US20040208772A1 - Sinter metal parts with homogeneous distribution of non-homogeneously melting components as method for the production thereof - Google Patents

Sinter metal parts with homogeneous distribution of non-homogeneously melting components as method for the production thereof Download PDF

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US20040208772A1
US20040208772A1 US10/483,645 US48364504A US2004208772A1 US 20040208772 A1 US20040208772 A1 US 20040208772A1 US 48364504 A US48364504 A US 48364504A US 2004208772 A1 US2004208772 A1 US 2004208772A1
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sintered
sinter
powder
metal
metal part
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Inventor
Anton Eiberger
Manfred Arlt
Manfred Heinritz
Rainhard Laag
Angelika Pohl
Jochen Schmid
Otto Stock
Gerhard Subek
Alfred Bolstler
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Schwaebische Huettenwerke Automotive GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • B22F2003/206—Hydrostatic or hydraulic extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention relates to sinter metal parts with homogeneous distribution of inhomogeneously melting components, essentially from inhomogeneously melting non-ferrous metal powder mixtures as well as processes for their manufacture.
  • non-ferrous as used here is also understood to mean metal mixtures which contain small quantities of iron, up to approx. 8 wt. %—lower quantities of iron should be possible as alloying additives.
  • a further known technique for compacting metal powder is powder forging. This is also a discontinuous process, in which individual parts are produced in swages.
  • multi-phase powders and powder mixtures are sintered in the vicinity of the melting or solidus temperature of the lowest melting component of the mixture.
  • sintering frequently takes place in a protective atmosphere on account of the increased oxidation rate and the prolonged soaking time at sintering temperature.
  • This actual compaction of the green compact was followed by heat treatment which improved the structure thus formed.
  • This is then frequently followed by finishing or calibration, in the course of which the sintered parts are given their final form.
  • hot sintered parts that tend to warp during cooling these additional operations are cost-intensive and difficult to integrate in a production line.
  • a sinter metal part with a homogeneous distribution of inhomogeneously melting components essentially from inhomogeneously melting non-ferrous metal powder mixtures, which can be produced by: continuous isostatic pressure sintering at temperatures of up to about 70% of the melting point of the main component of the initial metal powder mixture through a mould under conditions preventing the occurrence of a fluid phase in the powder, with a sintered profile close to the final contour being formed.
  • ⁇ y (T) representing the yield stress of the material at the projected pressure sintering temperature
  • D specifying the relative density of the cold isostatically precompressed initial product.
  • the relative density is the quotient of the absolute density of the precompressed initial product ⁇ 0 and the density of the solid alloy ⁇ B .
  • the pressure sintering operation is effected through a two-sided open mould to form a sintered profile; optionally, cutting of the sintered profile into sintered products, heat treatment of the sintered products or of the sintered profile and optionally finishing of the same.
  • Typical continuous isostatic pressure sintering at temperatures up to about 70% of the melting point of the main component of the initial metal powder mixture is preferably carried out on a hydraulic extruding press adapted to the process parameters—whereby conventional extrusion moulding, which is employed for homogeneously melting materials at temperatures near the melting point, leads to extrudates with low dimensional accuracy on account of an excessive heating of the extrudate, and these products then have to be finished, for example by pressing, forging etc.
  • the continuous isostatic pressure sintering at very high pressures used here, according to the above formula, also makes it possible to select a temperature at which the extrudate in the extrudate caused by friction is also taken into account.
  • T stands for the temperature for the selected yield point at elevated temperature of the material
  • Q B the quantity of heat fed to the initial material
  • Q ⁇ the quantity of heat given off to the tool surface
  • l the active tool length
  • c B the compression velocity
  • the process is characterised in that the powder material is heated only a little and briefly on account of the possible reduction of the preheating temperature—unlike conventional extruders, where a uniform and higher temperature rise in the pressed material is desirable.
  • the preferred initial material used for continuous isostatic pressing is a powder press compact—compressed using known pressing methods—without slip additive, lubricant or sintering aid.
  • This powder press compact may already have a non-homogeneous material distribution—in particular if non-homogeneous sintered parts—that is, composite parts—are to be produced.
  • a typical feature is for example an external material layer of a different, chemically or physically more resistant material—if for example a certain corrosion stability is required in an external or internal layer—as in powder metallurgical pipes or discs.
  • the powder press compact is then isostatically relatively cold pressed/sintered in a press with a die plate, and undergoes a bonding reaction at the grain boundaries of the components through the shearing forces during pressing, without the occurrence of a fluid phase which could lead to segregation. In this way, a homogeneous sintered product can be produced with superior material properties.
  • this continuously produced sintered product formed by the die plate, can be cooled down by controlled cooling, for example by spraying with water, in such a way that a fine grained state is achieved by quenching or that a defined heat treatment, e.g. a T4 heat treatment for aluminium alloys, may take place.
  • the cooled extrudate can then be mechanically aftertreated.
  • the continuously produced profile-type sintered product is usually cut at product height—by sawing, water cutting, laser cutting or other methods with which the expert is familiar. These sections of defined length of the continuously produced sintered product can then be used as such or after finishing—for example surface treatment or calibration.
  • the sintered product cut to product length in this way can also optionally be subjected to heat treatment in order to change or temper the material structure. In this case, the heat treatment must be such that no fluid phases can occur.
  • a typical form of finishing for the sintered product according to the invention is calibration on a press in order to obtain the dimensionally very close tolerances of the final form of the product. Machining is usually not required.
  • the product which has been sintered at temperatures of up to 70% of the melting point of the main component, already has final contour—this means that the finishing steps only require little effort.
  • the sintered parts made of inhomogeneously melting metal mixtures produced according to the invention show improved workability and higher ductility and higher elongation than those that were produced using methods according to the state of the art. In further production stages, this is shown by improved workability.
  • the mechanical technological parameters of the sintered parts, elasticity, tensile strength and elongation are influenced very favourably.
  • a component sintered without pressure, made of an aluminium alloy with 13% silicon by weight has a breaking elongation of less than 0.5%
  • a component made of the same alloy produced by a method according to the invention has typical breaking elongation values of 7 to 12%. This is achieved by the suppression of the formation of the melting phase, so that the structure cannot part-crystallise inhomogeneously.
  • the scatter of the material parameters of sintered parts produced according to the invention is very much lower than that of hot sintered parts of the same composition—that is, they have closer material parameter limits than is the case with conventional HIP or hot sintering.
  • non-miscible components such as hard phases can be incorporated so that they are homogeneously distributed, as well as materials which are hardly accessible or not accessible at all according to classical sintering methods.
  • the material powder used is a powder mixture of metals or their alloys, and further materials such as hard parts, fibres, and carriers of wear and tear such as boron carbide, BN.
  • Short or long fibres may be added, or particles in proportions of 5-30% by volume.
  • Short fibres or whiskers have a length that is considerably shorter than 100 times the fibre diameter.
  • Long, endless or continuous fibres are those whose fibre length is greater than 100 times their diameter. Fibres can serve to improve the strength of the sintered parts.
  • Particle reinforced materials can also be produced in this way, that is, those with silicon carbide, boron carbide etc.
  • other, typically sintered alloys can also be processed, such as Ti alloys, in particular Ti/Nb alloys, TiAl and TiAl Nb as well as Co—Ti—B Mg+SiC, boron carbide, Al2O3 or AlPb alloys with high heat storage capacities which cannot be produced by melting metallurgy—that is, sintered composite material parts can be continuously produced, or beryllium parts, magnesium parts etc.
  • Ti alloys in particular Ti/Nb alloys, TiAl and TiAl Nb as well as Co—Ti—B Mg+SiC, boron carbide, Al2O3 or AlPb alloys with high heat storage capacities which cannot be produced by melting metallurgy—that is, sintered composite material parts can be continuously produced, or beryllium parts, magnesium parts etc.
  • Examples of typical compounds are aluminium with Si, Mg, Cu, Zn and optionally Fe, for example with 10-40% Si, Mg 0-3%, Cu 0-5%, Zn and Fe 0-7%, as well as other light metal alloys, for example those of magnesium, calcium, beryllium etc.
  • AlSi, AlSiCu among others, are available, aluminium sintered materials: AlCuMg, with—Al Cu 3.8-4.4, Mg 0.5-1.0: AlMgSi with AlSi 0.4-0.8, Mg 0.5-1.0, AlZnMgCu 0.05-0.6, Cu 0.25-1.6, Mg 0.1-1.5, Zn 1.5-8.0, AlSi with more than approx. 7% Si are available.
  • the invention relates to sintered light metal parts made of light metal alloys that are difficult to machine. Hypereutectoid alloys can also be produced, and the expert will be able to see further advantages on account of his expert knowledge.
  • the sintered parts produced according to the invention are characterised by an elongation that is at least 150% higher than an elongation of the same material composition produced by powder forging, sintering or casting.
  • fibres such as ceramic fibres, carbon fibres or hard material fibres
  • higher strength is obtained—improvement in tensile strength, increase in the yield point, increase in the elasticity module, improved high temperature strength and creep resistance—a reduction in the thermal coefficient of expansion.
  • SiC particles, AlN, BN, TiB2, boron carbide, SiO2, tungsten carbide are typical as carriers of wear and tear or hard materials: fibres such as carbon fibres, metal fibres, ceramic or glass fibres.
  • Suitable metal phases may be selected from aluminium, titanium, copper, beryllium, magnesium, calcium, nickel, lithium, chromium, molybdenum, tungsten, bronze, niobium, lead, zinc and cobalt.
  • the method also allows a composite (preferably a powder press compact) consisting of several areas of differing composition—that is, a sintered part with layers, rings, strips etc to be sintered.
  • a composite preferably a powder press compact
  • This may be of interest, for example, if a hard layer is required as an external material—for example for cutting wheels or the like—but a cheaper, more ductile and more elastic material is required as internal material.
  • Previously, such parts had to be produced separately and then joined—while the process according to the invention allows production in one step through joint continuous isostatic pressing, allowing several materials to be sintered together.
  • Sintered parts with a hard cutting edge can also be produced from a different material composition than that used for other areas.
  • FIG. 1 shows a schematic view of the process steps compared to the conventional sinter pressing of an aluminium-silicon alloy
  • FIG. 2 shows a microscopic picture of a solid microsection from an AlSi14% alloy—produced by melting metallurgy-type casting, after the method according to the invention and after conventional sintering.
  • FIG. 3 hot pressure experiment with parts according to the invention
  • FIG. 4 friction coefficient curves of AlSi14% against 100 Cr6—parts produced by the method according to the invention and parts produced by sintering
  • FIG. 5 sintered products with non-homogeneous sections—a schematic view
  • FIG. 6 diagrammatic process sequence in the production of sintered products with non-homogeneous sections.
  • FIG. 1 shows a diagrammatic view of the process sequence according to the teaching of the invention.
  • the method comprises the manufacture of a continuously sintered part which is produced by the continuous isostatic pressing of a sinterable material mixture without lubricant, from a sinter form closed by a die plate.
  • the initial material an inhomogeneously melting mixture of aluminium powder with 13 wt. % silicon powder (AlSi only melts homogeneously in the range 5-7%) is homogeneously mixed and then transferred to a powder press for the manufacture of powder billets not close to the final contour. There it is cold pressed under high pressure to form a billet-like green compact.
  • the billet-like green compact is transferred to a system for continuous isostatic sintering—here an extruding press—and is sintered as it is pressed through the die plate.
  • the AlSi14 sintered part leaves the die plate at temperatures of up to 70% of the melting point of the main component as a continuous sintered profile, the external contour of which is close to the final form.
  • the continuously sintered profile is now mechanically separated according to the required disc height and the material discs are heat treated at 250° C. for 30 minutes.
  • the sintered discs come from the heat treatment they are then calibrated in a calibration press at a force of 150 KN—that is, the final form is achieved with very close dimensional tolerances.
  • the sintered parts produced in this way do not have to be decapsulated and have suitable flow properties for calibration. They can then be used as finished parts without any further finishing.
  • AlSi14% sintered parts were produced conventionally by sintering, by pressing a green compact, made of aluminium powder with 14wt. % of silicon with Hoechst Wachs C compression aiding material, into a disc, this disc was then treated for 20 minutes at 410° C. in a heat treatment stage, then sintered for 30 minutes at 590° C. in a sintering furnace and then heat-treated once more at 400° C. for 240 minutes, as a comparative product.
  • FIG. 2 shows a a comparison of the microstructures of the AlSi14 sintered aluminium discs, produced with conventional hot sintering according to the comparative test, and produced by isostatic pressing according to the invention. It is clearly shown that the part produced according to the invention has a smaller grain size and fewer segregated areas—the sintered part produced according to the invention is therefore more homogeneous in its properties.
  • FIG. 3 shows friction coefficient curves of hot isostatic pressed AlSi14% formed bodies and continuously isostatically pressure sintered AlSi14% formed bodies according to the invention against 100 Cr6.
  • the sintered bodies produced according to the invention have a lower scatter—that is, they can be set more precisely and thus also supply fewer waste parts.
  • the sintered parts are more homogeneous and can also be elongated more, thus providing improved elastic behaviour, as required in particular by mechanically stressed parts, such as chain wheels against steel chains, rotors and stators in a camshaft adjustment system or oil pump parts, bearing parts, pump wheels etc.
  • Table 1 shows that the strength of the isostatically continuously sintered AlSi14 part produced according to the invention is considerably better than that of the hot isostatically pressed part.
  • FIG. 5 shows the result of the manufacture of parts sintered according to the invention with different material areas—here in FIG. 5 a a section of a round sintered part with a different external layer—in FIG. 5 b a two-layered square sintered part; in FIG. 5 c a tubular sintered part with different layers; FIG. 5 d shows a striped distribution in sintered parts.
  • a combination of different sintering materials is thus possible with the simultaneous production of the sintered part—for example the application of an external layer reinforced with hard materials, as a separate process stage, can thus be prevented by direct “application by sintering”—etc.
  • a powder mixture of alloyed AlMgl powder and 2 wt. % silicon powder for the mixture of the internal material, and a powder mixture of aluminium powder with 40% SiC for the external material are homogeneously mixed and pressed in a divided mould which produces the required powder billet with AlSi as core and AlSiC as outer layer.
  • This powder billet is transferred to a continuous isostatic press with a round die plate and processed under high pressure at temperatures of up to 70% of the melting point of the main component to form a round sintered profile.
  • the sintered profile produced in this way is cut into discs with a height of 15 mm by means of a water jet.
  • These discs are suitable as pump gear wheels for oil and water pumps, said wheels having an easily workable internal zone for drilling holes, while the external zone with the SiC hard part phase is resistant to wear by friction.
US10/483,645 2001-07-20 2002-07-22 Sinter metal parts with homogeneous distribution of non-homogeneously melting components as method for the production thereof Abandoned US20040208772A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10135485.1 2001-07-20
DE10135485A DE10135485A1 (de) 2001-07-20 2001-07-20 Verfahren zur endkonturnahen Fertigung von Bauteilen bzw. Halbzeugen aus schwer zerspanbaren Leichtmetalllegierungen, und Bauteil bzw. Halbzeug, hergestellt durch das Verfahren
PCT/DE2002/002692 WO2003011501A2 (de) 2001-07-20 2002-07-22 Sintermetallteile mit homogener verteilung nicht homogen schmelzender komponenten, sowie verfahren zu ihrer herstellung

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US (1) US20040208772A1 (ja)
EP (2) EP1281461B1 (ja)
JP (1) JP2004536232A (ja)
KR (1) KR20040030054A (ja)
AT (2) ATE275015T1 (ja)
BR (1) BR0211267A (ja)
CA (1) CA2438397A1 (ja)
DE (4) DE10135485A1 (ja)
ES (2) ES2227044T3 (ja)
HU (1) HUP0401206A2 (ja)
WO (1) WO2003011501A2 (ja)

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US20070182073A1 (en) * 2004-12-20 2007-08-09 Speyer Robert F Density and hardness pressureless sintered and post-HIPed B4C
US7517491B2 (en) 2003-06-12 2009-04-14 Georgia Tech Research Corporation Processes and methods of making boron carbide
US20100288113A1 (en) * 2005-04-11 2010-11-18 Speyer Robert F Boron carbide component and methods for the manufacture thereof
US20110129380A1 (en) * 2008-05-23 2011-06-02 Rovalma, S.A. Method and device for producing a workpiece, particularly a shaping tool or a part of a shaping tool
US20120037104A1 (en) * 2010-08-11 2012-02-16 Schwabische Huttenwerke Automotive Gmbh Sintered composite and method for its manufacture
CN105026623A (zh) * 2013-01-29 2015-11-04 舍弗勒技术股份两合公司 带有由AlSi合金制成的承载体的张紧轨

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DE202008001976U1 (de) 2007-03-14 2008-07-24 Schwäbische Hüttenwerke Automotive GmbH & Co. KG Fluiddichte Sintermetallteile
DE102011009835A1 (de) 2011-01-31 2012-08-02 Audi Ag Verfahren zur Herstellung von Blechhalbzeugen oder Blechbauteilen aus Aluminium-Matrix-Komposite
CN105603271A (zh) * 2016-01-27 2016-05-25 东莞佛亚铝业有限公司 一种高硅铝合金线材及其制备方法

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US7517491B2 (en) 2003-06-12 2009-04-14 Georgia Tech Research Corporation Processes and methods of making boron carbide
US7592279B1 (en) 2003-06-12 2009-09-22 Georgia Tech Research Corporation Boron carbide and boron carbide components
US20070182073A1 (en) * 2004-12-20 2007-08-09 Speyer Robert F Density and hardness pressureless sintered and post-HIPed B4C
US8377369B2 (en) 2004-12-20 2013-02-19 Georgia Tech Research Corporation Density and hardness pressureless sintered and post-HIPed B4C
US20100288113A1 (en) * 2005-04-11 2010-11-18 Speyer Robert F Boron carbide component and methods for the manufacture thereof
US7854190B2 (en) 2005-04-11 2010-12-21 Georgia Tech Research Corporation Boron carbide component and methods for the manufacture thereof
US20110129380A1 (en) * 2008-05-23 2011-06-02 Rovalma, S.A. Method and device for producing a workpiece, particularly a shaping tool or a part of a shaping tool
US20120037104A1 (en) * 2010-08-11 2012-02-16 Schwabische Huttenwerke Automotive Gmbh Sintered composite and method for its manufacture
EP2418034A3 (de) * 2010-08-11 2014-05-28 Schwäbische Hüttenwerke Automotive GmbH Zahnrad-Sinterverbund und Verfahren zu seiner Herstellung
US9144844B2 (en) * 2010-08-11 2015-09-29 Schwabische Huttenwerke Automotive Gmbh Sintered composite and method for its manufacture
CN105026623A (zh) * 2013-01-29 2015-11-04 舍弗勒技术股份两合公司 带有由AlSi合金制成的承载体的张紧轨
US20150362048A1 (en) * 2013-01-29 2015-12-17 Schaeffler Technologies AG & Co. KG Tensioning rail having an alsi alloy support body

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KR20040030054A (ko) 2004-04-08
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WO2003011501A2 (de) 2003-02-13
ES2231721T3 (es) 2005-05-16
HUP0401206A2 (en) 2004-10-28
ES2227044T3 (es) 2005-04-01
BR0211267A (pt) 2004-08-03
EP1412113B1 (de) 2004-10-27
JP2004536232A (ja) 2004-12-02
ATE275015T1 (de) 2004-09-15
CA2438397A1 (en) 2003-02-13
EP1281461B1 (de) 2004-09-01
WO2003011501A3 (de) 2003-05-01
DE50103474D1 (de) 2004-10-07
DE10135485A1 (de) 2003-02-06
EP1281461A1 (de) 2003-02-05
DE50201420D1 (de) 2004-12-02

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