TW202223113A - Method for manufacturing composite material - Google Patents
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本發明是關於一種複合材料的製備方法,尤其是一種鋁基複合材料的製備方法。The present invention relates to a preparation method of a composite material, in particular to a preparation method of an aluminum matrix composite material.
中華民國申請第099110098號「鋁基複合材料的製備方法」,其揭露將一鋁基金屬加熱至該鋁基金屬的液相線和固相線之間的溫度,以得到一半固態的鋁基金屬;接著,將複數個奈米陶瓷顆粒﹝包括奈米碳化矽(SiC)顆粒、奈米氧化鋁(Al2O3)顆粒及奈米碳化硼(B4C)顆粒中的一種或多種﹞加入至該半固態的鋁基金屬混合,以得到一鋁基半固態混合漿料;最後,再將該鋁基半固態混合漿料升溫至液態,以得到一鋁基液態混合漿料。Republic of China Application No. 099110098 "Method for preparing aluminum-based composite material", which discloses heating an aluminum-based metal to a temperature between the liquidus and solidus of the aluminum-based metal to obtain a semi-solid aluminum-based metal Next, a plurality of nano-ceramic particles (including one or more of nano-silicon carbide (SiC) particles, nano-alumina (Al2O3) particles and nano-boron carbide (B4C) particles) are added to the semi-solid The aluminum-based metals are mixed to obtain an aluminum-based semi-solid mixed slurry; finally, the aluminum-based semi-solid mixed slurry is heated to a liquid state to obtain an aluminum-based liquid mixed slurry.
上述之該鋁基複合材料的製備方法,其係將碳化矽(SiC)等奈米顆粒混合於該半固態的鋁基金屬中,因此當混合有碳化矽(SiC)等奈米顆粒的該半固態的鋁基金屬在升溫成液態,並再降溫成固態後,會得到混合有碳化矽(SiC)等奈米顆粒的一固態鋁基複合材料。The above-mentioned preparation method of the aluminum-based composite material is to mix nano-particles such as silicon carbide (SiC) into the semi-solid aluminum-based metal, so when the semi-solid aluminum-based metal is mixed with nanoparticles such as silicon carbide (SiC) After the solid aluminum-based metal is heated to a liquid state, and then cooled to a solid state, a solid aluminum-based composite material mixed with nano-particles such as silicon carbide (SiC) is obtained.
然而,由於該固態鋁基複合材料含有該些碳化矽(SiC)等奈米顆粒,因此在該些碳化矽(SiC)、氧化鋁(Al2O3)及碳化硼(B4C)顆粒處容易產生裂縫,而使該固態鋁基複合材料產生疲勞破壞或斷裂,而這將影響該固態鋁基複合材料品質的可靠度,此外,由於該鋁基複合材料的製備方法是直接將混合有碳化矽(SiC)等奈米顆粒的該半固態的鋁基金屬升溫成液態,因此其加工時間較長,影響著製造效率。However, since the solid aluminum-based composite material contains nano-particles such as silicon carbide (SiC), cracks are easily generated at the silicon carbide (SiC), aluminum oxide (Al2O3) and boron carbide (B4C) particles, and This will cause fatigue failure or fracture of the solid aluminum matrix composite material, which will affect the reliability of the quality of the solid aluminum matrix composite material. In addition, since the preparation method of the aluminum matrix composite material is to directly mix silicon carbide (SiC) and the like The semi-solid aluminum-based metal of the nanoparticle heats up to a liquid state, so its processing time is long, which affects the manufacturing efficiency.
本發明的主要目的是用以製造一種含有金屬顆粒的複合材料。The main purpose of the present invention is to manufacture a composite material containing metal particles.
本發明之一種複合材料的製備方法包含提供一半固態金屬熔湯,維持一工作溫度於該半固態金屬熔湯的半固態溫度區間,且將複數個金屬顆粒混入於該半固態金屬熔湯中,以形成一工作熔湯,及將該工作熔湯與熔融的一金屬熔湯混合,使該工作熔湯熔融混合該金屬熔湯後,固化形成一複合材料,且該複合材料內分佈有顆粒狀的該些金屬顆粒。A preparation method of a composite material of the present invention includes providing a semi-solid metal molten soup, maintaining a working temperature in the semi-solid temperature range of the semi-solid metal molten soup, and mixing a plurality of metal particles into the semi-solid metal molten soup, To form a working molten soup, and the working molten soup is mixed with a molten metal molten soup, so that the working molten soup is melted and mixed with the metal molten soup, and then solidified to form a composite material, and granular particles are distributed in the composite material. of these metal particles.
本發明藉由預先形成該金屬熔湯,使得混合具有該些金屬顆粒的該工作熔湯與該金屬熔湯時,可縮短該工作熔湯與該金屬熔湯的混合時間及縮短該些金屬顆粒被加溫的時間,以降底該複合材料的製備時間,並使該些金屬顆粒仍維持為顆粒狀,以避免固化後的該複合材料產生裂縫,而發生疲勞破壞或斷裂,其可提升該複合材料品質的可靠度。The present invention forms the molten metal in advance, so that the mixing time of the working molten soup and the molten metal can be shortened and the metal particles can be shortened when mixing the working molten soup with the metal particles and the molten metal The time to be heated is to reduce the preparation time of the composite material and keep the metal particles in a granular shape, so as to avoid cracks in the cured composite material, and fatigue failure or fracture occurs, which can improve the composite material. Reliability of material quality.
請參閱第1圖,一種複合材料的製備方法包含「提供半固態金屬熔湯」步驟S1、「混合金屬顆粒與半固態金屬熔湯以形成工作熔湯」步驟S3、及「混合工作熔湯與金屬熔湯」步驟S4,較佳地,在該步驟S3前先進行「預熱金屬顆粒」步驟S2。Referring to FIG. 1, a method for preparing a composite material includes a step S1 of “providing a semi-solid metal bath”, a step S3 of “mixing metal particles and a semi-solid metal bath to form a working bath”, and “mixing the working bath with "Metal molten soup" step S4, preferably, "preheating metal particles" step S2 is performed before this step S3.
請參閱第1及2A圖,在「提供半固態金屬熔湯」步驟S1中,是將一第一金屬加熱升溫至半固態溫度後形成一半固態金屬熔湯10,或者,在不同實施例中,是將該第一金屬加熱升溫至液態溫度後,再降溫至半固態溫度,形成該半固態金屬熔湯10,但本發明並不以此為限。Please refer to FIGS. 1 and 2A, in the step S1 of "providing a semi-solid metal molten soup", a first metal is heated to a semi-solid temperature to form a semi-solid metal
首先,請參閱第1及2A圖,在本實施例中,以該第一金屬的材質為鋁說明,其係將一固態鋁材經加熱後,形成為一半固態鋁熔湯,該固態鋁材的熔點約為660°C,本實施例是將該固態鋁材加熱至720°C至750°C,使該固態鋁材形成為一鋁熔湯,再將該鋁熔湯降溫至590°C至600°C之間以形成一半固態鋁熔湯(即為該半固態金屬熔湯10)。First, please refer to Figures 1 and 2A, in this embodiment, the material of the first metal is aluminum, which is to heat a solid aluminum material to form a semi-solid aluminum molten soup, and the solid aluminum material is heated. The melting point is about 660 ° C, the present embodiment is to heat this solid aluminum material to 720 ° C to 750 ° C, so that this solid aluminum material is formed into an aluminum molten soup, and then this aluminum molten soup is cooled to 590 ° C between 600° C. to form a semi-solid aluminum molten soup (that is, the semi-solid metal molten soup 10 ).
請參閱第1及2A圖,在本實施例中,在將該鋁熔湯冷卻成該半固態鋁熔湯的過程中,是以一攪拌件40攪拌該鋁熔湯(即為該半固態金屬熔湯10),該攪拌件40的材質選自於不銹鋼或耐高溫材料製成,在本實施例中,該攪拌件40以轉速60rpm對該鋁熔湯進行攪拌,使該鋁熔湯形成為該半固態鋁熔湯。Please refer to Figures 1 and 2A, in this embodiment, in the process of cooling the aluminum molten metal into the semi-solid aluminum molten soup, a
接著,請參閱第1及2B圖,進行「混合金屬顆粒與半固態金屬熔湯以形成工作熔湯」步驟S3,在步驟S3中,是維持一工作溫度於該半固態金屬熔湯10的半固態溫度區間,且將複數個金屬顆粒20混入該半固態金屬熔湯10,並使該些金屬顆粒20與該半固態金屬熔湯10混合,以形成一工作熔湯,在本實施例中,藉由該攪拌件40攪拌該些金屬顆粒20與該半固態金屬熔湯10,使該些金屬顆粒20與該半固態金屬熔湯10混合,並使該半固態金屬熔湯10仍維持為半固態狀,且使該些金屬顆粒20仍維持為顆粒狀,較佳地,在步驟S3前,進行「預熱金屬顆粒」步驟S2,其係在混合該些金屬顆粒20與該半固態金屬熔湯10前,先預熱該些金屬顆粒20,並使該些金屬顆粒20仍維持為顆粒狀,以避免將該些金屬顆粒20加入於該半固態金屬熔湯10後,影響該半固態金屬熔湯10的溫度。Next, referring to FIGS. 1 and 2B, step S3 of “mixing metal particles and semi-solid metal molten soup to form a working molten soup” is performed. In step S3, a working temperature is maintained at half of the semi-solid metal
請參閱第1及2B圖,該些金屬顆粒20的粒徑界於40至80微米之間,較佳地,該些金屬顆粒20為不同材質,在本實施例中,該些金屬顆粒20至少包含複數個第一金屬顆粒20a及複數個第二金屬顆粒20b,較佳地,該些第一金屬顆粒20a的熔點與該半固態金屬熔湯10相同,該些第二金屬顆粒20b的熔點高於該半固態金屬熔湯10,在本實施例中,該些第一金屬顆粒20a選自於鋁顆粒,該些第二金屬顆粒20b選自於銅顆粒及鐵顆粒的至少其中之一。Please refer to FIGS. 1 and 2B, the particle size of the
接著,請參閱第1及2D圖,進行「混合工作熔湯與金屬熔湯」步驟S4,請參閱第2C圖,在步驟S4中,是將一第二金屬預先加熱升溫至液態溫度後形成一金屬熔湯30,在本實施例中,以該半固態金屬熔湯10與該金屬熔湯30為相同材質說明,該第一金屬、該第二金屬及該些第一金屬顆粒20a的材質為鋁,該些第一金屬顆粒20a的熔點與該金屬熔湯30相同,且該些第二金屬顆粒20b的熔點高於該金屬熔湯30,該金屬熔湯30係將一固態鋁材經加熱後,形成為一鋁熔湯。Next, referring to Figures 1 and 2D, step S4 of "mixing working molten metal and molten metal" is performed. Please refer to Figure 2C. In step S4, a second metal is pre-heated to a liquid temperature to form a The
請參閱第1及2D圖,在步驟S4中,將該工作熔湯與該鋁熔湯(即為該金屬熔湯30)混合時,在本實施例中,藉由該攪拌件40攪拌該工作熔湯及該鋁熔湯(即為該金屬熔湯30),使該工作熔湯熔融混合該金屬熔湯30後,固化成一複合材料50,在本實施例中,該複合材料50為一鋁基複合材料,且由於該金屬熔湯30已預先形成,因此當混合該工作熔湯與該鋁熔湯(即為該金屬熔湯30)時,可縮短該工作熔湯與該金屬熔湯30的混合時間及縮短該些金屬顆粒20被加溫的時間,使該些金屬顆粒20仍維持為顆粒狀,在本實施例中,由於縮短了該工作熔湯與該金屬熔湯30的混合時間,因此使得該些第一金屬顆粒20a(鋁顆粒)及該些第二金屬顆粒20b(銅顆粒及鐵顆粒的至少其中之一)仍可維持為顆粒狀。Please refer to Figures 1 and 2D. In step S4, when the working molten metal is mixed with the aluminum molten soup (ie, the metal molten soup 30), in this embodiment, the
在本實施例中,該複合材料50包含重量百分比為51%的該半固態鋁熔湯(即該半固態金屬熔湯10)、6-9%的該些金屬顆粒20及40-43%的鋁熔湯(即該金屬熔湯30)為佳,且該些金屬顆粒20包含重量百分比為64%的鋁顆粒、24%的銅顆粒及12%的鐵顆粒,因此當混合該些金屬顆粒20與該半固態鋁熔湯,或當混合具有該些金屬顆粒20的該工作熔湯及該鋁熔湯時,由於該銅顆粒及該鐵顆粒的熔點高於該半固態鋁熔湯及該鋁熔湯,因此使得該銅顆粒及該鐵顆粒仍可維持為顆粒狀,且由於該鋁熔湯已預先形成,因此可縮短該工作熔湯及熔融的該鋁熔湯的混合時間,使得該鋁顆粒僅為表層熔融,但仍可維持為顆粒狀,該複合材料50(如鋁基複合材料)可被運用於重力鑄造以製成一鑄件。In the present embodiment, the
本發明是藉由預先形成該金屬熔湯30,以縮短具有該些金屬顆粒20的該工作熔湯與該金屬熔湯30的混合時間,以降底該複合材料50的製備時間及該些金屬顆粒20被加溫的時間,以使該些金屬顆粒20仍維持為顆粒狀,並可避免固化後的該複合材料50產生裂縫,而發生疲勞破壞或斷裂,其可有效地提升該複合材料50品質的可靠度。The present invention shortens the mixing time of the working molten soup with the
本發明之保護範圍當視後附之申請專利範圍所界定者為準,任何熟知此項技藝者,在不脫離本發明之精神和範圍內所作之任何變化與修改,均屬於本發明之保護範圍。The protection scope of the present invention shall be determined by the scope of the appended patent application. Any changes and modifications made by anyone who is familiar with the art without departing from the spirit and scope of the present invention shall fall within the protection scope of the present invention. .
S1:提供半固態金屬熔湯
S2:預熱金屬顆粒
S3:混合金屬顆粒與半固態金屬熔湯以形成工作熔湯
S4:混合工作熔湯與金屬熔湯
10:半固態金屬熔湯
20:金屬顆粒
20a:第一金屬顆粒
20b:第二金屬顆粒
30:金屬熔湯
40:攪拌件
50:複合材料
S1: Provide semi-solid metal molten soup
S2: Preheat metal particles
S3: Mixing metal particles with semi-solid metal melt to form a working melt
S4: Mixing working molten and metal molten
10: Semi-solid metal molten soup
20:
第1圖:本發明的複合材料的製備方法的流程圖。 第2A至2D圖:本發明的複合材料的製備方法的示意圖。 Fig. 1: a flow chart of the method for preparing the composite material of the present invention. Figures 2A to 2D: Schematic representations of the method for preparing the composite material of the present invention.
S1:提供半固態金屬熔湯 S1: Provide semi-solid metal molten soup
S2:預熱金屬顆粒 S2: Preheat metal particles
S3:混合金屬顆粒與半固態金屬熔湯以形成工作熔湯 S3: Mixing metal particles with semi-solid metal melt to form a working melt
S4:混合工作熔湯與金屬熔湯 S4: Mixing working molten and metal molten
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