JPH1171620A - Production of metal-ceramics composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a composite material without forming a preform by filling ceramics powder into a produced molding flask and infiltrating an aluminum alloy into the ceramics powder in a specified temp. range. SOLUTION: At first, a molding flask is produced, ceramics powder mixed with an impregnation accelerator is packed into the flask by tapping, and an alloy essentially consisting of Al is infiltrated into the ceramics powder at 700 to 1000 deg.C. Preferably, the impregnation accelerator is composed of Al-Mg alloy powder having 1 to 100 μm average particle size, where the ratio of Mg to Al is >=1, and the amt. of the impregnation accelerator to the ceramics powder is regulated to 1 to 10 pts.wt. based on 100 pts.wt. ceramics powder. Furthermore, the molding flask is produced from a mixture of a glass frit contg. carbon, a carbon sheet, Al2 O3 and boron, the ceramics powder is composed of Al2 O3 , SiC or AlN having 0.1 to 150 μm average particle size, and the Al alloy is composed of the one contg. no Mg.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a metal-ceramic composite material in which a reinforcing material is combined with a metal, and more particularly, to a method in which a metal is penetrated into a reinforcing material to form a composite material.
The present invention relates to a method for manufacturing a ceramic composite material.

[0002]

2. Description of the Related Art A metal-ceramic composite material reinforced with ceramic fibers or particles has both characteristics of a metal and a ceramic. For example, this composite material has high rigidity, low thermal expansion, abrasion resistance and the like. It has the excellent properties of ceramics and the excellent properties of metals such as ductility, high toughness, and high thermal conductivity. As described above, since it has both the characteristics of ceramics and metal, which have been considered difficult, it has been drawing attention as a next-generation material from industries such as mechanical device manufacturers.

As a method for producing this composite material, particularly a composite material using aluminum as a matrix as a metal, methods such as powder metallurgy, high pressure casting, and vacuum casting have been conventionally known. However, all of these methods are not capable of increasing the content of ceramics as a reinforcing material, require a large-sized pressurizing device, are difficult to form near nets, and are extremely expensive. It was not satisfactory.

Accordingly, recently, a non-pressurized metal infiltration method developed by Rankside Company of the United States has attracted particular attention as a manufacturing method for solving the above problem. This method uses SiC or A
l to ₂ O ₃ preform formed of ceramic powder, such as, by contacting the aluminum ingots, which N ₂
This is a method of impregnating a preform with an aluminum alloy that has been heated to 700 to 900 ° C. and melted in an atmosphere. This is an excellent method in which the preform can be impregnated with the metal without applying pressure by improving the wettability of the molten metal to the ceramic powder using a chemical reaction.

Further, according to this method, the content of ceramics can be varied as wide as 30 to 85 vol% and a high range, and the preform formed by this method has a high degree of freedom in its shape. It is also possible to make quite complex shapes with near nets. As described above, this method does not require a pressurizing device, can increase the content of ceramics, and enables near-net molding. Therefore, this method is an excellent method that solves the above-described problem. .

[0006]

However, this method has the following problems by forming a preform. It takes time and effort to form the preform first, especially when forming a large preform,
Alternatively, when mass production is required, forming the same preform several times has a problem that the labor is extremely large.

Second, the strength of the preform is not so strong, and the preform is easily broken. Therefore, care must be taken in handling the preform, and when the preform is cracked, the part is impregnated with metal after penetration. There has been a problem in that only metal is used, which causes a defect called metal vane, which adversely affects mechanical properties.

Third, since an inorganic binder such as a colloidal solution of alumina hydrate or a colloidal silica solution is used to increase the strength of the preform,
There is a problem that it remains as an impurity in the composite material, hinders bonding between the metal and the ceramic powder, and deteriorates material properties such as tensile strength and fracture toughness.

Furthermore, fourthly, since the impregnation-promoting material for assisting metal penetration contains Mg metal therein, the wet-formed preform must contain the impregnation-promoting material in advance. However, there is no other choice but to impregnate the inside of the preform as the metal permeates from the outside of the preform, and there is a problem that the permeation time of the metal becomes long and poor permeation tends to occur. The bigger this was, the bigger the problem.

The present invention has been made in view of the problems of the above-described method for producing a metal-ceramic composite material, and has as its object to provide a metal capable of producing a composite material without forming a preform. -To provide a method for producing a ceramic composite material.

[0011]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to achieve the above object, and as a result, first produced a mold from which a desired composite material can be obtained, and placed ceramic powder in the mold. Filling and infiltrating the metal into the ceramic powder gives the knowledge that a metal-ceramic composite material having the desired size and shape can be obtained without forming a preform, thereby completing the present invention. Reached.

That is, according to the present invention, there is provided (1) a method for producing a metal-ceramic composite material using a ceramic powder as a reinforcing material. First, a mold is prepared, and a ceramic powder obtained by mixing an impregnation promoting material in the mold. And filling the ceramic powder with an alloy containing aluminum as a main component at a temperature of 700 to 1000 ° C. (Claim 1). (2) The impregnation-promoting material is a powder composed of an alloy of Al and Mg having an average particle diameter of 1 to 100 μm, the Mg content is at least 50% or more, and the mixing amount of the impregnation-promoting material is ceramic. The method for producing a metal-ceramic composite material according to claim 1, wherein the amount is 1 to 10 parts by weight based on 100 parts by weight of the powder. , (3) type frame, carbon, carbon sheet, according to claim, characterized in that it consists of a mixture or a mixture of glass frit including a SiO ₂ powder and boron glass frit containing Al ₂ O ₃ powder and boron 1 or 2 metal according - a method of producing a ceramic composite material (claim 3), furthermore, (4) ceramic powder, the average particle size of 0.1~150μm Al ₂ O ₃ powder, S
The method for producing a metal-ceramic composite material according to claim 1, wherein the alloy is an iC powder or an AlN powder (claim 4). , Mg, does not contain an aluminum alloy, wherein the method of manufacturing a metal-ceramic composite material according to any one of claims 1, 2, 3, and 4 is provided. This will be described in more detail below.

As described above, the method for producing a composite material is as follows. First, a required mold is prepared, and a ceramic powder mixed with an impregnation promoter is filled in the mold by tapping, and then aluminum is added to the ceramic powder. The alloy as a main component is infiltrated at a temperature of 700 to 1000 ° C. (Claim 1). In this method, if the ceramic powder is filled in the prepared mold, the filled ceramic powder becomes a substitute for the preform. Since a composite material having a desired size and shape can be produced without the need to form a preform, all of the above-described problems caused by producing a composite material by forming a preform are solved as follows.

In the first problem, since a composite material can be produced in the same manner as casting a metal, if a mold for obtaining a desired composite material is produced and the composite material is produced using the mold, Even if it is a large product or a complicated product, it is much easier and easier than forming and manufacturing a preform, and the same product can be manufactured many times, which is suitable for mass production. In the second problem, since a preform having low strength is not formed, metal vanes due to cracks in the preform do not occur. Further, in the third problem, since no binder is used at all, there is no mixing of impurities due to this, and the material characteristics do not deteriorate. Furthermore, in the fourth problem, since the impregnation promoting material can be directly mixed into the ceramic powder, the penetration of the metal can be further promoted, and poor penetration hardly occurs.

As described above, all of the above-mentioned problems are solved. However, in addition to the disadvantages due to a low powder filling rate as compared with the method of forming a preform to produce a composite material, the following points are also excluded. Is advantageous. That is, since the metal vanes do not occur and the material characteristics do not deteriorate, the deterioration of the mechanical characteristics of the composite material is suppressed. In addition, since the penetration of metal by the impregnation promoting material can be further promoted, the penetration time can be greatly reduced.
It takes 96 hours to penetrate a × 400 × 50 mm block, but this is due to the low powder filling rate.
It will be reduced to time. Furthermore, the yield is greatly improved by reducing the penetration failure.
As described above, in the present invention, the productivity is greatly improved including the fact that the step of forming the preform can be omitted, and the effect is remarkable especially for large-sized products and mass-produced products.

The impregnation promoting material to be mixed into the ceramic powder is a powder composed of an alloy of Al and Mg having an average particle diameter of 1 to 100 μm, and the ratio of Al to Mg is as follows:
At least 50% or more is made of Mg, and the amount of the impregnating accelerator mixed with the ceramic powder is as follows.
1 to 10 parts by weight with respect to 00 parts by weight (claim 2). The reason why the alloy powder of Al and Mg is used is that when the alloy of Al and Mg is used, the vapor pressure of Mg is lower than that of Mg alone, so that Mg is uniformly attached to the surface of the ceramic particles. Moreover, the fineness is 1 to
The reason why the thickness is set to 100 μm is that if it is too coarse, the evaporation of Mg becomes local, resulting in non-uniformity. If it is too fine, the flammability becomes strong and handling becomes difficult. Further, the reason why the content of Mg is set to 50% or more is that if the content of the Mg component is small, the AlN skeleton is easily formed by heating in nitrogen, and the metal spot is easily formed. Furthermore, the mixing ratio is 1 to
The reason for setting the amount to 10 parts by weight is that when the Mg component increases, the Mg vapor clogs between the particles, and the vapor solidifies and impedes the penetration of the metal. It depends.

The outer mold is a mold made of carbon, a carbon sheet, a mixture of Al ₂ O ₃ powder and glass frit containing boron or a mixture of SiO ₂ powder and glass frit containing boron (claim). Item 3). The molds were made from these materials because they have poor wettability with aluminum alloys and impede the penetration of metal.As a result, the aluminum alloy does not penetrate the molds and the mold is removed. By making it easier.

Further, as the ceramic powder to be used, Al ₂ O ₃ powder having an average particle size of 0.1 to 150 μm, S ₂
iC powder or AlN powder (claim 4). The type of ceramic powder is Al ₂ O ₃ powder, SiC powder or A
The reason for using 1N powder is that these powders easily penetrate into aluminum metal. As the average particle size of the powder is only filling by tapping, the powder filling rate is limited to about 50 vol%, and it is impossible to make a preform having a higher filling rate than before, so use finer powders. By appropriately combining them to improve the filling rate, the thickness is set to 0.1 to 150 μm. If the average particle size of the ceramic powder is smaller than 0.1 μm, it is difficult to penetrate the metal, and the powder filling ratio is too low. If the ceramic powder is coarser than 150 μm, the powder filling ratio is too low.

Further, the aluminum alloy used is an aluminum alloy containing no Mg. It is of course possible to use an alloy containing Mg,
It is more preferable that the alloy does not contain Mg for the following reasons.
The reason is that the alloy containing Mg has a eutectic point, so its melting point is much lower than that of the alloy without Mg, and the alloy melts and starts to infiltrate before the reaction between Mg and N ₂ proceeds sufficiently. If the penetration starts early, Mg
The reaction product is also deteriorated wettability of the alloy on the ceramic powder becomes impossible sufficiently cover the surface of the ceramic powder, the composite proceeding involving an alloy of penetration pores when the wettability is deteriorated and N ₂ and This is because there is a possibility that large pores remain in the material, but in an alloy containing no Mg, the possibility can be suppressed.

[0020]

DETAILED DESCRIPTION OF THE INVENTION The production method of the present invention will be described in more detail. First, SiC having an average particle size of 0.1 to 150 .mu.m is used.
Powder, Al ₂ O ₃ powder and AlN powder are prepared. These powders may be used alone or another powder may be partially mixed.

The prepared powder has an average particle size of 1 to 100 μm.
Then, 1 to 10 parts by weight of an alloy powder of Al and Mg containing 50% or more of Mg is added to 100 parts by weight of the ceramic powder, and dry-mixed with a ball mill or the like. The dry mixing is performed because the contained Mg metal hydrates and loses the effect of promoting the penetration of the metal. The longer the mixing time, the better,
If the length is too long, the ceramic powder is crushed and the particle size distribution is changed, which is not preferable.

Next, a mold is manufactured using the above-mentioned materials such as carbon. For example, if the method is simple, it can be manufactured by assembling a combination of plate-like materials such as carbon, and if it is a complex shape product, it can be burned in air inside a mold or the like to which the shape has been transferred. A material that disappears by injection, for example, plastic, is injected, molded, the periphery of the molded body is covered with powder of a mixture of Al ₂ O ₃ powder and glass frit containing boron, etc., and fired to form a space having a required shape. Can be produced.

A ceramic powder containing an impregnating material is filled into the formed mold by tapping. An aluminum alloy ingot is placed above the molten metal injection port of the formwork, set in an electric furnace or the like, and the aluminum alloy is infiltrated at a temperature of 700 to 1000 ° C. in a nitrogen stream at a non-pressurized temperature and cooled. Thereby, a metal-ceramic composite material is obtained. The aluminum alloy used is Al-Mg,
Examples include those containing Mg such as Al-Mg-Si or those not containing Mg such as pure Al and Al-Si, but are not limited thereto, and are required for final products. Any aluminum alloy containing no element that deteriorates the physical properties may be used.

When a metal-ceramic composite material is prepared by the above method, the metal-ceramic composite material can be formed without forming a preform.
A ceramic composite material can be manufactured.

[0025]

EXAMPLES Hereinafter, the present invention will be described in more detail by giving specific examples of the present invention.

Example 1 (1) Preparation of Metal-Ceramic Composite Material Commercially available Al having # 320 (average particle size: 40 μm) as a reinforcing material
To commercially available Al ₂ O ₃ powder 30 parts by weight of ₂ O ₃ powder 70 parts by weight # 600 (average particle size 20 [mu] m), an alloy powder of Al and Mg (weight ratio 4: 6) was added 3 parts by weight, medium The mixture was dry-mixed for 12 hours in a pot mill containing no. The obtained powder is filled by tapping into a mold having a block of length 600 × width 400 × height 50 mm made of a carbon sheet (Nika film manufactured by Nippon Carbon Co., Ltd.). An ingot of Al-7Mg of the same weight as the powder was placed and infiltrated at 825 ° C. for 24 hours in a nitrogen atmosphere in an electric furnace, then cooled at 100 ° C./hr, demolded from the mold, and then subjected to metal-ceramics. A composite material was made.

(2) Evaluation The bulk density of the obtained preform was measured by the Archimedes method, and the powder filling rate was determined. As a result, it was 42 vol%. Further, the obtained composite material was cut, and the permeation state of the metal on the cut surface was visually observed. As a result, the aluminum alloy was completely infiltrated.

Example 2 (1) Production of Metal-Ceramic Composite Material Commercially available Si of # 180 (average particle size 66 μm) as a reinforcing material
Pot mill with no medium added, with 70 parts by weight of C powder and 30 parts by weight of commercially available SiC powder of # 800 (average particle size: 14 μm) added with 4 parts by weight of an alloy powder of Al and Mg (weight ratio 4: 6). For 12 hours. The obtained powder is filled by tapping into a mold having a length of 760 × 430 × 200 mm blocks made of carbon sheet (Nika film manufactured by Nippon Carbon Co., Ltd.). An ingot of Al-12Si-5Mg of the same weight as the powder was placed and infiltrated at 825 ° C. for 48 hours in a nitrogen atmosphere, cooled at 100 ° C./hr, demolded from the mold, and subjected to metal-ceramic composite. Materials were made.

(2) Evaluation The bulk density of the obtained preform was measured by the Archimedes method, and the powder filling rate was determined. As a result, it was 49 vol%. Further, the obtained composite material was cut, and the permeation state of the metal on the cut surface was visually observed. As a result, the aluminum alloy was completely infiltrated. This shows that a composite material having no problem can be produced by the infiltration method without forming a preform including Example 1.

Example 3 (1) Preparation of Metal-Ceramic Composite Material 100 parts by weight of silica-coated AlN powder (manufactured by Dow Chemical Company) having an average particle size of 16 μm as a reinforcing material, and alloy powder of Al and Mg (Weight ratio of 4: 6) was added in an amount of 10 parts by weight, and dry-mixed in a pot mill containing no medium for 12 hours. The obtained powder was filled by tapping into a mold having a block of 200 × 200 × 40 mm thick made of a carbon sheet (Nika Film manufactured by Nippon Carbon Co., Ltd.), and the same powder as the powder was placed above the injection port of the mold. A weight of pure Al ingot is placed in a nitrogen atmosphere at a temperature of 825 ° C.
After infiltration for 100 hours, the mixture was cooled at 100 ° C./hr, and released from the mold to produce a metal-ceramic composite material.

(2) Evaluation The bulk density of the obtained preform was measured by the Archimedes method to determine the powder filling rate. As a result, it was 47 vol%. Further, the obtained composite material was cut, and the permeation state of the metal on the cut surface was visually observed. As a result, the aluminum alloy was completely infiltrated. Furthermore, after cutting about 3 mm from the surface of the produced composite material using a carbide tip mill, the surface was polished with diamond abrasive grains, and the surface was visually observed. As a result, pores of 0.5 mm or more were not observed at all. This indicates that when an aluminum alloy containing no Mg is used, infiltration can be performed in a short time as in the case of an alloy containing Mg, and in addition, generation of large pores can be suppressed.

[0032]

As described above, according to the method for producing a metal-ceramic composite material of the present invention, a composite material having no problem can be produced without forming a preform. As a result, compared with the conventional method of forming a preform to produce a composite material, the yield is improved, the permeation time of the metal is reduced, and as a result, the productivity of the metal-ceramic composite material is significantly improved. Manufacturing methods can now be provided. In particular, the effect is great for manufacturing large-sized products and mass-produced products. Therefore, as in the case where a composite material having a high powder filling factor is required, it is naturally possible to produce the composite material only by a method of forming a preform. It is better to use different manufacturing methods depending on the method.

 ────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Tomiwa Koyama 1-3-1-805 Ukima, Kita-ku, Tokyo

Claims (5)

[Claims] 1. A metal comprising a ceramic powder as a reinforcing material.
In the method for producing a ceramic composite material, first, a mold is prepared, and the mold is filled with a ceramic powder mixed with an impregnating accelerator by tapping, and then an alloy containing aluminum as a main component is added to the ceramic powder. ~ 1
A method for producing a metal-ceramic composite material, comprising infiltrating at a temperature of 000 ° C. 2. The impregnation-promoting material has an average particle size of 1 to 100 μm.
m is a powder composed of an alloy of Al and Mg, the ratio of Mg is at least 50% or more, and the mixing amount of the impregnating accelerator is 1 to 100 parts by weight of the ceramic powder.
The method for producing a metal-ceramic composite material according to claim 1, wherein the amount is 10 parts by weight. 3. A mold made of carbon, carbon sheet, A
l ₂ O ₃ powder according to claim 1 or 2, wherein the metal, characterized in that it consists of a mixture of glass frit containing boron or a mixture of glass frit including a SiO ₂ powder and a boron - method of manufacturing a ceramic composite material. 4. The ceramic powder has an average particle size of 0.1%.
~ 150 μm Al ₂ O ₃ powder, SiC powder or AlN
4. The method for producing a metal-ceramic composite material according to claim 1, wherein the composite material is a powder. 5. An alloy containing aluminum as a main component is selected from the group consisting of M
5. The method for producing a metal-ceramic composite material according to claim 1, wherein the metal alloy is an aluminum alloy containing no g.