US20160346841A1 - Method of making a metal matrix composite material - Google Patents

Method of making a metal matrix composite material Download PDF

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Publication number
US20160346841A1
US20160346841A1 US15/117,214 US201515117214A US2016346841A1 US 20160346841 A1 US20160346841 A1 US 20160346841A1 US 201515117214 A US201515117214 A US 201515117214A US 2016346841 A1 US2016346841 A1 US 2016346841A1
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Prior art keywords
metal
powder
metal box
box
mixed powder
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US15/117,214
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Inventor
Étienne LANDRY-DÉSY
Geneviéve GIASSON
Muhammad Zubair NAWAZ
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3M Innovative Properties Co
Ceradyne Inc
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3M Innovative Properties Co
Ceradyne Inc
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Priority to US15/117,214 priority Critical patent/US20160346841A1/en
Assigned to 3M INNOVATIVE PROPERTIES COMPANY reassignment 3M INNOVATIVE PROPERTIES COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LANDRY-DESY, ETIENNE, NAWAZ, Muhammad Z., GIASSON, GENEVIEVE
Publication of US20160346841A1 publication Critical patent/US20160346841A1/en
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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
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • B22F1/0003—
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/12—Metallic powder containing non-metallic particles
    • 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
    • B22F3/02—Compacting only
    • 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
    • B22F3/18—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by using pressure rollers
    • 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
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C22C32/0052—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides
    • C22C32/0057—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides based on B4C
    • 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
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • B22F2003/175—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging by hot forging, below sintering temperature
    • 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
    • B22F3/18—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by using pressure rollers
    • B22F2003/185—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by using pressure rollers by hot rolling, below sintering temperature
    • 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
    • B22F2003/208—Warm or hot extruding
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • B22F2007/042—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal characterised by the layer forming method
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/05—Light metals
    • B22F2301/052—Aluminium
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/05—Light metals
    • B22F2301/058—Magnesium
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/35—Iron
    • 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
    • B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
    • B22F2302/10—Carbide
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00—Energy generation of nuclear origin
    • Y02E30/30—Nuclear fission reactors

Definitions

  • a process for making a metal matrix composite is described.
  • the metal matrix composite is used as a neutron shielding material.
  • Metal matrix composite (MMC) materials comprising a metal and a ceramic, increasingly have been used as neutron absorber materials in the nuclear industry for storage and transportation of fresh and spent fuel.
  • MMC articles having increased final density and/or higher ceramic content, resulting in, in at least one embodiment, improved performance. There is also a need for improved processing and/or reducing manufacturing costs.
  • a method for making a metal matrix composite material comprising:
  • FIG. 1 is a perspective view of pre-rolling assembly 10
  • FIG. 2 is a perspective view of metal box 20 , depicting the length ( 1 ), width (w) and height (h);
  • FIG. 3 is a side view of compaction assembly 30 ;
  • FIG. 4 are micrographs of the metal matrix composite material compacted at (A) 0 TSI, (B) 3 TSI, and (C) 7 TSI.
  • At least one includes all numbers of one and greater (e.g., at least 2, at least 4, at least 6, at least 8, at least 10, at least 25, at least 50, at least 100, etc.).
  • each function can be increased by increasing the amount of ceramics having the required function, but simply increasing the amounts can cause the workability, extrusion ability, rolling ability, ductility, and forging ability to be largely reduced.
  • U.S. Pat. No. 7,998,401 discloses an alternative method of increasing the ceramic content in an MMC, which is said to be easy to produce.
  • Okaniwa et al. discloses electric pressure sintering of an aluminum/ceramic powder mix within a metal sheet and then subjecting this metal clad material to a plastic working step.
  • FIG. 1 Shown in FIG. 1 is pre-rolling assembly 10 comprising metal box 12 , compacted powder preform 15 , and top forming plate 18 .
  • the pre-rolling assembly is subsequently rolled to form an encased metal matrix composite.
  • the metal box comprises 5 metal sides: a bottom forming plate, a first pair of side forming plates, and a second pair of side forming plates.
  • the metal box may be fabricated from five individual metal pieces or less.
  • the metal box could be fashioned from 2 metal pieces: a single piece forming the sidewalls and a bottom piece.
  • the forming plates are made of metal.
  • the metal used is not particularly limited as long as the metal excels in adhesion to the powder material and is suitable for hot rolling, such metals include: aluminum, magnesium, and stainless steel.
  • Exemplary metals include, for example, pure aluminum (AA1100, AA1050, AA 1070, etc.) aluminum alloy materials such as Al—Cu alloy (AA2017 etc.), Al—Mg alloy (AA5052 etc.), Al—Mg—Si alloy (AA6061 etc.), Al—Zn—Mg alloy (AA7075 etc.) and Al—Mn alloy; magnesium alloy materials such as Mg—Al—Zn—Mn (AZ31, AZ61, etc); and stainless steel alloy material such as Fe—Cr (SAE 304, 316, 316, 316L, etc).
  • the metal box primarily functions as a container to hold the compacted powder as it is worked.
  • the metal selected should be determined in consideration of the desired properties, cost, and the like. For example, when wishing to improve the workability and heat dissipation ability, pure aluminum is preferable. Pure aluminum is also preferable in terms of contamination control for nuclear application and raw material cost as compared with aluminum alloys. When wishing to improve the strength or workability, an Al Mg alloy (AA5052 etc.) is preferable.
  • a mixed powder comprising a metal powder and a ceramic powder is contained within the metal box.
  • the metal powder is aluminum, however other metal powders may be used including magnesium or stainless steel.
  • Exemplary types of metal powders include pure aluminum (aluminum powder with purity of at least 99.0%, e.g., AA1100, AA1050, AA1070 etc.), or an aluminum alloy containing aluminum and 0.2 to 2% by mass of another metal.
  • Such alloys include: Al—Cu alloys (AA2017 etc.), Al—Mg alloys (AA5052 etc.), Al—Mg—Si alloys (AA6061 etc.), Al—Zn—Mg alloys (AA7075 etc.) and Al—Mn alloys, either alone or as a mixture of two or more.
  • the composition of the metal powder to be selected can be determined in consideration of for example, the desired properties, corrosion resistance, contamination control, deformation resistance in hot working, amount of ceramic particles mixed, and raw material costs.
  • a pure aluminum powder such as a series AA1XXX aluminum where X is a number
  • a pure aluminum powder is also advantageous in terms of raw material costs as compared with the case of aluminum alloy powders.
  • the pure aluminum powder it is preferable to use one with a purity of at least 99.0% by mass (commercially available pure aluminum powders usually have a purity of at least 99.7% by mass).
  • a boron compound is used as the ceramic particles to be described below, but when wishing to further increase the resulting neutron absorbing ability, it is preferable to add 1-50% by mass of one type of element providing neutron absorbing ability such as hafnium (Hf), samarium (Sm) or gadolinium (Gd) to the aluminum powder.
  • Hf hafnium
  • Sm samarium
  • Gd gadolinium
  • At least one element chosen from titanium (Ti), vanadium (V), chrome (Cr), manganese (Mn), iron (Fe), copper (Cu), nickel (Ni), molybdenum (Mo), niobium (nb), zirconium (Zr) and strontium (Sr), and when room-temperature strength is required, it is possible to add at least one element chosen from silicon (Si), copper (Cu), magnesium (Mg) and zinc (Zn), at a proportion of 2% by mass or less for each element, and a total of 15% by mass or less.
  • the metal powder should generally be at most about 500 ⁇ m (micrometers), 150 ⁇ m, or even 60 ⁇ m or less. While the lower limit of the average particle size is not particularly limited as long as producible, the powder should generally be at least 1 ⁇ m, 5 ⁇ m, 10 ⁇ m, or even 20 ⁇ m.
  • the average particle size shall refer to the D 50 value measured by laser diffraction particle size distribution.
  • the shape of the metal powder is also not limited, and may be any of teardrop-shaped, spherical, ellipsoid, flake-shaped or irregular.
  • the metal powder has a monomodal particle size distribution. In another embodiment of the present disclosure, the metal powder has a multimodal particle size distribution (e.g., bimodal, trimodal, etc.). In one embodiment, the metal powder has a bimodal distribution, wherein the ratio of the average particle of the first mode (comprising the smaller particles) to the second mode (comprising the larger particles) is at least 1:2, 1:3, 1:5, 1:7, 1:11, or even 1:20. The widths of the modes may be wide or narrow.
  • the method of production of the metal powder is not limited, and it may be produced by publicly known methods of production of metallic powders.
  • the method of production can, for example, be by atomization, melt-spinning, rotating disk, rotating electrode or other rapid-cooling solidification method, but an atomization method, particularly an inert gas atomization method, wherein a powder is produced by atomizing a melt is preferable for industrial production.
  • the ceramic powder is mixed with the metal powder to eventually form the metal matrix composite.
  • Exemplary ceramic powders include Al 2 O 3 , SiC or B 4 O, BN, aluminum nitride and silicon nitride. These may be used atone or as a mixture, and selected depending on the intended use of the composite material.
  • the composition of the ceramic powder to be selected can be determined in consideration of, for example, the desired properties, the amount of ceramic particles used, and the cost.
  • a boron compound is used for the ceramic particle.
  • Boron (B) has the ability to absorb neutrons, so the MMC of the present disclosure can be used as a neutron-absorbing material if boron-containing ceramic particles are used.
  • the boron-containing ceramic can be, for example, B 4 C, TiB 2 , B 2 O 3 , BN FeB or FeB 2 , used either alone or as a mixture.
  • the method of production of the ceramic powder is not limited, and it may be produced by publicly known methods of production of ceramic powders.
  • a finishing process such as jet milling or ball milling
  • a finishing process that leads to an ellipsoid-shaped particle or spherical-shaped particles is preferred.
  • the ceramic powder should generally be at most about, 60 ⁇ m, 40 ⁇ m, or even 20 ⁇ m and at least 1 ⁇ m, 3 ⁇ m, or even 5 ⁇ m. If the average particle size is greater than 60 ⁇ m, coarse particles fragilize the metal matrix composite affecting mechanical properties. If the average particle size is smaller than 1 ⁇ m, then these fine powders may clump together, making it difficult to achieve an even mixture with the metal powder.
  • the average particle size shall refer to the D 50 value measured by laser diffraction particle size distribution measurement.
  • the shape of the powder is also not limited, and may be any of spherical, ellipsoid, flake-shaped or irregular.
  • the ceramic powder has a monomodal particle size distribution. In another embodiment of the present disclosure, the ceramic powder has a multimodal particle size distribution (e.g., bimodal, trimodal, etc.). In one embodiment, the ceramic powder has a bimodal distribution, wherein the average particle of the first mode (comprising the smaller particles) to the second mode (comprising the larger particles) is at least 1:2, 1:3, 1:5, 1:7, 1:11 or even 1:20. The widths of the modes may be wide or narrow.
  • the method for producing a metal matrix composite material comprises (a) forming a metal box; (b) mixing a metal powder and a ceramic powder and placing it in the metal box; (c) compacting the mixed powder within the metal box; (d) placing a top forming plate on top of the metal box and sealing the box to form a pre-rolling assembly; and (e) hot working the pre-rolling assembly.
  • the metal box may be formed from a plurality of plate forming members, or may be a single piece.
  • the metal box is made from a single piece of metal obtained by (i) cutting out the central portion of a metal plate material, or (ii) a hollow extruded material cut to an appropriate length, and then fashioning a bottom plate to the single piece of metal forming a box.
  • FIG. 2 Shown in FIG. 2 is a schematic of metal box 20 comprising bottom forming plate 21 , first pair of side forming plates, 23 a and 23 b, which are opposite one another, and second pair of side forming plates, 25 a and 25 b, which are also opposite one another.
  • the bottom plate has a first thickness, a length and a width.
  • the first pair of side forming plates have a second thickness, a length, and a height.
  • the second pair of side forming plates have a third thickness, a width, and a height.
  • the metal forming plates can be sealed together to form a metal box.
  • the sealing of the metal box may be continuous or discontinuous so long as the box is held together enabling it to contain the mixed powder described below even while the assembly is subjected to the hot rolling.
  • sealing materials include: a metal (e.g., metal inert gas welding such as tungsten inert gas welding; or friction stir welding).
  • a smooth welded junction is provided between the edges of the pieces.
  • the weld can be formed by a continuous, neat, even flow. In one embodiment, no voids in the weld are permitted as this will mean a structural weakness in the box or ingot and cause it to break open during subsequent rolling.
  • the metal box has a length (l), width (w), and height (h) as shown in FIG. 2 .
  • the length and the width of the metal box are both greater than the height. It will be understood that boxes of different sizes may be employed and that subsequent operations may produce finished goods of different thicknesses.
  • the length of the box is not particularly limited as the hot working step is conducted along the length axis.
  • the width of the box is limited by the length of the machinery used (e.g., rolls, size of extruder), which are used to flatten the article in the hot working step.
  • the length and width of the box are not the same.
  • Exemplary lengths include: at least 10 cm (centimeter), 15 cm, 25 cm, or even 50 cm; and no more than 1 m (meter), 2 m, 5 m, or even 10 m.
  • Exemplary widths include: at least 5 cm, 10 cm, 15 cm, 25 cm or even 50 cm; and at most 50 cm, 100 cm, or even 200 cm.
  • the height of the metal box is typically limited by the dimensions of the hot working machinery (e.g., the rollers). Exemplary heights include: at most 600 mm (millimeter), 400 mm, 200 min, 80 mm or even 50 trim; and at least 10 mm, 20 mm or even 30 mm.
  • the height of the metal box is less the length and width of the metal box. This is especially preferable when performing cold compaction because of the friction generated between the mixed powder and the sides of the metal box.
  • the ratio of the height to the width of the metal box is at least 1: 2, 1: 2,5, or even 1: 5; and no more than 1:100, or even 1:200.
  • Each plate will have a thickness, typically less than 1 inch (2.5 cm).
  • the plates should be sufficiently thick to withstand the compaction and stress of hot working, but thin enough to minimize the clad thickness, and reduce the cost, weight and bulk of the resulting finished good.
  • the top forming plate and the bottom forming plate are the same thickness.
  • the top forming plate and the bottom forming plate are different thicknesses,
  • the bottom and opposing top forming plate are thinner than the pairs of side forming plates.
  • the bottom and opposing top plate are the same or thicker than the pairs of side forming plates.
  • Exemplary thickness for each of the plates include at least 1 mm, 2 mm, 5 mm, 8 mm, 10 mm, 12 mm, or even 20 mm; and no greater than 50 mm, 100 mm, 125 mm, or even 200 mm.
  • the metal powder and ceramic powder are uniformly mixed.
  • the mixed powder comprises at least 0.1, 0.5, 1, 5, 10, 20 or even 30% and at most 40, 50, 55, or even 60% by mass of the ceramic powder.
  • the active material is boron carbide
  • the more boron carbide present the better.
  • the adhesion between the metal and ceramic particles becomes poor, and gaps can occur, thus not enabling the desired functions to be obtained and reducing the density, strength, and thermal conductivity of the resulting MMC.
  • the cutting ability is also reduced as the ceramic content increases.
  • the metal powder may be of one type alone, or may be a mixture of a plurality of types, and the ceramic particles may likewise consist of one type alone or a plurality of types, such as by mixing in B 4 C and Al 2 O 3 .
  • the powders may comprise a monomodal or multimodal (e.g., bimodal) distribution of particle sizes.
  • the average particle size of the metal powder and the ceramic powder will be selected for uniformity in the final material, and maximum processing ease (e.g. increase compressibility). For example, if the metal and ceramic powder have a similar density, it is preferable to match the metal powder particle size distribution with the ceramic particle size. This would allow the ceramic powder particles to be more evenly distributed in the resulting MMC, having a property stabilizing effect. If the average particle size becomes too large, it becomes difficult to achieve an even mixture with ceramic particles whose average particle size cannot be made too large due to a tendency to break, and if the average particle size becomes too small, the fine metal powder can clump together, making it extremely difficult to obtain an even mixture with the ceramic powder.
  • the powdered material is thoroughly mixed to insure substantially absolute uniformity.
  • the method of mixing as known in the art may be used, for example, using a mixer such as a cross-flow V-blender, a V blender or cross-rotary mixer, or a vibrating mill or planetary mill, for a designated time (e.g. 5 minutes to 10 hours).
  • media such as alumina balls or the like can be added for the purposes of crushing during mixture.
  • mixing can be performed under dry or wet conditions.
  • a material such as water, oil, solvents, dissolvents or other organic or inorganic compounds may be used.
  • the completely mixed powder which is a loose mixed powder having a first density is then placed into the metal box and compacted using pressure to generate a mixed powder having a second density.
  • the compacted powder preform has a density ratio (or relative density) of at least 0.65, 0.68, 0.70, 0.73, 0.75, 0.78, or even 0.80; and no greater than 1.00.
  • the density ratio refers to the actual density of the mixed powder compared to the density of the same material completely free of porosity (i.e., assuming a fully dense material).
  • the metal box is placed within a die and the metal box is completely filled with the mixed powder.
  • the sides of the box may be struck with a mallet or hammer, or the filled container may be vigorously vibrated to accomplish the same purpose.
  • a calculated amount of mixed powder is used such that upon compaction, ideally, the compacted mixed powder is level with the top surface of the metal box.
  • a riser frame or sleeve is placed over the metal box, which is located within a die, to contain the extra mixed powder having a first density. See FIG. 3 .
  • the mixed powder is compacted within the metal box.
  • compaction refers to the use of pressure (or force) to compact the powder, which increases the density of the material, while allowing the powder to remain in a solid state.
  • the compaction not only rearranges the particles within the metal box to more tightly pack them, but it also deforms the particles enabling tighter packing The particles are tightly packed preventing their displacement upon further handling and processing. However, no substantial melting of the metal powder occurs during the compaction step.
  • Any method of compaction i.e., application of pressure or force
  • CIP cold isostatic press
  • a punch may be inserted into the die to compact the mixed powder.
  • the compaction not only densifies the material, but also “sets” the particles preventing their movement or flow during subsequent handling and processing, resulting in a uniform metal matrix composite.
  • the pressure (or force) should be substantial enough to set the mixed powder, preventing the settling or movement of the particles upon handling and/or processing.
  • the materials can become more dense as more pressure is applied.
  • the ceramic particle can be crushed under the pressure of the compaction, which can diminish the resulting performance of the MMC.
  • Typical pressures applied are at least 1 TSI (ton per square inch), 3 TSI, 5 TSI, 7 TSI, or even 9 TSI depending on the nature of the powders used. In some embodiments the pressure applies is no more than 10 TSI, 15 TSI, or even 20 TSI depending on the nature of the powders used.
  • vibration is used along with compaction.
  • the mixed powder is not subjected to sintering.
  • FIG. 3 Shown in FIG. 3 is a side-view of compaction assembly 30 , showing metal box 31 , mixed powder 32 , die bottom plate 33 , and die frame 35 .
  • Sleeve 34 serves as a riser for the over-filled mixed powder which is compacted with top punch 36 .
  • the compaction of the mixed powder maximizes the amount of active material in a given part, improving the functionality of the resulting material.
  • the compaction of the powders may also set the powders before hot working, forcing compaction and limiting deformation during the hot working step.
  • the filled metal box comprising the compacted mixed powder is then closed by a top forming plate, which is cut to the required dimensions.
  • the top forming plate is in solid abutment with the metal box opposite the bottom forming plate.
  • the top forming plate may be the same materials as described for the metal box.
  • the top forming plate is sealed into place in a similar manner as sealing the bottom and side members of the metal box described above to form a pre-rolling assembly.
  • small openings are provided on the sides to the pre-roll assembly for venting.
  • three 1 ⁇ 4 inch (6 mm) holes are drilled and are then temporarily closed by the insertion of 1 ⁇ 4 inch (6 mm) aluminum rivets. These rivets operate as plugs and hold the material in the pre-roll assembly until they are to be rolled. When the pre-roll assembly is to be rolled, the plugs are removed from the drilled holes to permit the escape of any entrapped air.
  • the pre-rolling assembly is subjected to hot working such as hot rolling, hot extrusion, or hot forging, thus further improving the powder mixed density while simultaneously achieving the desired shape.
  • hot working such as hot rolling, hot extrusion, or hot forging
  • the hot working may consist of a single procedure, or may be a combination of a plurality of procedures.
  • cold working may be performed after hot working. In the case of cold working, the material can be made easier to work by annealing at 100-530° C. (preferably 400-520° C.) prior to working.
  • the pre-roll assembly is first preheated to soften the metal before the hot working (e.g., hot rolling) step.
  • the temperature used can vary depending on the composition of the mixed powder and the metal box. For example, when the mixed powder comprises more than 22% by weight of the ceramic powder, the preheating should be such that the temperatures used should be at least 90%, 92%, 94% or even 96% of the melting temperature of the metal powder but not greater than the metal box melting point.
  • the pre-rolling assembly for aluminum (AA1XXX series) is heated to lower the resistance of the material, such temperature include: at least 400° C., 450° C., or even 500° C.; and at most 600° C., 620° C., or even 630 ° C.
  • the pre-roll assembly made of is stackloaded in a soaking furnace and preferably 1 inch spacers are provided between pre-roll assemblies to permit uniform heat-up from all sides.
  • the furnace temperature is held at 400° C., or preferably 500° C. or even as high as 600° C. but not higher than 700° C. and heated until the pre-roll assembly is heated to the required hot working temperature.
  • the surface will not have any ceramic particles that might otherwise be a point of origin for damage during hot working or wear down the dies, the rolls or any other equipment touched by the material.
  • a metal matrix composite material with good workability, excelling in strength and surface properties.
  • the resulting material which has been subjected to hot working will have a surface clad with a metal, with good adhesion between the metal on the surface and the metal matrix material inside, thus having corrosion resistance, impact resistance and thermal conductivity superior to aluminum composite materials whose surfaces are not clad with a metallic material.
  • the hot working operation reduces not only the thickness of the mixture of ceramic powder and metal powder, but also reduces the thickness of the plates constituting opposite outer covers on the finished material.
  • the finishing clad to core ratio is dependent on the starting thickness ratio of the top and bottom metal plate on the compacted powder.
  • the metal sheathing on opposite sides of the MMC core varies from 5 to 75% of final total thickness achieved.
  • the MMC core of course being formed of the molecular bonded particles of ceramic powder and metal powder, and being permanently molecularly bonded to the interior surfaces of the external sheathing.
  • the thickness of the pre-roll assembly via the hot working step, to not more than 1 ⁇ 4th to 1/60th of its original thickness, and to reduce the metal sheathing at opposite sides of the rolled material to a thickness not thinner than 0.003 inch (0.07 mm).
  • the MMC material is flattened.
  • it may be thermal flattened under weights or it may be flattened using a coil set remover, roller leveler or any similar process.
  • the thermal flattening in an oven is preferred.
  • the MMC material is placed in stacks under heavy weights in an oven at a temperature of about 400° C. If not all the material is flattened at the end of the cycle, those pieces which are flat are removed and the balance are returned for flattening. In some cases, the MMC material will be flat after rolling and will not undergo a flattening treatment.
  • the MMC material with the metal cladding has a thickness of at least 1 mm, 1.5 mm, 2 mm, 5 mm, 10 m, 15 mm, or even 20 mm; and at most 50 mm, 100 mm, or even 200 mm.
  • a guillotine shear, water jet cutting, or any other metal cutting process may be used to cut the MMC material to the required size for use.
  • the MMC is removed from the metal cladding.
  • a metal box (inside dimensions of 6 inches (152 mm) in width ⁇ 10 inches (254 mm) in length ⁇ 2 inches (50.8 mm) high) was constructed by metal inert gas (MIG) welding 4 side plates and a bottom plate.
  • the base material is chamfered 45°, % inch (9.5 mm) deep to optimize weld resistance.
  • the weld is done using 1/16 inch (1.6 mm) AA1100 welding wire.
  • the aluminum powder comprised 30 wt % fine aluminum and 70 wt % coarse aluminum.
  • the boron carbide powder comprised 30 wt % fine boron carbide and 70 wt % coarse boron carbide.
  • 64 wt % of the aluminum powder was blended with 36 wt % of the boron carbide powder for 10 minutes in a Patterson-Kelley crossflow V-blender (Buflovak LLC, Buffalo, N.Y.) under a nitrogen atmosphere.
  • Blended powder comprised 19.2 wt % fine aluminum, 44.8 wt % coarse aluminum, 10.8 wt % fine boron carbide, and 25.2 wt % coarse boron carbide.
  • a predetermined amount of the mixed powder was placed in the metal box. (7.30 lbs/box for no pressing (0 tons per square inch, TSI), 8.15 lbs/box at 3 TSI, and 8.80 lbs/box at 7 TSI.) Note: when doing compaction, the loose mixed powder overfills the metal box, therefore a sleeve is placed around the metal box to contain loose powder. The mixed powder is then compacted, if stated, at a given pressure using a 470T nominal compacting press (Accudyne Engineering & Equipment Co., Bell Gardens, Calif.). The metal box is placed in a 7 in ⁇ 11 in steel die, a 6 in ⁇ 10 in steel punch was placed on top.
  • the applied force was either 180 tons (3 TSI) or 420 tons (7 TSI). Then, the sleeve was removed if used and a Top plate was placed on top of the box and MIG welded with AA1100 filler wire to make a pre-roll assembly. Vent holes (4 ⁇ 1 ⁇ 4 in diameter holes) were drilled into opposing sides of the metal box. The pre-roll assembly was heat for 16 hours to 600° C. ⁇ 5° C. in a convection furnace. The heated pre-roll assembly was then rolled using a 2-high Fenn reversing rolling mill (800 tons separating force).
  • the pre-roll assembly was passed 13 times at a 22% reduction reducing the thickness from 2.5 inches (63.5 mm) to 0.100 inch (2.5 mm). Rolling coolant is applied on the 30 inch diameter steel rolls between each pass. Two cross-rolls (widthwise rolling) are done at passes 3 and 4. The resulting articles are allowed to cool to room temperature.
  • Table 1 Shown in Table 1 below are the results of the resulting MMC articles. For each applied pressure, 2 or 3 samples were prepared and measured as described below and the average is reported in Table 1.
  • the Density ratio before hot rolling is calculated by dividing the weight of the mixed powder used by the volume of the metal box then dividing by the theoretical density of the mixed powder assuming fully dense material (which is 2.63 g/cm3).
  • the Measured core fraction is determined from a micrograph of the resulting article by dividing the area of the MMC to the total area of the article and multiplying by 100 to yield a percentage.
  • the 10 B isotope areal density was calculated based on the amount of boron carbide used versus the thickness of the MMC using the equation (adapted from Turner & Thomas, Nuclear Technology, Vol. 169 (2010)):
  • FIG. 4 A micrograph of the resulting material is presented in FIG. 4 , where (A) is the metal matrix composite material composite not compacted (0 TSI), (B) is the metal matrix composite material compacted at 3 TSI, and (C) is the metal matrix material compacted at 7 TSI.
  • the boron carbide (ceramic) particles are in dark grey while the metal (aluminum) is white. It is noted that in FIG. 4A , narrow curved horizontally oriented dark patterns are observed, which are thought to be flow patterns attributed to powder movement of loose powder during hot rolling. It is also noted that in FIG. 4C , some of the boron carbide particles are lumped together and/or broken.

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CN106392077B (zh) * 2016-10-09 2019-03-19 中国核动力研究设计院 一种高硼不锈钢板的制备方法
SE540060C2 (en) * 2016-10-27 2018-03-13 Damasteel Ab Method of making a patterned composite metal plate
CN106735184B (zh) * 2016-11-30 2019-08-09 中国科学院金属研究所 一种高b4c含量铝基中子吸收材料板材的高效率制备方法
CN107217190B (zh) * 2017-06-23 2018-12-14 南华大学 用于屏蔽核辐射的Fe-W-B-C合金材料及其制备方法
CN109834273A (zh) * 2017-11-28 2019-06-04 北京有色金属研究总院 一种颗粒增强铝基复合材料薄板的制备方法
CN114761159B (zh) * 2019-12-04 2025-05-23 格兰富控股公司 制造沿纵向方向具有不同电阻率的复合部件的方法
CN111438362A (zh) * 2020-05-18 2020-07-24 湖南金马铝业有限责任公司 一种热挤压包套及使用包套生产预成型件的方法
CN115178741B (zh) * 2022-06-17 2024-06-04 北京有研粉末新材料研究院有限公司 一种多孔复合管的制备方法
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