44
- 239000011230 binding agent Substances 0.000 claims description 24
- 150000001875 compounds Chemical class 0.000 claims description 19
- 238000002844 melting Methods 0.000 claims description 15
- 230000008018 melting Effects 0.000 claims description 15
- 238000005275 alloying Methods 0.000 claims description 11
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 10
- 238000005238 degreasing Methods 0.000 claims description 7
- 229910052710 silicon Inorganic materials 0.000 claims description 7
- 239000010703 silicon Substances 0.000 claims description 7
- 229910052786 argon Inorganic materials 0.000 claims description 5
- 239000007789 gas Substances 0.000 claims description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 3
- 229910001873 dinitrogen Inorganic materials 0.000 claims description 3
- 238000000034 method Methods 0.000 description 29
- 239000002994 raw material Substances 0.000 description 21
- 238000000465 moulding Methods 0.000 description 13
- 230000007423 decrease Effects 0.000 description 12
- 230000000052 comparative effect Effects 0.000 description 11
- 230000000694 effects Effects 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000001993 wax Substances 0.000 description 6
- 230000004907 flux Effects 0.000 description 4
- 239000011812 mixed powder Substances 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 239000011362 coarse particle Substances 0.000 description 2
- 230000006866 deterioration Effects 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 238000009864 tensile test Methods 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000001192 hot extrusion Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
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Description
本発明は、アルミニウム焼結材とその製造方法に関するものであり、更に詳しくは、アルミニウムを主成分とする粉末を原料として、高密度のアルミニウム焼結材を製造する新しい技術に関するものである。 The present invention relates to an aluminum sintered material and a method for producing the same, and more particularly to a new technique for producing a high-density aluminum sintered material using a powder mainly composed of aluminum as a raw material.
本発明は、金属粉末射出成形法によるアルミニウム焼結体の製造方法において、少量のシリコン粉末を焼結助剤として使用することにより、合金化による材料特性の変化（融点の低下、延性の低下）を招くことなく、アルミニウム粉末の焼結を促進して緻密な焼結体を製造することを可能とするアルミニウム焼結材の製造方法及びそのアルミニウム焼結材を提供するものである。 The present invention uses a small amount of silicon powder as a sintering aid in a method for producing an aluminum sintered body by metal powder injection molding, thereby changing material properties due to alloying (decreasing melting point and ductility). The present invention provides a method for producing an aluminum sintered material that can promote the sintering of aluminum powder and produce a dense sintered body without incurring, and the aluminum sintered material.
本発明は、特に、平均粒径１０μｍを超える粒径の粗いアルミニウム粉末に対して好適に適用することが可能であり、しかも、本発明により製造されたアルミニウム焼結体は、純度９９％のアルミニウム板材（焼鈍材）と比較して、遜色のない機械特性を有することを特徴とするものであり、近年、軽量化が求められている自動車をはじめとする各種輸送機のアルミニウム焼結部材として有用である。 The present invention can be suitably applied particularly to a coarse aluminum powder having an average particle size exceeding 10 μm, and the aluminum sintered body produced according to the present invention is an aluminum having a purity of 99%. Compared with plate material (annealed material), it has the same mechanical properties and is useful as an aluminum sintered member for various transportation equipment including automobiles that are required to be lighter in recent years. It is.
従来から、アルミニウム粉末は、その表面の強固な酸化物のため、難焼結性であり、高密度の焼結体を得ることは困難とされてきた。このため、従来、アルミニウム粉末焼結材の製造方法に関しては、粉末から成形体を作製する段階で、粉末充填率をできるだけ高くして、粉末相互を高い圧力下において接触させ、部分的に酸化皮膜を破壊した状態の成形体を形成し、これを焼結することによって、高密度の焼結体を得る方法が採られてきた。 Conventionally, aluminum powder is hard to sinter because of its strong oxide on the surface, and it has been difficult to obtain a high-density sintered body. For this reason, conventionally, with regard to the method for producing an aluminum powder sintered material, at the stage of producing a molded body from powder, the powder filling rate is made as high as possible, the powders are brought into contact with each other under high pressure, and partially oxidized film A method of obtaining a high-density sintered body has been taken by forming a molded body in a state of breaking and sintering it.
先行技術として、例えば、アルミニウム粉末を主成分とする金属粉末に潤滑剤を混合したものをプレス成形して、９５％以上の相対密度の成形体を成形し、脱脂・焼結してアルミニウム焼結材を得る方法が提案されている（特許文献１参照）。しかし、この種の成形法では、成形体の粉末充填率をできるだけ高くするために、成形前に粉末に添加する潤滑剤あるいは有機バインダーを極力少なくすることが必要となる。 As a prior art, for example, a metal powder mainly composed of aluminum powder is press-molded and a molded body having a relative density of 95% or more is molded, and then degreased and sintered to sinter aluminum. A method for obtaining a material has been proposed (see Patent Document 1). However, in this type of molding method, it is necessary to minimize the amount of lubricant or organic binder added to the powder before molding in order to maximize the powder filling rate of the compact.
そのために、粉末相互の摩擦あるいは粉末と成形型内面との摩擦により、成形体内部の粉末充填率が不均一になり、結果として、焼結体の密度が不均一になったり、焼結変形が発生する可能性がある。特に、成形体の形状が複雑になり、肉厚変動が大きくなると、その傾向が顕著になる。また、形状が複雑になると、成形後の型抜きが困難になるため、型抜きできるように成形型に様々な工夫が必要となり、成形型が高価になる。 Therefore, friction between powders or friction between the powder and the inner surface of the mold makes the powder filling rate in the molded body non-uniform, resulting in non-uniform density of the sintered body and sintering deformation. May occur. In particular, when the shape of the molded body becomes complicated and the thickness variation increases, the tendency becomes remarkable. Further, when the shape becomes complicated, it becomes difficult to perform die cutting after molding, so that various measures are required for the molding die so that the die can be punched, and the molding die becomes expensive.
これらの理由から、プレス成形法では、複雑形状品の作製が困難であり、そのため、まず、単純形状品の焼結体をプレス成形で作製し、目的とする製品形状を得るために機械加工することが必要となり、製造工程が複雑化する。 For these reasons, it is difficult to produce a complex-shaped product by the press molding method. Therefore, first, a sintered body of a simple-shaped product is produced by press molding and machined to obtain the desired product shape. This complicates the manufacturing process.
また、ホットプレス法（特許文献２参照）や熱間押し出し法（特許文献３参照）の様に、焼結時に加圧するいわゆる加圧焼結法であれば高密度焼結体が得られるが、これらの方法は、粉末を型に充填したまま焼結するため、成形型の制約などから、やはり複雑な形状の焼結体の製造は困難である。 In addition, a high-density sintered body can be obtained by a so-called pressure sintering method in which pressure is applied during sintering, such as a hot press method (see Patent Document 2) and a hot extrusion method (see Patent Document 3). Since these methods sinter while the powder is filled in the mold, it is difficult to produce a sintered body having a complicated shape due to limitations of the mold.
また、化学的に酸化皮膜を破壊する方法として、脱脂後の成形体（脱脂体）をほう化物系フラックス溶液に浸漬して化学的に酸化物を除去する方法（特許文献４参照）、また、原料となるアルミニウム粉末にフッ化物系フラックス粉末を添加して焼結する方法（特許文献５参照）がある。 In addition, as a method of chemically destroying the oxide film, a method of chemically removing oxides by immersing a degreased molded body (degreasing body) in a boride-based flux solution (see Patent Document 4), There is a method (see Patent Document 5) in which fluoride flux powder is added to aluminum powder as a raw material and sintered.
これらの方法は、成形時の粉末充填率をプレス成形法ほど高くする必要はない。しかし、強固なアルミニウム酸化物を破壊するフラックスは、取り扱いが難しく、作業時の危険性が高く、焼結炉を腐蝕するなど、環境汚染を起こす恐れがある。しかも、フラックスが成形体内部に残留すると、焼結体を腐蝕して性能劣化を招く可能性もある。 These methods do not require the powder filling rate during molding to be as high as that of the press molding method. However, the flux that destroys the strong aluminum oxide is difficult to handle, has a high risk of working, and may cause environmental pollution such as corrosion of the sintering furnace. In addition, if the flux remains inside the molded body, the sintered body may be corroded to cause performance deterioration.
上記課題を解決するために、本発明者らは、以前に相対密度が９０％以上のアルミニウム焼結材をネットシェイプで得るための製造方法を提案した（特許文献６参照）。その方法を以下に示す。平均粒径１０〜１μｍのアルミニウム粉末を主成分とする金属粉末に、ワックスや樹脂などの高分子から構成される有機バインダーを適量添加、混練して、可塑性のあるアルミニウム粉末と有機バインダーで構成された混練物（コンパウンド）を作製する。 In order to solve the above problems, the present inventors have previously proposed a manufacturing method for obtaining an aluminum sintered material having a relative density of 90% or more in a net shape (see Patent Document 6). The method is shown below. An appropriate amount of an organic binder composed of a polymer such as wax or resin is added to a metal powder mainly composed of aluminum powder having an average particle size of 10 to 1 μm, and kneaded to form a plastic aluminum powder and an organic binder. A kneaded product (compound) is prepared.
次に、この混練物を目的の形状に成形した後、不活性雰囲気において脱脂して、１×１０−１〜１×１０−５Ｐａの範囲の真空度において加熱して焼結体を得る。この方法は、金属粉末射出成形法（Ｍｅｔａｌ Ｉｎｊｅｃｔｉｏｎ Ｍｏｌｄｉｎｇ：ＭＩＭ）と称され、複雑形状部品をネットシェイプ成形する方法として注目され、様々な金属材料への適用が試されている。 Next, the kneaded product is formed into a desired shape, degreased in an inert atmosphere, and heated at a degree of vacuum in the range of 1 × 10 −1 to 1 × 10 −5 Pa to obtain a sintered body. This method is called a metal injection molding method (MIM), has attracted attention as a method for net-shape molding of complex shaped parts, and has been tried to be applied to various metal materials.
しかしながら、この方法では、アルミニウム材料の場合、平均粒径が１０μｍ以上の粉末では高密度の焼結体が得られない（特許文献６参照）。このことは、使用できる粉末を限定することになり、しかも、金属粉末は、一般的に、粒径が小さくなるほど重量当たりの単価が高くなるため、粒径の大きい粉末を原料とした方がコスト的には有利である。 However, in this method, in the case of an aluminum material, a high-density sintered body cannot be obtained with a powder having an average particle size of 10 μm or more (see Patent Document 6). This limits the powder that can be used, and metal powder generally has a higher unit price per weight as the particle size becomes smaller, so it is more costly to use powder with a larger particle size as a raw material. This is advantageous.
また、その後の研究で、試料のサイズが大きくなると、上記の条件で焼結材を製造しても、相対密度が９０％以上にはならないことが明らかになった。すなわち、同一条件で作製しても、試料の大きさが大きくなるほど、焼結材の相対密度は低下することが明らかになった。 Further, in subsequent studies, it has been clarified that when the sample size is increased, the relative density does not exceed 90% even if the sintered material is manufactured under the above conditions. In other words, it was found that the relative density of the sintered material decreases as the size of the sample increases even when manufactured under the same conditions.
相対密度を上昇させるには、１）焼結温度を高くする、２）焼結時間を長くする、という対策が考えられる。しかし、１）の焼結温度を高くすることに関しては、アルミニウムの融点が６６０℃であるため限度がある。 In order to increase the relative density, measures such as 1) increasing the sintering temperature and 2) increasing the sintering time can be considered. However, there is a limit to increasing the sintering temperature in 1) because the melting point of aluminum is 660 ° C.
また、２）の焼結時間を長くすることに関しては、焼結温度における保持時間を２時間から、その２倍の４時間にしてもさしたる効果は認められず、更に長時間の保持時間を必要とすることが予想され、その間、焼結炉を高温に維持しなければならず、時間的にも経済的にも不利である。この様な背景から、本発明者らは、上述の特許文献６の金属粉末射出成形法によるプロセスに基づき、アルミニウム粉末の焼結性を更に向上させるための焼結助剤の探索をこれまで進めてきた。 In addition, regarding the increase in the sintering time of 2), the effect that the holding time at the sintering temperature is increased from 2 hours to 2 times that of 4 hours is not recognized, and a longer holding time is required. In the meantime, the sintering furnace must be maintained at a high temperature, which is disadvantageous in terms of time and cost. Against this background, the present inventors have so far pursued a search for a sintering aid for further improving the sinterability of aluminum powder based on the process by the metal powder injection molding method of Patent Document 6 described above. I came.
このような状況の中で、本発明者らは、上記従来技術に鑑みて、金属粉末射出成形法によるアルミニウム焼結体の製造方法において、緻密でかつ機械的特性に優れた焼結部材を簡便に製造する方法を開発することを目標として鋭意研究を積み重ねた結果、金属粉末射出成形法におけるアルミニウム焼結部材の製造工程において、アルミニウム粉末を主成分とする金属粉末にシリコン粉末を添加することにより所期の目的を達成できることを見出し、更に研究を重ねて、本発明を完成するに至った。 Under such circumstances, the present inventors, in view of the above-mentioned conventional technology, can easily produce a sintered member having a high density and excellent mechanical properties in a method for producing an aluminum sintered body by a metal powder injection molding method. As a result of intensive research with the goal of developing a method for manufacturing aluminum, in the manufacturing process of aluminum sintered members in metal powder injection molding method, by adding silicon powder to metal powder mainly composed of aluminum powder The inventors have found that the intended purpose can be achieved, and have further researched to complete the present invention.
本発明は、平均粒径が１０μｍを超える粒径の大きいアルミニウム粉末を原料として使用した場合であっても、少なくとも８０％の高密度の焼結体を得ることができるアルミニウム焼結材の製造方法を提供すること、また、射出成形法によるアルミニウム焼結体の製造方法に使用するための、平均粒径が１０μｍを超える粒径の大きいアルミニウム粉末、焼結助剤としてのシリコン粉末、及び有機バインダーを含有するコンパウンドを提供すること、また、各種機械部品の軽量化を可能とする高強度、高密度を有するアルミニウム焼結材を提供すること、を目的とするものである。 The present invention provides a method for producing an aluminum sintered material capable of obtaining a sintered body having a high density of at least 80% even when aluminum powder having an average particle size exceeding 10 μm is used as a raw material. In addition, an aluminum powder having a large average particle diameter exceeding 10 μm, a silicon powder as a sintering aid, and an organic binder for use in a method for producing an aluminum sintered body by an injection molding method An object of the present invention is to provide an aluminum sintered material having a high strength and a high density that enables weight reduction of various machine parts.
上記課題を解決するための本発明は、以下の技術的手段から構成される。
（１）アルミニウムを主成分とする粉末と有機バインダーからなるコンパウンドを射出成形することにより所定形状に成形した成形体を脱脂、焼結して焼結体を製造する金属粉末射出成形法によるアルミニウム焼結材の製造方法において、１）平均粒子径が１０μｍを超え３５μｍまでのアルミニウム粉末を主成分とする粉末を使用し、２）上記コンパウンドとして、アルミニウム粉末に対して０．７５〜２．０％（重量比）の範囲のシリコン粉末を焼結助剤として添加したコンパウンドを使用し、３）それにより、シリコン粉末の添加前と比べて合金化による融点の低下と延性の低下によるアルミニウムの材料特性を損なうことなくアルミニウム焼結体の焼結性を向上させて、４）少なくとも８０％の相対密度を有する高密度アルミニウム焼結材を作製する、ことを特徴とする高密度アルミニウム焼結材の製造方法。
（２）アルミニウム粉末に対するシリコン粉末の添加量が、０．７５〜２．０％（重量比）である、前記（１）に記載の高密度アルミニウム焼結材の製造方法。
（３）アルミニウム粉末の平均粒径が、１１μｍ以上３４μｍ以下である、前記（１）に記載の高密度アルミニウム焼結材の製造方法。
（４）アルゴンガス又は窒素ガスを含有する雰囲気下で脱脂する、前記（１）に記載の高密度アルミニウム焼結材の製造方法。
（５）真空中で焼結する、前記（１）に記載の高密度アルミニウム焼結材の製造方法。
（６）シリコン粉末を焼結助剤として添加することにより、焼結体の相対密度を１５％以上向上させる、前記（１）に記載の高密度アルミニウム焼結材の製造方法。
（７）前記（１）から（６）のいずれかに記載の製造方法を用いて作製された高密度アルミニウム焼結部材であって、焼結助剤として添加したシリコン成分を含有し、しかもシリコン粉末の添加前と比べて合金化による融点の低下と延性の低下によるアルミニウムの材料特性を損なうことなく、少なくとも８０％の相対密度を有することを特徴とする高密度アルミニウム焼結部材。
The present invention for solving the above-described problems comprises the following technical means.
(1) Aluminum firing by a metal powder injection molding method in which a compact formed by injection molding a powder composed mainly of aluminum and an organic binder is degreased and sintered to produce a sintered body. the method of manufacturing a sintered material, 1) the average particle diameter using a powder based on aluminum powder up to 35μm exceed 10 [mu] m, 2) as the compound, the aluminum powder from 0.75 to 2.0 % use the added compound to silicon powder in the range of (by weight) as a sintering aid, 3) whereby the aluminum as compared with before the addition of the silicon powder due to a decrease in reduction and ductility of the melting point by alloying material and the sinterability of the sintered aluminum improves without impairing the properties, 4) high-density aluminum having a relative density of at least 80% Making binding material, manufacturing method of high-density sintered aluminum material, characterized in that.
(2) The method for producing a high-density aluminum sintered material according to (1), wherein the amount of silicon powder added to aluminum powder is 0.75 to 2.0% (weight ratio).
(3) The manufacturing method of the high-density aluminum sintered material as described in said (1) whose average particle diameter of aluminum powder is 11 micrometers or more and 34 micrometers or less.
(4) The method for producing a high-density aluminum sintered material according to (1), wherein degreasing is performed in an atmosphere containing argon gas or nitrogen gas.
(5) The method for producing a high-density aluminum sintered material according to (1), wherein sintering is performed in a vacuum.
(6) The method for producing a high-density aluminum sintered material according to (1), wherein the relative density of the sintered body is improved by 15% or more by adding silicon powder as a sintering aid.
(7) A high-density aluminum sintered member produced by using the production method according to any one of (1) to (6), comprising a silicon component added as a sintering aid, and silicon A high-density aluminum sintered member characterized by having a relative density of at least 80% without impairing the material properties of aluminum due to a decrease in melting point and a decrease in ductility due to alloying as compared to before powder addition .
次に、本発明について更に詳細に説明する。
本発明は、金属粉末射出成形法によるアルミニウム焼結材の製造方法において、平均粒子径が略３５μｍまでのアルミニウム粉末を主成分とする粉末を使用し、上記コンパウンドとして、シリコン粉末を焼結助剤として添加したコンパウンドを使用し、それにより、合金化による融点の低下を招くことなくアルミニウム焼結体の焼結性を向上させて、少なくとも８０％の相対密度を有する高密度アルミニウム焼結材を作製する、ことを特徴とするものである。
Next, the present invention will be described in more detail.
The present invention uses a powder mainly composed of aluminum powder having an average particle size of up to about 35 μm in a method for producing an aluminum sintered material by a metal powder injection molding method, and uses silicon powder as a sintering aid as the compound. A high-density aluminum sintered material having a relative density of at least 80% is produced by using the added compound as a material, thereby improving the sinterability of the aluminum sintered body without causing a decrease in melting point due to alloying. It is characterized by that.
また、本発明は、上記高密度アルミニウム焼結材の製造方法に使用するためのコンパウンドであって、略３５μｍまでの平均粒径を有するアルミニウム粉末を主成分とする粉末と有機バインダー及び焼結助剤としてのシリコン粉末を含有することを特徴とするものである。更に、本発明は、アルミニウムを主原料とする粉末と有機バインダーからなるコンパウンドを用いて作製されたアルミニウム焼結部材であって、焼結助剤として添加したシリコン成分を含有し、しかも合金化による融点の低下がなく、少なくとも８０％の相対密度を有することを特徴とする高密度アルミニウム焼結部材、である。 The present invention is also a compound for use in the above-described method for producing a high-density aluminum sintered material, comprising a powder mainly composed of aluminum powder having an average particle size of up to about 35 μm, an organic binder, and a sintering aid. It contains silicon powder as an agent. Furthermore, the present invention is an aluminum sintered member produced using a compound comprising a powder mainly composed of aluminum and an organic binder, containing a silicon component added as a sintering aid, and by alloying. A high-density aluminum sintered member characterized by having a relative density of at least 80% without lowering the melting point.
本発明のアルミニウム焼結材の製造方法では、原料粉末の段階で、アルミニウムを主成分とする粉末にシリコン粉末を添加して、乾式の粉体混合機（Ｖ型ミキサーなど）で両粉末を均一に混合し、この混合粉末にワックスや樹脂などの高分子から構成される有機バインダーを適量添加、混練して、可塑性のあるアルミニウム粉末と有機バインダーで構成される混練物（コンパウンド）を作製する。 In the method for producing an aluminum sintered material according to the present invention, silicon powder is added to a powder containing aluminum as a main component at the raw material powder stage, and both powders are made uniform with a dry powder mixer (such as a V-type mixer). Then, an appropriate amount of an organic binder composed of a polymer such as wax or resin is added to the mixed powder and kneaded to prepare a kneaded product (compound) composed of a plastic aluminum powder and an organic binder.
次に、この混練物を射出成形機で目的の形状に成形した後、脱脂、焼結して焼結体を得る。本発明では、上記コンパウンドに、焼結助剤としてシリコン粉末を添加することにより、１０μｍを越える平均粒径のアルミニウム粉末を原料粉末とする場合において、相対密度が高く、機械的特性に優れた焼結体を製造することを可能とするものである。本発明において、「平均粒子径が３５μｍまでのアルミニウム粉末」とは、平均粒子径が工業的に作製可能な数ｎｍ以上から略３５μｍまでの範囲のアルミニウム粉末であるものとして定義される。 Next, this kneaded product is molded into an intended shape by an injection molding machine, and then degreased and sintered to obtain a sintered body. In the present invention, by adding silicon powder as a sintering aid to the above compound, when an aluminum powder having an average particle size exceeding 10 μm is used as a raw material powder, the relative density is high and the firing is excellent in mechanical properties. It is possible to produce a ligature. In the present invention, “aluminum powder having an average particle size of up to 35 μm” is defined as an aluminum powder having an average particle size in the range of several nanometers or more to about 35 μm that can be produced industrially.
本発明では、原料粉末としては、アトマイズ法で作製された平均粒径が３５μｍ程度までのアルミニウム粉末を主成分とする粉末が好適に用いられる。本発明においては、アルミニウム原料粉末の平均粒径は、特に限定されることはないが、平均粒径１〜１０μｍの原料粉末だけではなく、特に、１０μｍを越える粗い粒径の原料粉末を使用した場合であっても８０％以上の相対密度を有する高密度の焼結体を製造することが可能である。 In the present invention, as the raw material powder, a powder mainly composed of an aluminum powder having an average particle size of up to about 35 μm produced by an atomizing method is preferably used. In the present invention, the average particle size of the aluminum raw material powder is not particularly limited, but not only the raw material powder having an average particle size of 1 to 10 μm but also a raw material powder having a coarse particle size exceeding 10 μm is used. Even in this case, it is possible to produce a high-density sintered body having a relative density of 80% or more.
本発明で使用するシリコン（Ｓｉ、ケイ素）粉末としては、平均粒径が２μｍ程度のシリコン粉末が好適に用いられるが、これに制限されるものではない。シリコン粉末の添加量は、アルミニウム粉末に対して、約０．５％以上とすることが好ましく、好適には０．７５％以上、更に好適には０．７５〜２．０％の範囲が挙げられる。本発明では、シリコン粉末は、焼結助剤として添加するものであり、２．０％以下の少量を添加することが重要であり、２．０％を越えると、合金化による材料特性の変化（融点の低下、延性の低下）が顕在化するので好ましくない。 As the silicon (Si, silicon) powder used in the present invention, silicon powder having an average particle size of about 2 μm is preferably used, but is not limited thereto. The amount of silicon powder added is preferably about 0.5% or more with respect to the aluminum powder, preferably 0.75% or more, and more preferably 0.75 to 2.0%. It is done. In the present invention, silicon powder is added as a sintering aid, and it is important to add a small amount of 2.0% or less. If it exceeds 2.0%, the material characteristics change due to alloying. (Deterioration of melting point, reduction of ductility) becomes obvious, which is not preferable.
アルミニウム粉末に可塑性を与えて射出成形を可能とするために、アルミニウム粉末に有機バインダーを添加してコンパウンドを作製する。有機バインダーとしては、ワックス類や樹脂類などの高分子材料に、必要に応じて、可塑剤、分散剤などを添加したものが使用されるが、これらに制限されるものではなく、アルミニウム粉末に、射出成形が可能な程度の可塑性を付与することができる適宜の有機バインダーが用いられる。アルミニウム粉末に対する有機バインダーの添加量は、特に制限されるものではなく、アルミニウム粉末の粒度分布などにより、４０ｖｏｌ％程度までの範囲内が好適であり、更に、３８〜４０ｖｏｌ％が好適である。 In order to give plasticity to the aluminum powder and enable injection molding, an organic binder is added to the aluminum powder to produce a compound. As the organic binder, a polymer material such as waxes or resins, to which a plasticizer or a dispersant is added as necessary, is not limited to these. An appropriate organic binder that can impart plasticity to such an extent that injection molding is possible is used. The amount of the organic binder added to the aluminum powder is not particularly limited, and is preferably within a range of up to about 40 vol%, and more preferably 38 to 40 vol%, depending on the particle size distribution of the aluminum powder.
本発明のコンパウンドは、例えば、アルミニウムを主原料とする粉末にシリコン粉末を添加して、乾式の粉末混合機（Ｖ型ミキサーなど）で両粉末を均一に混合し、この粉末にワックスや樹脂などの高分子から構成される有機バインダーを適量添加、混練することにより作製される。有機バインダーの添加量は、上記の好適な範囲内で、個々の原料特性に応じて決定される。その場合、コンパウンドの粘度、成形時のひけ（シュリンケージ）の発生、成形体の強度、脱脂時の欠陥の発生、焼結による収縮、寸法精度などを考慮して好適な範囲が決定される。この様にして調製されたコンパウンドは、室温では固体状態を呈するが、有機バインダーが溶融する温度にまで加熱すれば、十分な可塑性を示す。 In the compound of the present invention, for example, a silicon powder is added to a powder mainly made of aluminum, and both powders are uniformly mixed with a dry powder mixer (V-type mixer, etc.). An appropriate amount of an organic binder composed of the above polymer is added and kneaded. The addition amount of the organic binder is determined in accordance with the characteristics of each raw material within the above preferable range. In that case, a suitable range is determined in consideration of the viscosity of the compound, the occurrence of sink marks (shrinkage) during molding, the strength of the molded body, the occurrence of defects during degreasing, shrinkage due to sintering, dimensional accuracy, and the like. The compound thus prepared exhibits a solid state at room temperature, but exhibits sufficient plasticity when heated to a temperature at which the organic binder melts.
本発明では、成形体の脱脂は、例えば、アルゴンガス、窒素ガスなどの不活性雰囲気下で加熱して有機バインダーを８０％以上除去することで行われる。大気雰囲気下で脱脂すると、粉末が酸化され、焼結性が低下して十分に緻密な焼結体が得られないことがある。また、脱脂後の試料の焼結は、例えば、１×１０−１〜１×１０−５Ｐａの範囲の真空度の真空中で行うことが好適である。真空度が１×１０−１Ｐａまでの真空雰囲気、不活性ガス雰囲気あるいは還元雰囲気では、アルミニウム粉末の拡散が十分に行われず、焼結密度が向上しないことがある。また、１×１０−５Ｐａ以上の真空では、アルミニウム粉末が蒸発、気散し易くなり、焼結体表面が損傷されることがある。 In this invention, degreasing | defatting of a molded object is performed by heating in inert atmosphere, such as argon gas and nitrogen gas, and removing an organic binder 80% or more, for example. When degreasing in an air atmosphere, the powder is oxidized, the sinterability is lowered, and a sufficiently dense sintered body may not be obtained. Moreover, it is suitable to perform sintering of the sample after degreasing in the vacuum of the vacuum degree of the range of 1 * 10 < -1 > -1 * 10 < -5 > Pa, for example. In a vacuum atmosphere, an inert gas atmosphere, or a reducing atmosphere with a degree of vacuum of up to 1 × 10 −1 Pa, the aluminum powder is not sufficiently diffused and the sintered density may not be improved. Further, in a vacuum of 1 × 10 −5 Pa or more, the aluminum powder is easily evaporated and diffused, and the sintered body surface may be damaged.
アルミニウム粉末は、その表面の強固な酸化物のため、難焼結性を示し、高密度の焼結体を得ることは困難であり、従来、アルミニウム粉末にワックスや樹脂などからなる有機バインダーを添加して、成形時に可塑性を呈するコンパウンドとし、これを射出成形して成形体となし、脱脂、焼結して焼結体を作製する金属粉末射出成形法による高密度、高強度のアルミニウム焼結体を作製する方法が提案されていた。しかし、原料粉末の粒径が焼結材の密度に及ぼす影響は大きく、従来技術においては、平均粒径が１０μｍを越えると、相対密度が低下し、十分に緻密な焼結体が得られないのが実情であり、また、粒径が小さい金属粉末は重量当たりの単価が高くなるため、製品が高価となる問題があった。 Aluminum powder is hard to sinter due to its strong oxide on the surface, and it is difficult to obtain a high-density sintered body. Conventionally, an organic binder made of wax or resin is added to aluminum powder. A high-density, high-strength aluminum sintered body produced by a metal powder injection molding method in which a compound exhibiting plasticity at the time of molding is formed into a molded body by injection molding and degreased and sintered to produce a sintered body. There has been proposed a method of fabricating the above. However, the influence of the particle size of the raw material powder on the density of the sintered material is large. In the prior art, when the average particle size exceeds 10 μm, the relative density decreases and a sufficiently dense sintered body cannot be obtained. In fact, the metal powder having a small particle size has a problem that the unit price per weight is high and the product is expensive.
これに対して、本発明は、アルミニウム粉末に焼結助剤としてシリコン粉末を添加することにより、１０μｍを越える粗い粒径の原料粉末を使用しても、低い温度及び短時間で、８０％以上の相対密度を有する高密度のアルミニウム焼結体を作製することを可能としたものである。本発明により、２．０％以下の添加量でシリコン粉末をアルミニウムを主成分とする粉末に添加することにより、合金化による融点の低下を招くことなくアルミニウム焼結体の焼結性を向上させて、少なくとも８０％の相対密度を有する高密度のアルミニウム焼結材を作製することが可能である。 On the other hand, in the present invention, by adding silicon powder as a sintering aid to aluminum powder, even if a raw material powder having a coarse particle size exceeding 10 μm is used, it is 80% or more at a low temperature and in a short time. Thus, it is possible to produce a high-density aluminum sintered body having a relative density of 1 to 5 mm. According to the present invention, by adding silicon powder to a powder containing aluminum as a main component in an addition amount of 2.0% or less, the sinterability of an aluminum sintered body can be improved without causing a decrease in melting point due to alloying. Thus, it is possible to produce a high-density aluminum sintered material having a relative density of at least 80%.
本発明により、次のような効果が奏される。
（１）本発明の金属粉末射出成形法におけるアルミニウム焼結助剤としてのシリコン粉末の添加は、アルミニウム粉末の粒径の大小に依らず、添加量が１％前後、具体的には０．７５〜２％と少量で焼結を促進し、焼結体の密度を大幅に向上させる効果がある。
（２）しかも、シリコン粉末の添加量が少ないため、シリコン粉末を添加することによる焼結後の材料特性の変化（融点の低下、延性の低下）がきわめて少ない。
（３）すなわち、アルミニウムの有する優れた材料特性を損なわずに、緻密な焼結部材を製造可能である。
（４）原料として平均粒径が約１０〜３５μｍのＡｌ粉末を用いた場合でも、相対密度が８０％以上で、高密度で優れた室温引張強度を有するアルミニウム焼結材を製造することができる。
（５）本発明は、ネットシェイプ成形を特徴とする金属粉末射出成形法によるアルミニウム焼結部品の製造の範囲を拡大し、特に、近年、軽量化が求められている自動車をはじめとする各種輸送器機の焼結部材の製造法に適用することで、大きな波及効果が期待できる。
The present invention has the following effects.
(1) The addition of silicon powder as an aluminum sintering aid in the metal powder injection molding method of the present invention does not depend on the particle size of the aluminum powder, but the addition amount is around 1%, specifically 0.75. Sintering is accelerated with a small amount of ˜2%, and the density of the sintered body is greatly improved.
(2) Moreover, since the amount of silicon powder added is small, changes in material properties after sintering due to the addition of silicon powder (decrease in melting point and ductility) are extremely small.
(3) That is, a dense sintered member can be produced without impairing the excellent material properties of aluminum.
(4) Even when an Al powder having an average particle diameter of about 10 to 35 μm is used as a raw material, an aluminum sintered material having a relative density of 80% or more, a high density and excellent room temperature tensile strength can be produced. .
(5) The present invention expands the scope of production of aluminum sintered parts by metal powder injection molding, which is characterized by net shape molding, and in particular, various transportation including automobiles that have recently been required to be lighter. A large ripple effect can be expected by applying to the manufacturing method of the sintered member of the machine.
次に、本発明を、試験例、実施例及び比較例に基づいて具体的に説明するが、本発明は、以下の実施例によって何ら限定されるものではない。 Next, although this invention is demonstrated concretely based on a test example, an Example, and a comparative example, this invention is not limited at all by the following examples.
試験例
シリコン粉末の上記最適添加量を決定するために、以下の予備試験を行った。平均粒径２０μｍのアルミニウム粉末と平均粒径が２μｍのシリコン粉末を様々な配合で混合して混合粉末を作製し、金属粉末射出成形によるグリーン体を想定して充填密度が６０〜６５％となる直径１１ｍｍ、高さ１５ｍｍの圧粉体を作製し、この圧粉体を６２５℃で２時間真空焼結した。
Test Example The following preliminary test was performed in order to determine the optimum addition amount of silicon powder. Aluminum powder having an average particle diameter of 20 μm and silicon powder having an average particle diameter of 2 μm are mixed in various blends to produce a mixed powder, and the packing density is 60 to 65% assuming a green body by metal powder injection molding. A green compact having a diameter of 11 mm and a height of 15 mm was produced, and this green compact was vacuum-sintered at 625 ° C. for 2 hours.
シリコン粉末の添加量と焼結体の相対密度の関係を図１に示す。図１からシリコン粉末を添加しない焼結体は、密度が６０％にも満たないが、シリコン粉末の添加量を増加させていくと密度が向上し、添加量が１％になると密度は９５％まで上昇した。シリコン粉末の添加量を１％以上に増加させても密度の変化はほとんど無かった。また、シリコン粉末の添加量が３％以上になると、表面に微小な溶融球の付着が観察され、焼結体の融点が低下したと考えられる。 The relationship between the amount of silicon powder added and the relative density of the sintered body is shown in FIG. From FIG. 1, the sintered body to which no silicon powder is added has a density of less than 60%. However, as the amount of silicon powder added is increased, the density is improved, and when the amount is 1%, the density is 95%. Rose to. Even when the amount of silicon powder added was increased to 1% or more, there was almost no change in density. In addition, when the amount of silicon powder added is 3% or more, it is considered that adhesion of minute molten spheres was observed on the surface and the melting point of the sintered body was lowered.
（１）成形体の作製
本実施例では、以下の方法により成形体及び焼結体を作製し、その特性を調べた。原料粉末には、アトマイズ法で作製された平均粒径が１１μｍの純アルミニウム粉末と、平均粒径が２μｍのシリコン粉末を使用した。各アルミニウム粉末に、シリコン粉末を１ｍａｓｓ．％添加した混合粉末（アルミニウム粉末：シリコン粉末＝９９：１（ｍａｓｓ．％））に、ワックスと樹脂より構成される有機バインダーを添加して、コンパウンドを作製し、全長１１０ｍｍ、幅７．５ｍｍ、厚さ４ｍｍの板状引張試験片の形状に射出成形した。
(1) Manufacture of a molded object In the present Example, the molded object and the sintered compact were produced with the following method, and the characteristic was investigated. As the raw material powder, pure aluminum powder having an average particle diameter of 11 μm and silicon powder having an average particle diameter of 2 μm prepared by an atomizing method were used. Silicon powder is added to each aluminum powder for 1 mass. % To the mixed powder (aluminum powder: silicon powder = 99: 1 (mass.%)), An organic binder composed of wax and resin is added to produce a compound, and the total length is 110 mm, the width is 7.5 mm, It was injection molded into the shape of a plate-shaped tensile test piece having a thickness of 4 mm.
（２）焼結体の作製
有機バインダーの添加量は、３８ｖｏｌ．％、である。得られた成形体をアルゴンガス気流中で３９０℃まで加熱脱脂して、添加した有機バインダーを８０％以上除去した後、１０−３Ｐａオーダーの真空中で２時間焼結し、その後、室温まで炉冷した。焼結後の焼結体の相対密度を表１に示す。焼結体の相対密度は９６．０％と高い値を示した。なお、相対密度は、純アルミニウムの理論密度２．７ｇ／ｃｍ３を１００％として換算した。
(2) Production of sintered body The amount of organic binder added was 38 vol. %. The obtained molded body was heated and degreased to 390 ° C. in an argon gas stream to remove 80% or more of the added organic binder, then sintered in a vacuum of the order of 10 −3 Pa for 2 hours, and then to room temperature. The furnace was cooled. Table 1 shows the relative density of the sintered body after sintering. The relative density of the sintered body was as high as 96.0%. The relative density was converted with the theoretical density of pure aluminum being 2.7 g / cm 3 as 100%.
原料粉末として、アトマイズ法で作製された平均粒径が２０μｍの純アルミニウム粉末を使用した以外は、実施例１と同様にして、アルミニウム焼結体を作製した。焼結後の焼結体の相対密度を表１に示す。焼結体の相対密度は９１．６％と高い値を示した。 An aluminum sintered body was produced in the same manner as in Example 1 except that pure aluminum powder having an average particle diameter of 20 μm produced by the atomizing method was used as the raw material powder. Table 1 shows the relative density of the sintered body after sintering. The relative density of the sintered body was as high as 91.6%.
原料粉末として、アトマイズ法で作製された平均粒径が３４μｍの純アルミニウム粉末を使用した以外は、実施例１と同様にして、アルミニウム焼結体を作製した。焼結後の焼結体の相対密度を表１に示す。焼結体の相対密度は、８５．８％であり、原料粉末の平均粒径が３４μｍと大きい場合であっても高い相対密度を示した。 An aluminum sintered body was produced in the same manner as in Example 1 except that pure aluminum powder having an average particle diameter of 34 μm produced by the atomizing method was used as the raw material powder. Table 1 shows the relative density of the sintered body after sintering. The relative density of the sintered body was 85.8%, and a high relative density was exhibited even when the average particle diameter of the raw material powder was as large as 34 μm.
比較例１
原料粉末には、アトマイズ法で作製された平均粒径が１１μｍの純アルミニウム粉末を使用した。アルミニウム粉末に、ワックスと樹脂より構成される有機バインダーを３８ｖｏｌ．％添加してコンパウンドを作製し、板状引張試験片の形状に射出成形した。得られた成形体をアルゴンガス気流中で３９０℃まで加熱脱脂して、添加した有機バインダーを８０％以上除去した後、１０−３Ｐａオーダーの真空中、６５０℃で２時間焼結し、その後、室温まで炉冷した。焼結体の相対密度を表１に示す。この焼結体の相対密度は８０．８％であった。
Comparative Example 1
As the raw material powder, pure aluminum powder having an average particle diameter of 11 μm prepared by an atomizing method was used. An organic binder composed of wax and resin is added to aluminum powder at 38 vol. % Was added to prepare a compound, which was injection molded into the shape of a plate-like tensile test piece. The obtained compact was heated and degreased to 390 ° C. in an argon gas stream to remove 80% or more of the added organic binder, and then sintered at 650 ° C. for 2 hours in a vacuum of the order of 10 −3 Pa. The furnace was cooled to room temperature. Table 1 shows the relative density of the sintered body. The relative density of this sintered body was 80.8%.
比較例２
原料粉末に、アトマイズ法で作製された平均粒子径が２０μｍの純アルミニウム粉末を使用した以外は、比較例１と同様にして、アルミニウム焼結体を作製した。焼結体の相対密度を表１に示す。この焼結体の相対密度は７５．８％であった。
Comparative Example 2
An aluminum sintered body was produced in the same manner as in Comparative Example 1 except that pure aluminum powder having an average particle diameter of 20 μm produced by the atomizing method was used as the raw material powder. Table 1 shows the relative density of the sintered body. The relative density of this sintered body was 75.8%.
比較例３
原料粉末に、アトマイズ法で作製された平均粒子径が３４μｍの純アルミニウム粉末を使用した以外は、比較例１と同様にして、アルミニウム焼結体を作製した。焼結体の相対密度を表１に示す。この焼結体の相対密度は６５．５％であった。
Comparative Example 3
An aluminum sintered body was produced in the same manner as in Comparative Example 1 except that pure aluminum powder having an average particle diameter of 34 μm produced by the atomizing method was used as the raw material powder. Table 1 shows the relative density of the sintered body. The relative density of this sintered body was 65.5%.
表１において、参考例１は、純アルミニウムの溶製法による板材の値である。シリコン粉末を添加していない比較例１、２、３では、アルミニウム粉末の平均粒径が３４μｍ、２０μｍ、１１μｍのとき、焼結体の相対密度は、それぞれ６５．６％、７５．８％、８０．８％となり、粒径が小さくなる程、密度が高くなるが、焼結部材としては不十分である。実施例１、２、３では、シリコン粉末の添加により、アルミニウム粉末の粒径に関わらず相対密度が１５〜２０％程度増加することが分かる。表１の中で最も粒径の大きい（３４μｍの）アルミニウム粉末を使用した実施例３でも、８５．８％まで相対密度が向上し、焼結部材として実用に近いレベルに達している。以上の実施例及び比較例の対比により、シリコン粉末を添加すると、アルミニウム粉末の粒径に関わらず相対密度が大幅に向上することが分かる。 In Table 1, Reference Example 1 is a value of a plate material by a pure aluminum melting method. In Comparative Examples 1, 2, and 3 in which no silicon powder was added, when the average particle diameter of the aluminum powder was 34 μm, 20 μm, and 11 μm, the relative densities of the sintered bodies were 65.6%, 75.8%, 80.8%, the smaller the particle size, the higher the density, but it is insufficient as a sintered member. In Examples 1, 2, and 3, it can be seen that the addition of silicon powder increases the relative density by about 15 to 20% regardless of the particle size of the aluminum powder. Even in Example 3 in which the aluminum powder having the largest particle size (34 μm) in Table 1 was used, the relative density was improved to 85.8%, which reached a practical level as a sintered member. From the comparison of the above Examples and Comparative Examples, it can be seen that when silicon powder is added, the relative density is greatly improved regardless of the particle size of the aluminum powder.
図２に、実施例１の焼結体（ａ）、比較例１の焼結体（ｂ）、及び射出成形後のグリーン成形体（ｃ）、の外観写真を示す。試験片の全長は、グリーン成形体で１１０ｍｍであるが、焼結による収縮により、実施例１では全長９５ｍｍ、比較例１では全長１０２ｍｍとなり、焼結後の密度を反映した収縮を現している。 In FIG. 2, the external appearance photograph of the sintered compact (a) of Example 1, the sintered compact (b) of the comparative example 1, and the green molded object (c) after injection molding is shown. The total length of the test piece is 110 mm for the green molded body, but due to shrinkage due to sintering, the total length is 95 mm in Example 1 and 102 mm in Comparative Example 1, and the shrinkage reflects the density after sintering.
本実施例では、表１に記載した焼結体の中で最も高密度となった実施例１の焼結体の室温引張特性（実施例１）を測定し、日本工業規格（ＪＩＳ Ｈ４０００：２００６）の純度９９．０％の純アルミニウム板材（焼鈍材）の室温引張特性（参考例２）と比較した。その結果を表２に示す。 In this example, the room temperature tensile properties (Example 1) of the sintered body of Example 1 having the highest density among the sintered bodies described in Table 1 were measured, and Japanese Industrial Standard (JIS H4000: 2006) was measured. ) And a room temperature tensile property (Reference Example 2) of a pure aluminum plate (annealed material) having a purity of 99.0%. The results are shown in Table 2.
表２から明らかなように、実施例１の焼結体と参考例２の溶製板材の引張特性に大きな変化は認められない。この原因としては、シリコン粉末の添加量が１％と少量であり、合金化の作用が少ないため、材料特性の変化がほとんどなく、シリコン粉末添加が焼結性の向上に大部分作用するものと考えられる。言い換えれば、シリコン粉末が焼結助剤として作用したものと云える。 As is clear from Table 2, there is no significant change in the tensile properties of the sintered body of Example 1 and the melted plate material of Reference Example 2. This is because the addition amount of silicon powder is as small as 1% and the effect of alloying is small, so there is almost no change in material properties, and the addition of silicon powder has a major effect on improving the sinterability. Conceivable. In other words, it can be said that the silicon powder acted as a sintering aid.
なお、アルミニウム粉末に対するシリコン粉末の添加量は、０．７５〜２．０％（重量比）までとすることが好適である。図１の結果から、添加量が０．７５％未満では、焼結性向上の効果が弱い。また、２％を超えると、合金化による材料特性の変化（融点の低下、延性の低下）が顕在化する。 The amount of silicon powder added to the aluminum powder is preferably 0.75 to 2.0% (weight ratio). From the result of FIG. 1, when the addition amount is less than 0.75%, the effect of improving the sinterability is weak. On the other hand, if it exceeds 2%, changes in material properties due to alloying (decrease in melting point, decrease in ductility) become obvious.
以上詳述したように、本発明は、金属粉末射出成形法による高密度のアルミニウム焼結材の製造方法に係るものであり、本発明により、平均粒径が３５μｍ程度までの粒径の粗いアルミニウム粉末にシリコン粉末を焼結助剤として添加することにより、シリコン粉末は焼結助材としての作用を示し、少量で焼結を促進し、しかも焼結体の材料特性の変化（融点の低下、延性の低下）を招くことなく８０％以上の相対密度を有する緻密な焼結材を製造することが可能となる。本発明により製造されたアルミニウム焼結材は、平均粒径が３５μｍ程度までの粒径の粗いアルミニウム粉末を用いた場合でも、純度９９％のアルミニウム板材（焼鈍材）と比較して遜色のない機械特性を有することから、本発明は、金属粉末射出成形法によるアルミニウム焼結部材の製造、及び製品の用途範囲を拡大するものであり、特に、近年、軽量化が求められている自動車をはじめとする各種輸送機の部材として好適に使用可能な新しいアルミニウム焼結材を提供するものとして有用である。 As described above in detail, the present invention relates to a method for producing a high-density aluminum sintered material by metal powder injection molding, and according to the present invention, coarse aluminum particles having an average particle size of up to about 35 μm. By adding silicon powder as a sintering aid to the powder, the silicon powder acts as a sintering aid, promotes sintering in a small amount, and changes in material properties of the sintered body (decrease in melting point, It becomes possible to manufacture a dense sintered material having a relative density of 80% or more without causing a decrease in ductility. The sintered aluminum material produced according to the present invention is a machine that is comparable to an aluminum plate (annealed material) with a purity of 99% even when coarse aluminum powder having an average particle size of up to about 35 μm is used. Since the present invention has characteristics, the present invention expands the range of application of products and products for the production of aluminum sintered members by metal powder injection molding. Therefore, the present invention is useful as a new aluminum sintered material that can be suitably used as a member of various transport aircraft.
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