WO2015046623A1 - アルミニウム系多孔質体およびその製造方法 - Google Patents
アルミニウム系多孔質体およびその製造方法 Download PDFInfo
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- WO2015046623A1 WO2015046623A1 PCT/JP2014/076475 JP2014076475W WO2015046623A1 WO 2015046623 A1 WO2015046623 A1 WO 2015046623A1 JP 2014076475 W JP2014076475 W JP 2014076475W WO 2015046623 A1 WO2015046623 A1 WO 2015046623A1
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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
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/005—Casting metal foams
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
- B22D21/002—Castings of light metals
- B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/003—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using inert gases
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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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
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
- B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
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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
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
- B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
- B22F3/1137—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers by coating porous removable preforms
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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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/05—Light metals
- B22F2301/052—Aluminium
Definitions
- the present invention relates to a porous body having a three-dimensional network structure in which three-dimensionally connected skeletons are formed and communication holes that are three-dimensionally communicated are formed by the skeleton, and in particular, the skeleton is made of aluminum or an aluminum alloy. Relates to an aluminum-based porous body constituted by the above and a method for producing the same.
- the porous body having a skeleton that is three-dimensionally connected and having a three-dimensional network structure in which communication holes are formed in three dimensions by the skeleton allows a fluid such as gas or liquid to pass through the communication holes, It is used for filters (Patent Documents 1 and 2 etc.) for filtering these fluids, and catalyst carriers and the like (Patent Document 2 and the like) for reforming these fluids with a catalyst supporting the surface of the skeleton.
- a porous body having such a three-dimensional network structure is obtained by conducting a conductive treatment on the surface of a foamed resin skeleton having communication holes and electroplating, followed by heating to decompose and remove the resin (Patent Document 3, etc.)
- Patent Document 3 A method in which a kneaded product of an organic polymer binder and a metal microparticle is applied to a foamed resin having communication holes by dipping, spraying, etc., and then heating to decompose and remove the resin and to sinter the metal microparticle (Patent Documents 1, 2, 4, etc.) and after applying adhesion to the skeleton surface of the foamed resin having communication holes and attaching the powder, it is heated to decompose and remove the resin and sinter the powder Manufactured by a method (Patent Document 5 or the like).
- a heat exchanger is a device that is used for heating and cooling by efficiently transferring heat from a high-temperature object to a low-temperature object.
- a fluid such as a liquid or a gas is used as a heat exchange medium. Heating or cooling is performed by applying heat to the fluid (heating) or by removing heat from the fluid (cooling).
- a fin made of a metal material having high thermal conductivity is provided to increase the contact area with the fluid to increase the efficiency of heat exchange.
- JP 05-339605 A Japanese Patent Laid-Open No. 08-020831 JP-A-57-174484 Japanese Patent Publication No. 61-053417 Japanese Patent Laid-Open No. 06-235033 Japanese Patent Publication No. 06-089376
- a kneaded product of an organic polymer binder and aluminum powder is applied to a foamed resin having communication holes by dipping or spraying, and then heated at 520 ° C. for 2 hours in a hydrogen stream.
- the aluminum powder has a strong oxide film (alumina: Al 2 O 3 ) on the surface and is sintered by the above method. Only a small portion of the aluminum powder is bonded, and only brittle and extremely low strength can be produced.
- the present invention uses an aluminum powder and an aluminum alloy powder having a strong oxide film on the surface, and the aluminum system having a three-dimensional network structure in which these powders are firmly bonded and have sufficient strength. It aims at providing a porous body and its manufacturing method.
- the aluminum-based porous body of the present invention is a three-dimensional network structure having a skeleton that is three-dimensionally connected and a communication hole that communicates three-dimensionally with the skeleton, wherein the skeleton has a density ratio. It is made of 90% or more of aluminum or aluminum alloy, and aluminum oxide is dispersed inside the skeleton.
- “aluminum” is defined as Al: 95% by mass or more, the balance being impurities such as C and N, and not containing other metal elements.
- the density ratio inside the skeleton is 90% or more, the strength of the skeleton is high, and aluminum oxide (alumina: Al 2 O 3 ) is dispersed in this skeleton. As a result, the aluminum base is strengthened, resulting in higher strength.
- aluminum oxide alumina: Al 2 O 3
- the size of pores inside the skeleton is preferably 10 ⁇ m or less from the viewpoint of the strength of the skeleton.
- the aluminum oxide (alumina: Al 2 O 3 ) that reinforces the aluminum base also decreases the strength of the skeleton when it is coarse, so the size of the aluminum oxide (outermost diameter) is: It is preferable that it is 10 micrometers or less.
- the oxide of aluminum is preferably 5 to 20% in terms of the area ratio of the skeleton cross section. When the oxide of aluminum is less than 5%, the effect of strengthening the base is poor, while when it exceeds 20%, the production is impossible.
- the image of the skeleton cross section is automatically binarized using image analysis software (such as WinRoof made by Mitani Sangyo), or the image is converted to gray scale. Measurement can be performed by setting an appropriate threshold.
- image analysis software such as WinRoof made by Mitani Sangyo
- the aluminum-based porous body of the present invention includes a form in which the skeleton is hollow.
- the aluminum-based porous body of the present invention has a skeleton that is three-dimensionally connected and has a communication hole that communicates three-dimensionally with the skeleton, and the skeleton is made of aluminum or an aluminum alloy. It shows a stress-strain diagram in which the stress increases almost as the skeleton collapses after the stress increases as the strain increases when a load is applied, and then the stress increases.
- the porous aluminum body as in Patent Document 4 has a slight bond between aluminum powders, the bond between aluminum powders breaks when stress is applied, and the bond between aluminum powders breaks as the stress increases. To go. Further, along with this breakage, a large number of crushed particles are generated from the aluminum porous body.
- An aluminum-based porous body having such a skeleton is elastically deformed up to a certain amount of strain applied to it, but when the amount exceeds a certain amount of strain, the skeleton is plastically deformed to communicate in a three-dimensional form. Even if the amount of strain further increases, deformation of the aluminum-based porous body proceeds while the stress is almost flat (constant). Furthermore, after the amount of strain applied to the aluminum-based porous body is increased and the crushing of the communication holes communicating in a three-dimensional shape is completed, if further strain is applied to the aluminum-based porous material, the communication communicating in a three-dimensional shape is performed. Strain is generated in the aluminum-based porous body in which the pores are closed, and the stress increases as the strain amount increases.
- the elastic limit for deformation of the skeleton is desirably 0.5 MPa or more.
- An aluminum-based porous body showing such a stress-strain diagram is deformed plastically without breaking the skeleton because the bonds between aluminum powders are strong when a certain amount of strain is applied.
- the density ratio inside the skeleton is preferably 90% or more from the viewpoint of the strength of the skeleton.
- the pore size inside the skeleton is preferably 10 ⁇ m or less.
- the amount of crushed particles generated after applying the stress until the stress increases after the stress is almost flat is 5% by mass or less of the aluminum-based porous body. Preferably there is.
- the aluminum-based porous material according to the present invention can be obtained by the method for producing an aluminum-based porous material of the present invention. That is, the manufacturing method is based on a resin-made three-dimensional network structure having a resin-made skeleton that is three-dimensionally connected and communication holes that are three-dimensionally communicated with the resin-made skeleton. After the aluminum powder and / or aluminum alloy powder is adhered to the resin-made skeleton surface of the substrate, the aluminum powder and / or the aluminum alloy powder is heated to a melting point or higher in a non-oxidizing atmosphere, The substrate is removed and the aluminum powder and / or the aluminum alloy powder is melted.
- a resin-made three-dimensional structure in which a resin-made skeleton that is three-dimensionally connected and a communication hole that communicates three-dimensionally is formed by the resin-made skeleton.
- a network structure is used as a base, and after the aluminum powder and / or aluminum alloy powder is adhered to the surface of the resin skeleton of the base, the resin base is lost by heating in a non-oxidizing atmosphere.
- the present invention is characterized in that the aluminum powder and / or aluminum alloy powder is melted at a heating temperature equal to or higher than the melting point of the aluminum powder and / or aluminum alloy powder.
- the average particle diameter of the aluminum powder or the aluminum alloy powder is 1 to 50 ⁇ m.
- the heating temperature is preferably the melting point + 100 ° C. or less.
- the oxide film formed on the powder surface becomes a substitute skeleton, and molten aluminum and / or aluminum alloy wets outside the substitute skeleton, so that adjacent powders are bonded by molten aluminum and / or aluminum alloy. Is done.
- the aluminum type porous body obtained after a heating has carried out the metal bond firmly, and can implement
- the present inventors conducted a similar experiment using copper powder, the copper powder melted and dropped, and a porous body could not be formed. Therefore, it can be said that it is an effect peculiar to aluminum and an aluminum alloy having an oxide film that the shape can be maintained even when the powder is melted.
- the skeleton of the aluminum-based porous body thus obtained has a density ratio of, for example, 90% or more, and an oxide film formed on the surface of the original powder, that is, alumina (Al 2 O 3 ) is dispersed therein. It is formed as aluminum or an aluminum alloy. Alumina is hard and is dispersed in the base aluminum or aluminum alloy to strengthen the base. As a result, the aluminum or aluminum alloy exhibits high strength. Since the density ratio of the skeleton cannot be measured by the Archimedes method, the cross section of the skeleton is observed, and the area ratio of the pores dispersed in the skeleton cross section area (base part excluding the hollow part) and the base part of the skeleton cross section Calculate as the difference.
- alumina Al 2 O 3
- the image of the skeleton cross-section is automatically binarized using image analysis software (such as WinRoof made by Mitani Sangyo), or the image is converted to gray scale. Then, these area ratios can be measured by setting an appropriate threshold value.
- image analysis software such as WinRoof made by Mitani Sangyo
- the final three-dimensional network structure of the aluminum-based porous body is constituted by melting aluminum powder and / or aluminum alloy powder supported on and supported by the skeleton surface of the substrate. For this reason, the three-dimensional network structure of the substrate affects the final three-dimensional network structure of the aluminum-based porous body. Therefore, an aluminum-based porous body having a desired three-dimensional network structure can be obtained by changing the three-dimensional network structure of the substrate.
- the thickness of the skeleton is preferably 50 to 500 ⁇ m.
- the skeleton of the aluminum-based porous body is formed by adhering and melting aluminum powder and / or aluminum alloy powder on the surface of the resin skeleton of the substrate, but is adhered to the surface of the resin skeleton of the substrate.
- the amount of aluminum powder and / or aluminum alloy powder increases, the amount of molten aluminum and / or aluminum alloy becomes excessive, shape retention due to surface tension becomes difficult, and mold deformation tends to occur.
- the aluminum powder and / or the aluminum alloy powder to be adhered to the surface of the resin skeleton is formed after melting if it is adhered so that the thickness from the surface of the resin skeleton is 100 to 1000 ⁇ m. This is preferable because the aluminum and / or aluminum alloy has a skeleton thickness of 50 to 500 ⁇ m.
- the aluminum powder and / or aluminum alloy powder is adhered to the surface of the resin skeleton of the substrate as described above by dispersing the aluminum powder and / or aluminum alloy powder in a dispersion medium and having a viscosity of 25 ° C.
- a dispersion liquid adjusted to 50 to 1000 Pa ⁇ s under temperature conditions is prepared, and after immersing the substrate in this dispersion liquid, the substrate is dried, so that aluminum powder and / or aluminum is formed on the resin-made skeleton surface of the substrate. Examples include a form in which alloy powder is adhered.
- the aluminum-based porous material of the present invention exhibits high strength, and the aluminum-based porous material exhibiting such high strength can be easily mass-produced by a simple method by the method for producing the aluminum-based porous material of the present invention. And the effect that it can manufacture cheaply is show
- the substrate uses a three-dimensional network structure having a skeleton that is three-dimensionally connected and pores that are three-dimensionally connected by the skeleton.
- This substrate is supported by adhering aluminum powder and / or aluminum alloy powder to the surface of the skeleton, and is composed of a resin because it should be decomposed and disappeared by heating.
- polyurethane foam is most commonly used as the substrate, but silicone resin, polyester resin foam, and the like can also be used.
- Al powder or aluminum alloy powder As described above, an aluminum powder is used as the powder to be attached to the resin skeleton of the base body in view of the balance of thermal conductivity and specific gravity. Instead of the aluminum powder, an aluminum alloy powder obtained by previously alloying a component that strengthens aluminum is used. Also good. For example, when aluminum alloy powder in which alloying elements such as Cu, Mn, Mg, and Si are prealloyed is used for Al, the skeleton of the aluminum-based porous body is formed of the aluminum alloy, and the aluminum-based porous body Strength can be improved.
- the thermal conductivity is lower than that of Al alone, but the base metal is Al, so it maintains a sufficiently high thermal conductivity. can do.
- the aluminum powder or aluminum alloy powder a general one, that is, a powder having an oxide film (alumina: Al 2 O 3 ) of about 10 mm on the surface is used.
- the aluminum powder and / or aluminum alloy powder to be adhered to the resin skeleton of the substrate is preferably a fine one because it can adhere closely to the resin skeleton surface of the thin substrate.
- the average particle size is 50 ⁇ m or less and does not contain powder having a particle size exceeding 100 ⁇ m.
- Al is an active metal, it is difficult to handle an excessively fine powder. From this viewpoint, it is preferable to use an aluminum powder and / or an aluminum alloy powder having an average particle size of 1 ⁇ m or more.
- Adhesion process Various conventional methods can be applied to adhere the aluminum powder and / or aluminum alloy powder to the resin skeleton of the substrate. A typical method is described below.
- the aluminum powder and / or the aluminum alloy powder adhering to the surface of the resin skeleton of the substrate can be controlled by the viscosity of the dispersion. That is, when the viscosity of the dispersion liquid is high, the amount of aluminum powder and / or aluminum alloy powder adhering to the surface of the resin skeleton of the substrate increases. Conversely, when the viscosity of the dispersion liquid is low, the surface of the resin skeleton of the substrate is increased. The amount of aluminum powder and / or aluminum alloy powder adhering to the surface is reduced.
- the viscosity of the dispersion liquid is preferably 1000 Pa ⁇ s or less under a temperature condition of 25 ° C.
- the viscosity of the dispersion is preferably 50 Pa ⁇ s or more under a temperature condition of 25 ° C.
- the viscosity can be measured by detecting the twist angle of the two slit disks due to the viscous torque and converting the viscosity into a viscosity using a TVB10 viscometer manufactured by Toki Sangyo Co., Ltd.
- the substrate on which the aluminum powder or the aluminum alloy powder is adhered to the surface of the skeleton is heated to a temperature higher than the melting point of the aluminum powder and / or the aluminum alloy powder in a non-oxidizing atmosphere. In the process of raising the temperature to the melting point, the resin substrate is decomposed and removed to disappear.
- the aluminum powder or aluminum alloy powder melts inside. That is, the surface of the aluminum powder or aluminum alloy powder is covered with an oxide film (alumina: Al 2 O 3 ), and the melting point of alumina is as high as 2072 ° C., so the oxide film on the surface of the aluminum powder or aluminum alloy powder melts. The inside of these powders melts. As shown in FIG. 1, the aluminum or aluminum alloy thus melted inside breaks the oxide film on the surface of the powder and wets the powder surface, and the molten aluminum or molten aluminum alloy generated from each powder Mix and combine.
- alumina Al 2 O 3
- the oxide film formed on the powder surface becomes a substitute skeleton, maintains the shape of the skeleton, and the surface tension of the molten aluminum or molten aluminum alloy bonded to each other makes the skeleton surface relatively smooth and the neck portion disappears. It becomes a continuous metal surface.
- the skeleton of the aluminum-based porous body thus obtained is formed as aluminum or an aluminum alloy in which the oxide film formed on the original powder surface, that is, alumina (Al 2 O 3 ) is dispersed.
- This alumina is hard and contributes to strengthening of the base by being dispersed in the base aluminum or aluminum alloy.
- the skeleton since the skeleton has a hollow shape having a cavity in the portion where the resin skeleton was present, it is effective for applications that require weight reduction.
- the atmosphere in the heating process is an oxidizing atmosphere such as the air
- the molten aluminum or molten aluminum alloy exposed by breaking the oxide film on the powder surface is immediately oxidized and wetted or covered with the powder surface, or generated from each powder. Mixing of molten aluminum or molten aluminum alloy is prevented, and bonding of powders is inhibited.
- the atmosphere in the heating step be a non-oxidizing atmosphere such as nitrogen gas or inert gas.
- the above heating step is not intended to remove the oxide film on the surface of the aluminum powder or aluminum alloy powder, so it is not necessary to be in a reducing atmosphere such as hydrogen gas or a hydrogen mixed gas. Since this atmosphere is a non-oxidizing atmosphere, it may be a reducing atmosphere. Moreover, it is good also as a pressure-reduced atmosphere (vacuum atmosphere) whose pressure is 10 ⁇ -3 > Pa or less.
- the heating temperature can be melted as long as the temperature exceeds the melting point of the aluminum powder or aluminum alloy powder adhered to the substrate. However, heating at a temperature greatly exceeding the melting point requires extra energy and melting.
- the heating temperature is preferably up to the melting point + 100 ° C., because the viscosity of the aluminum or aluminum alloy is lowered and the mold is likely to lose its shape.
- the skeleton of the aluminum-based porous body having a three-dimensional network structure is too thin, the strength of the aluminum-based porous body decreases. On the other hand, when the thickness increases, the flow of fluid passing through the communicating pores is hindered, and the pressure loss increases.
- the skeleton of the aluminum-based porous body is formed by adhering and melting aluminum powder or aluminum alloy powder on the surface of the resin skeleton of the base, but the aluminum powder or aluminum adhering to the surface of the resin skeleton of the base is used.
- the amount of alloy powder increases, the amount of molten aluminum or aluminum alloy increases. However, when the amount of molten aluminum or aluminum alloy is excessive, shape retention due to surface tension becomes difficult, and mold deformation tends to occur.
- the thickness of the skeleton of the aluminum-based porous body is preferably 50 to 500 ⁇ m.
- the amount of aluminum powder or aluminum alloy powder to be adhered to the surface of the resin skeleton is such that the aluminum formed after melting when the thickness from the surface of the resin skeleton is 100 to 1000 ⁇ m.
- / or the thickness of the skeleton of the aluminum alloy is preferably 50 to 500 ⁇ m.
- the three-dimensional network structure of the aluminum-based porous body manufactured by the above manufacturing method is the one in which the three-dimensional network structure of the resin base is maintained as it is. Therefore, by changing the three-dimensional network structure of the resin substrate, the three-dimensional network structure of the aluminum porous body can be changed, and the porosity and pore size of the entire aluminum porous body can be changed. It is possible to adjust to the desired one.
- the porosity can be 80 to 95%, preferably 85 to 95%
- the pore size can be 30 to 4000 ⁇ m
- 6 to 80 ppi (cell Several / 25.4 mm) can be easily manufactured.
- ingredients (Cu, Mg, etc.) that generate a eutectic liquid phase with Al as raw material powder were added to the aluminum powder as a simple powder or an aluminum alloy powder.
- a method of using an aluminum-based mixed powder, attaching the aluminum-based mixed powder to the surface of a resin substrate having a three-dimensional network structure, and sintering at a temperature at which a eutectic liquid phase is generated can be considered. Then, the distribution of the component elements in the aluminum-based porous body is not uniform, and the aluminum oxide is not dispersed inside the skeleton, so that it is difficult to obtain a desired strength.
- the distribution of the component elements in the aluminum-based porous body becomes uniform by using the aluminum prealloy powder in which the component elements are previously alloyed in Al as described above.
- aluminum oxide resulting from the manufacturing method is dispersed inside the skeleton. For this reason, high intensity
- a polyurethane foam (trade name Everlight SF, manufactured by Bridgestone Corporation) having a length of 10 mm, a width of 20 mm, and a thickness of 10 mm was prepared as a resin base having a three-dimensional network structure.
- This polyurethane foam had a porosity (ratio of the volume of communication holes to the total volume) of 95%, and the size of the communication holes was 3000 ⁇ m in terms of the equivalent circle diameter.
- polyvinyl alcohol (trade name: Gohsenol GH-23, manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) having a resin content of 1% by mass was prepared as a dispersion medium, and a mass ratio of 1 to a dispersion medium prepared with aluminum powder having an average particle size of 6 ⁇ m. 1 was mixed to prepare an aluminum powder dispersion (viscosity at 25 ° C .: 50 to 75 Pa ⁇ s: measured with a TVB10 viscometer manufactured by Toki Sangyo Co., Ltd.). After dipping the prepared substrate in the prepared aluminum powder dispersion, excess slurry was removed by a roll and then dried at 100 ° C.
- the substrate to which the aluminum powder thus prepared was attached was heated for 210 minutes at the heating temperature shown in Table 1 under a reduced pressure atmosphere (vacuum atmosphere) having a pressure of 10 ⁇ 3 Pa, and the porous samples of sample numbers 01 to 07 were used. A quality sample was prepared.
- the porosity of these porous samples was measured by the Archimedes method. In addition, by observing with an optical microscope and measuring the size of the pores using image analysis software (WinRoof manufactured by Mitani Sangyo), the average value of the equivalent circle diameters of the pores (communication holes) of the three-dimensional network structure is obtained. Asked.
- a porous sample is embedded in resin, mirror-polished, and corroded with Keller's solution (hydrochloric acid 0.5 ml, nitric acid 2.5 ml, hydrofluoric acid 1.5 ml, distilled water 95 ml), and the metal structure of the skeleton part is obtained.
- Image analysis software WinRoof made by Mitani Sangyo
- the cross-sectional area ratio of the pores was measured to determine the density ratio of the skeleton.
- the metal structure of the base part excluding the hollow part in the cross section of the skeleton part was observed with a magnification of 5,000 times with an EPMA apparatus, and the size of the oxide dispersed in the cross section of the skeleton part was similarly analyzed using image analysis software (Mitani Sangyo Using WinRoof), the area of a region (180 to 255) having a threshold value 180 of 180 or more was measured by the valley method, and the oxide size and the cross-sectional area ratio were measured.
- the porous samples of sample numbers 01 to 07 have a porosity almost the same as that of the urethane foam used as the substrate, and the size of the communicating holes is almost the same as the urethane foam of the substrate. From this result, it was confirmed that the porosity of the urethane foam as a base and the size of the communication holes were directly the porosity and the size of the communication holes of the porous sample.
- the density ratio of the skeleton is 90% or more, indicating a high density ratio.
- the pore size of the skeleton is as small as 2 to 10 ⁇ m.
- oxide dispersion was observed inside the skeleton, and the oxide had a size of 10 ⁇ m and a cross-sectional area ratio of 8 area%.
- the samples 01 to 03 which are comparative examples only a small portion of the aluminum powder was bonded, the oxide was observed only on the surface of the aluminum powder, and the oxide dispersed inside the matrix was not observed.
- FIG. 3 shows a photograph observing the pore state of the porous sample of sample number 04, which is an example of the present invention.
- the porous sample of the example of the present invention is a metal in which molten aluminum binds adjacent powders, and the surface of the skeleton is relatively smooth due to the surface tension of molten aluminum, and the neck portion disappears and continues. It is the surface.
- FIG. 5 a photograph observing the pore state of the porous sample of sample number 03, which is a comparative example, is shown in FIG.
- the porous sample of the comparative example is only bonded by solid phase diffusion in a part of the aluminum powder, and the neck portion (powder bonding portion) is not grown, and the shape of the original powder Can be confirmed.
- the aluminum-based porous material samples of sample numbers 04 to 07 showed an elastic limit of 0.5 MPa or more before reaching the plateau region. This elastic limit reached 1.7 MPa with increasing density ratio.
- the result of the compression yield test will be described in detail with reference to FIG.
- the elastic deformation occurs at the initial stage of deformation and the stress increases as the amount of strain increases. Thereafter, the stress is constant even when the amount of strain increases. . This is a state in which deformation is proceeding while the communication hole of the aluminum-based porous material sample is compressed and crushed.
- the plateau region did not exist in the aluminum-based porous material samples of sample numbers 01 to 03.
- the bonding between the powders is insufficient, it is destroyed at the initial stage of deformation when a compression load is applied.
- the sample was in a loose powder state.
- the aluminum system of the present invention shows a stress-strain diagram in which stress increases substantially as the skeleton collapses after the stress increases as the strain increases when a load is applied, and the stress increases thereafter. It was confirmed that the porous body sample has higher strength than the conventional aluminum-based porous body sample.
- the aluminum-based porous body of the present invention exhibits high strength and is therefore suitable for use in various porous members.
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Abstract
Description
[基体]
基体は、三次元状に連結する骨格を有し、その骨格により三次元状に連結する気孔が形成される三次元網目状構造体を用いる。この基体は骨格表面にアルミニウム粉末および/またはアルミニウム合金粉末を付着させて担持するものであり、加熱されて分解、消失すべきものであることから、樹脂により構成される。具体的には、基体としてポリウレタンフォームが最も一般的に用いられるが、他にシリコーン樹脂、ポリエステル樹脂のフォームなどを用いることができる。
基体の樹脂骨格に付着させる粉末は、上記のとおり、熱伝導率および比重のバランスよりアルミニウム粉末を用いるが、アルミニウム粉末に替えて、アルミニウムを強化する成分を予め合金化したアルミニウム合金粉末を用いてもよい。たとえば、AlにCu、Mn、Mg、Si等の合金化元素を予合金化したアルミニウム合金粉末を用いた場合は、アルミニウム系多孔質体の骨格がアルミニウム合金で形成され、アルミニウム系多孔質体の強度を向上させることができる。AlにCu、Mn、Mg、Si等の合金化元素を添加することにより、熱伝導率はAl単体の場合よりも低下するが、ベース金属がAlであるため、充分に高い熱伝導率を維持することができる。アルミニウム粉末またはアルミニウム合金粉末は、一般的なもの、すなわち表面に10Å程度の酸化被膜(アルミナ:Al2O3)を有するものを用いる。
基体の樹脂骨格へアルミニウム粉末および/またはアルミニウム合金粉末を付着させるにあたっては、従来から行われている各種方法を適用することができる。以下に代表的な方法を記載する。
特許文献1、2、4等に記載された方法であり、アルミニウム粉末および/またはアルミニウム合金粉末を分散媒中に分散させた分散液を作成し、この分散液中に基体を浸漬した後、基体を乾燥させる方法である。分散媒としては、アルコール等の揮発性を有する液体や水を溶媒とし、これに結着剤を溶解した液を用いることができる。この場合、粉末が沈降しないよう分散媒に分散剤を添加してもよい。また、分散媒としては、フェノール樹脂等の高分子有機物の溶液を用いてもよい。
特許文献5に記載された方法であり、基体表面にアクリル系、ゴム系等の粘着剤溶液またはフェノール樹脂、エポキシ樹脂、フラン樹脂等接着性の樹脂溶液を塗布することにより粘着性を付与し、粉体中で基体を揺動させるか、あるいは基体に粉体をスプレーする等の方法により、骨格表面に粉体を被着させる方法である。
骨格表面にアルミニウム粉末またはアルミニウム合金粉末を付着させた基体は、非酸化性雰囲気中で、アルミニウム粉末および/またはアルミニウム合金粉末の融点以上に加熱される。この融点までの昇温過程で樹脂製の基体は分解し除去されて消失する。
Claims (14)
- 三次元状に連結する骨格を有するとともに前記骨格により三次元状に連通する連通孔を有する三次元網目状構造体であって、前記骨格が、密度比が90%以上のアルミニウムもしくはアルミニウム合金からなるとともに、前記骨格の内部にアルミニウムの酸化物が分散することを特徴とするアルミニウム系多孔質体。
- 前記骨格内部の気孔の大きさが10μm以下であることを特徴とする請求項1に記載のアルミニウム系多孔質体。
- 前記アルミニウムの酸化物の大きさが10μm以下であることを特徴とする請求項1または2に記載のアルミニウム系多孔質体。
- 前記骨格は、中空状をなすことを特徴とする請求項1~3のいずれかに記載のアルミニウム系多孔質体。
- 三次元状に連結する骨格を有するとともに前記骨格により三次元状に連通する連通孔を有し、前記骨格が、アルミニウムもしくはアルミニウム合金からなる三次元網目状構造体であり、
荷重を加えた際にひずみ量の増加に従って応力量が増加した後、骨格の圧壊に伴って応力がほぼ横ばいとなり、その後応力が増加する応力−ひずみ線図を示すことを特徴とするアルミニウム系多孔質体。 - 前記骨格の密度比が90%以上であることを特徴とする請求項5に記載のアルミニウム系多孔質体。
- 前記骨格内部の気孔の大きさが10μm以下であることを特徴とする請求項6に記載のアルミニウム系多孔質体。
- 前記応力−ひずみ線図において、前記応力がほぼ横ばいとなった後、応力が増加するまで応力を加えた後に発生する破砕粒子の発生量が、アルミニウム系多孔質体の5質量%以下であることを特徴とする請求項5~7のいずれかに記載のアルミニウム系多孔質体。
- 三次元状に連結する樹脂製の骨格を有し、前記樹脂製の骨格により三次元状に連通する連通孔が形成された樹脂製の三次元網目状構造体を基体とし、前記基体の樹脂製の骨格表面に、アルミニウム粉末および/またはアルミニウム合金粉末を付着させた後、非酸化性雰囲気中で、前記アルミニウム粉末および/または前記アルミニウム合金粉末の融点以上に加熱して、前記基体を消失除去するとともに前記アルミニウム粉末および/または前記アルミニウム合金粉末を溶融することを特徴とするアルミニウム系多孔質体の製造方法。
- 前記加熱温度が融点+100℃以下であることを特徴とする請求項9に記載のアルミニウム系多孔質体の製造方法。
- 前記アルミニウム粉末またはアルミニウム合金粉末の平均粒径が1~50μmであることを特徴とする請求項9または10に記載のアルミニウム系多孔質体の製造方法。
- 前記樹脂製の骨格の表面に付着させるアルミニウム粉末またはアルミニウム合金粉末の厚さが100~1000μmであることを特徴とする請求項9~11のいずれかに記載のアルミニウム系多孔質体の製造方法。
- アルミニウム粉末および/またはアルミニウム合金粉末を分散媒中に分散させるとともに、粘度を25℃の温度条件下において50~1000Pa・sに調整した分散液を作製し、この分散液中に前記基体を浸漬した後、基体を乾燥させることで前記基体の樹脂製の骨格表面に、アルミニウム粉末および/またはアルミニウム合金粉末を付着させることを特徴とする請求項9~12のいずれかに記載のアルミニウム系多孔質体の製造方法。
- 請求項9~13のいずれかに記載の製造方法によって得られる請求項1~12のいずれかに記載のアルミニウム系多孔質体。
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DE112014004497.0T DE112014004497T5 (de) | 2013-09-30 | 2014-09-26 | Aluminiumbasierter poröser Körper und Verfahren zu seiner Herstellung |
US15/025,497 US20160221078A1 (en) | 2013-09-30 | 2014-09-26 | Aluminum-based porous body and method for manufacturing same |
CN201480053665.7A CN105579167A (zh) | 2013-09-30 | 2014-09-26 | 铝系多孔质体及其制造方法 |
JP2015539480A JP6132026B2 (ja) | 2013-09-30 | 2014-09-26 | アルミニウム系多孔質体の製造方法 |
KR1020177035314A KR20170139688A (ko) | 2013-09-30 | 2014-09-26 | 알루미늄계 다공질체 및 그 제조 방법 |
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CN106825541A (zh) * | 2016-12-26 | 2017-06-13 | 有研粉末新材料(北京)有限公司 | 一种粘结粉末的制备方法 |
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