WO2021056806A1 - 铝合金粉末及其制造方法、铝合金制品及其制造方法 - Google Patents

铝合金粉末及其制造方法、铝合金制品及其制造方法 Download PDF

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WO2021056806A1
WO2021056806A1 PCT/CN2019/121428 CN2019121428W WO2021056806A1 WO 2021056806 A1 WO2021056806 A1 WO 2021056806A1 CN 2019121428 W CN2019121428 W CN 2019121428W WO 2021056806 A1 WO2021056806 A1 WO 2021056806A1
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aluminum alloy
aluminum
powder
copper
manganese
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PCT/CN2019/121428
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French (fr)
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傅圣峻
黄扬升
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圆融金属粉末股份有限公司
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • 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
    • B22F1/05—Metallic powder characterised by the size or surface area of the 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • 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
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • 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
    • C22C1/02—Making non-ferrous alloys by melting
    • 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
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • 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
    • 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

Definitions

  • the invention relates to an alloy powder and a manufacturing method thereof, an alloy product and a manufacturing method thereof, and particularly relates to an aluminum alloy powder and a manufacturing method thereof, an aluminum alloy product and a manufacturing method thereof.
  • Cida Patent Application Publication No. CN109175350A discloses a method for preparing Al-Mg-Mn-Sc-Zr aluminum alloy powder for additive manufacturing, which includes the following steps: adding a pure aluminum ingot to a crucible in an intermediate frequency furnace, and The aluminum ingot is preheated; the temperature of the melting chamber is increased to 700 ⁇ 850°C, argon gas is introduced into the melting chamber after the melting of pure aluminum starts, so that the pressure of the melting chamber is 0.6 ⁇ 0.9MPa; the temperature of the melt in the crucible reaches 1150 ⁇ 1300°C, add pure manganese and pure zirconium, keep it for 15 ⁇ 25min; increase the crucible temperature to 800 ⁇ 900°C, adjust the pressure of the melting chamber to 0.3 ⁇ 0.7MPa, add Al-Sc master alloy to melt, keep it for 5 ⁇ 15min; Reduce the temperature of the melt in the crucible to 700 ⁇ 790°C, adjust the pressure in the melting chamber to 0.05 ⁇ 0.15MPa, add pure magnesium in
  • silicon (Si), magnesium (Mg), manganese (Mn), zinc (Zn) or copper (Cu) is used as the main alloy element, and nickel (Ni), iron (Fe) and other elements Treated as an impurity element.
  • the tensile strength of aluminum alloy products prepared by the laminated manufacturing method using aluminum alloy powder is mostly lower than 500MPa, except for aluminum alloys for aviation applications, such as 7075, 7050, 2024, etc., which can be higher than 500MPa, but these high-strength Aluminum alloys are obtained through complicated heat treatment processes, and have poor ductility and heat resistance.
  • the ductility (elongation at break) is less than 10% and cannot be used above 300°C.
  • An object of the present invention is to provide an aluminum alloy product with high ductility, high tensile strength and better heat resistance.
  • the present invention provides an aluminum alloy powder, calculated based on its total weight as 100wt.%, the aluminum alloy powder includes the following elements: nickel (Ni): 3.0-5.0wt.%, copper (Cu): 2.0 ⁇ 3.0wt.%, iron (Fe): 1.0 ⁇ 2.0wt.%, manganese (Mn): 0.5 ⁇ 1.0wt.%, zirconium (Zr): 0.4 ⁇ 1.0wt.%, chromium (Cr): 0.40 ⁇ 1.0 wt.%, silicon (Si): 0.05 to 4.0 wt.%, the remainder is aluminum (Al) and unavoidable impurities.
  • the present invention also provides an aluminum alloy powder.
  • the total weight of the aluminum alloy powder is 100wt.%.
  • the aluminum alloy powder consists of only the following elements: Nickel (Ni): 3.0 ⁇ 5.0wt.%, Copper (Cu): 2.0 ⁇ 3.0wt.%, iron (Fe): 1.0 ⁇ 2.0wt.%, manganese (Mn): 0.5 ⁇ 1.0wt.%, zirconium (Zr): 0.4 ⁇ 1.0wt.%, chromium (Cr): 0.40 ⁇ 1.0wt. .%, silicon (Si): 0.05-4.0wt.%, the remainder is aluminum (Al) and unavoidable impurities.
  • the present invention further provides a method for manufacturing aluminum alloy powder, which includes the following steps: performing a smelting process to contain aluminum (Al), nickel (Ni), copper (Cu), iron (Fe), manganese (Mn), and zirconium). (Zr), chromium (Cr) and silicon (Si) each material is melted into an aluminum alloy broth; and a powdering process is performed to make the aluminum alloy molten broth form an aluminum alloy powder; wherein the aluminum alloy powder includes the following elements :Nickel (Ni): 3.0 ⁇ 5.0wt.%, Copper (Cu): 2.0 ⁇ 3.0wt.%, Iron (Fe): 1.0 ⁇ 2.0wt.%, Manganese (Mn): 0.5 ⁇ 1.0wt.%, Zirconium (Zr): 0.4 to 1.0 wt.%, chromium (Cr): 0.40 to 1.0 wt.%, silicon (Si): 0.05 to 4.0 wt.%, the remainder is aluminum (Al)
  • the smelting process includes the following steps:
  • pure aluminum ingot After the pure aluminum ingot is melted, put in the pure copper ingot (or aluminum-copper intermediate alloy or copper agent), pure nickel ingot (or aluminum-nickel intermediate alloy or nickel agent), pure iron ingot (or aluminum-iron intermediate alloy or iron agent) in order ), pure manganese ingot (or aluminum-manganese intermediate alloy or manganese agent), pure zirconium ingot (or aluminum-zirconium intermediate alloy), pure chromium ingot (or aluminum-chromium intermediate alloy or chromium agent) and pure silicon ingot (or aluminum-silicon intermediate alloy) );as well as
  • the milling process includes the following steps:
  • the atomizing gas is turned on, and the powder is made by gas atomization, so that the aluminum alloy molten soup is formed into the aluminum alloy powder.
  • the present invention also provides an aluminum alloy product.
  • the total weight of the aluminum alloy product is calculated as 100w%.
  • the aluminum alloy product includes the following elements: nickel (Ni): 3.0-5.0wt.%, copper (Cu): 2.0-3.0wt.% , Iron (Fe): 1.0 ⁇ 2.0wt.%, Manganese (Mn): 0.5 ⁇ 1.0wt.%, Zr: 0.4 ⁇ 1.0wt.%, Chromium (Cr): 0.40 ⁇ 1.0wt.%, Silicon (Si): 0.05-4.0wt.%, the remainder is aluminum (Al) and unavoidable impurities.
  • the tensile strength of the aluminum alloy product is greater than 500Mpa, and the ductility is greater than 10%.
  • the present invention also provides a method for manufacturing an aluminum alloy product, which includes: subjecting the aluminum alloy powder to a 3D printing process or a powder metallurgy process to form an aluminum alloy product.
  • the 3D printing process includes the following steps:
  • the aluminum alloy powder is subjected to powder sieving through cyclone sorting and vibration sorting. After the particle size of the powder is sieved to 20-63 ⁇ m, it is heated to 70-90°C for about 0.5-1.0 hours to remove moisture, and the aluminum alloy The powder is vacuumed and stored; and
  • the aluminum alloy product is obtained by 3D printing with laser selective melting equipment.
  • the aluminum alloy product is removed and surface treatment is applied.
  • the powder metallurgy process includes the following steps:
  • An aluminum alloy green embryo is made by slurry casting, strip casting and static pressing;
  • the aluminum alloy product is obtained by high-temperature sintering or forging of the aluminum alloy green blank.
  • the present invention further provides a manufacturing method of aluminum alloy products, including:
  • the present invention mainly uses nickel (Ni), copper (Cu), and iron (Fe) as main alloying elements, manganese (Mn), zirconium (Zr), chromium (Cr) and silicon (Si) as secondary alloying elements, and the rest For aluminum (Al) and unavoidable impurities, it provides an aluminum alloy material with high ductility, high tensile strength and better heat resistance, which can be used for multilayer manufacturing (3D printing, powder metallurgy), casting, etc.
  • the tensile strength is better than common aluminum silicon (Al-Si), aluminum magnesium (Al-Mg), aluminum copper (Al-Cu), aluminum magnesium silicon (Al-Mg-Si), aluminum zinc magnesium copper ( Al-Zn-Mg-Cu) and other alloys.
  • Fig. 1 is a flow chart of a method for manufacturing aluminum alloy powder according to an embodiment of the present invention
  • FIG. 2 is a schematic cross-sectional view of a smelting furnace and gas atomization equipment according to an embodiment of the present invention
  • FIG. 3 is a flowchart of the manufacturing method of aluminum alloy products according to the first embodiment of the present invention.
  • FIG. 4 is a flowchart of a method for manufacturing an aluminum alloy product according to a second embodiment of the present invention.
  • Fig. 5 is a flow chart of a manufacturing method of an aluminum alloy product according to a third embodiment of the present invention.
  • Fig. 1 is a flow chart of a manufacturing method of aluminum alloy powder according to an embodiment of the present invention.
  • the manufacturing method of the aluminum alloy powder includes the following steps: (1) Perform a smelting process S11: make it contain aluminum (Al), nickel (Ni), copper (Cu), iron (Fe), manganese (Mn), zirconium (Zr) ), each of chromium (Cr) and silicon (Si) is melted into an aluminum alloy molten stock; and (2) a powdering process S12 is performed: the aluminum alloy molten stock is formed into an aluminum alloy powder.
  • the smelting process of the present invention includes the following steps: placing a pure aluminum ingot into a carrying crucible 10 of a melting furnace (such as a vacuum induction melting furnace), and preheating the pure aluminum ingot; After the ingot is melted, put in the pure copper ingot (or aluminum-copper intermediate alloy or copper agent), pure nickel ingot (or aluminum-nickel intermediate alloy or nickel agent), pure iron ingot (or aluminum-iron intermediate alloy or iron agent), pure copper ingot (or aluminum-iron intermediate alloy or iron agent), Manganese ingot (or aluminum-manganese intermediate alloy or manganese agent), pure zirconium ingot (or aluminum-zirconium intermediate alloy), pure chromium ingot (or aluminum-chromium intermediate alloy or chromium agent) and pure silicon ingot (or aluminum-silicon intermediate alloy); and Increase the smelting power, increase the temperature to 850 ⁇ 950°C, keep stirring for about 15 ⁇ 20 minutes, make it contain aluminum (Al), nickel (N
  • the aluminum alloy molten soup includes the following elements: nickel (Ni): 3.0 to 5.0 wt.%, copper (Cu): 2.0 to 3.0 wt.%, iron (Fe): 1.0 to 2.0 wt.%, and manganese (Mn): 0.5 ⁇ 1.0wt.%, zirconium (Zr): 0.4 ⁇ 1.0wt.%, chromium (Cr): 0.40 ⁇ 1.0wt.%, silicon (Si): 0.05 ⁇ 4.0wt.%, the rest is aluminum (Al) And inevitable impurities.
  • the powdering process of the present invention includes the following steps: after the stirring is completed, the aluminum alloy molten stock 11 is slag-removed and refined, and the pressure of the lower chamber 12 is adjusted to be controlled at 0.07 ⁇ 0.10MPa, and the temperature of the carrying crucible is controlled at 850 ⁇ 880°C, open
  • the atomizing gas G (for example, argon or nitrogen) is used for gas atomization to make powder, so that the aluminum alloy molten soup 11 is formed into the aluminum alloy powder P, which is collected in the powder collecting bucket 13.
  • the aluminum alloy molten stock 11 is impacted and atomized with a high-speed cooling gas, and then rapidly solidified into aluminum alloy powder P.
  • the aluminum alloy powder P includes the following elements: nickel (Ni): 3.0 to 5.0 wt.%, copper (Cu): 2.0 to 3.0 wt.%, iron (Fe): 1.0 to 2.0 wt.%, and manganese (Mn): 0.5 ⁇ 1.0wt.%, zirconium (Zr): 0.4 ⁇ 1.0wt.%, chromium (Cr): 0.40 ⁇ 1.0wt.%, silicon (Si): 0.05 ⁇ 4.0wt.%, the rest is aluminum (Al ) And inevitable impurities.
  • Fig. 3 is a flow chart of a method for manufacturing an aluminum alloy product according to the first embodiment of the present invention.
  • the manufacturing method of the aluminum alloy product includes: subjecting the aluminum alloy powder of the present invention to a 3D printing process to form the aluminum alloy powder into an aluminum alloy product.
  • the 3D printing process includes the following steps: In step S21, the aluminum alloy powder is powder sieved through cyclone and vibration separation, and the particle size of the powder is sieved to 20-63 ⁇ m, and then heated to 70-90°C for about 0.5 ⁇ 1.0 hour, remove moisture, and save the aluminum alloy powder in a vacuum; in step S22, 3D printing is performed by selective laser melting (SLM) technology to obtain the aluminum alloy product (selective laser melting technology is An advanced laser additive manufacturing technology developed on the basic principle of prototype manufacturing technology. The three-dimensional digital model of the part is sliced and layered through special software. After obtaining the profile data of each section, the high-energy laser beam is used according to the profile data.
  • SLM selective laser melting
  • the metal powder is selectively melted layer by layer, and three-dimensional solid parts are manufactured by spreading powder layer by layer, melting and solidifying layer by layer.
  • three-dimensional solid parts are manufactured by spreading powder layer by layer, melting and solidifying layer by layer.
  • 3D printing of aluminum alloy with German SLM Solutions 280 laser selective melting equipment and, in step In S23, after the 3D printing is completed, the aluminum alloy product is removed and surface treatment is applied.
  • the aluminum alloy product includes the following elements: nickel (Ni): 3.0 to 5.0 wt.%, copper (Cu): 2.0 ⁇ 3.0wt.%, iron (Fe): 1.0 ⁇ 2.0wt.%, manganese (Mn): 0.5 ⁇ 1.0wt.%, zirconium (Zr): 0.4 ⁇ 1.0wt.%, chromium (Cr): 0.40 ⁇ 1.0 wt.%, silicon (Si): 0.05 to 4.0 wt.%, the remainder is aluminum (Al) and unavoidable impurities.
  • the tensile strength of the aluminum alloy products of Examples 1 to 3 can be greater than 500 MPa, and the elongation at break is greater than 10%, and is suitable for environments above 300°C.
  • the aluminum alloy product of the present invention adds a large amount of nickel, copper, iron and a small amount of manganese, zirconium and chromium to the aluminum alloy, and the solubility of Cu, Mn, Si and Cr in Al produces partial solid solution strengthening, and
  • the dispersion strengthening phases (CrFe)Al 7 , (CrMn)Al 12 , (FeMn)Al 6 , (Fe2Si)Al 8 , FeSiAl 5 , and Al 3 Zr formed between the elements improve the strength and heat resistance of the aluminum alloy.
  • the age hardening phases Al 3 Ni and Al 2 Cu are precipitated to further improve the tensile strength and ductility.
  • the reason for the high ductility of the aluminum alloy product of the present invention lies in the dispersed strengthening phases of Al 3 Ni and Al 3 Fe.
  • Such precipitated phases are rod-shaped structures. When the cracks propagate, this structure is parallel to the cracks, which is not easy to cause stress concentration.
  • the addition of Cr and Mn elements can adjust the microstructure of Fe in the aluminum alloy to form (CrFe)Al 7 , (CrMn)Al 12 and (FeMn)Al 6 , which can improve ductility and tensile strength at the same time.
  • the silicon (Si) content of the aluminum alloy product of the present invention is only between 0.05-4.0wt.%. If the content of Si in the aluminum alloy is too high, it will cause Al 5 FeSi (alpha phase, script-like phase) to increase, which is easy to form. Cracks reduce ductility. In the heat treatment, the Si content is too high and it is easy to form Si aggregates, and coarse Si particles or Si sheets may be produced, which reduces the tensile strength of the aluminum alloy.
  • Fig. 4 is a flowchart of a manufacturing method of an aluminum alloy product according to a second embodiment of the present invention.
  • the manufacturing method of the aluminum alloy product includes: subjecting the aluminum alloy powder of the present invention to a powder metallurgy process to form the aluminum alloy powder into an aluminum alloy product.
  • the powder metallurgy process includes the following steps: in step S31, 65 to 90% of the aluminum alloy powder by volume is mixed with 10 to 35% of the binder; in step S32, in the manner of slurry casting, strip casting and static pressing An aluminum alloy green blank is made; and, in step S33, the green blank is sintered or forged at a high temperature to obtain the aluminum alloy product, wherein the aluminum alloy product includes the following elements: nickel (Ni): 3.0-5.0 wt.% , Copper (Cu): 2.0 ⁇ 3.0wt.%, iron (Fe): 1.0 ⁇ 2.0wt.%, manganese (Mn): 0.5-1.0wt.%, zirconium (Zr): 0.4 ⁇ 1.0wt.%, chromium (Cr): 0.40 to 1.0 wt.%, silicon (Si): 0.05 to 4.0 wt.%, and the remainder is aluminum (Al) and unavoidable impurities.
  • Fig. 5 is a flow chart of a manufacturing method of an aluminum alloy product according to a third embodiment of the present invention.
  • the method for manufacturing aluminum alloy products includes the following steps: (1) Perform a smelting process S41: make it contain aluminum (Al), nickel (Ni), copper (Cu), iron (Fe), manganese (Mn), and zirconium (Zr) , Chromium (Cr) and silicon (Si) materials are melted into an aluminum alloy broth; and (2) a casting process S42 is performed: the aluminum alloy broth is formed into an aluminum alloy product.
  • the smelting process S41 includes: placing a pure aluminum ingot into a melting furnace, and preheating the pure aluminum ingot material; after the pure aluminum ingot is melted, the pure copper ingot (or aluminum-copper intermediate alloy Or copper agent), pure nickel ingot (or aluminum-nickel intermediate alloy or nickel agent), pure iron ingot (or aluminum-iron intermediate alloy or iron agent), pure manganese ingot (or aluminum-manganese intermediate alloy or manganese agent), pure zirconium ingot (Or aluminum-zirconium intermediate alloy), pure chromium ingot (or aluminum-chromium intermediate alloy or chromium agent) and pure silicon ingot (or aluminum-silicon intermediate alloy); and, increase the melting power, heat up to 850 ⁇ 950°C, continue to stir about 15-20 minutes to melt materials containing aluminum (Al), nickel (Ni), copper (Cu), iron (Fe), manganese (Mn), zirconium (Zr), chromium (Cr) and silicon (Si) Into the aluminum alloy
  • the casting process S42 includes: after the stirring is completed, the molten slag on the surface of the aluminum alloy broth is stripped off, the temperature of the aluminum alloy broth is adjusted to 850 to 870 degrees, and the casting process S42 is poured into a mold so that the aluminum alloy broth forms the aluminum alloy broth.
  • Aluminum alloy products wherein the aluminum alloy products include the following elements: nickel (Ni): 3.0 to 5.0 wt.%, copper (Cu): 2.0 to 3.0 wt.%, iron (Fe): 1.0 to 2.0 wt.%, manganese (Mn): 0.5 ⁇ 1.0wt.%, zirconium (Zr): 0.4 ⁇ 1.0wt.%, chromium (Cr): 0.40 ⁇ 1.0wt.%, silicon (Si): 0.05 ⁇ 4.0wt.%, the rest is Aluminum (Al) and unavoidable impurities.
  • the present invention mainly uses nickel (Ni), copper (Cu), and iron (Fe) as main alloying elements, manganese (Mn), zirconium (Zr), chromium (Cr) and silicon (Si) as secondary alloying elements, and the rest For aluminum (Al) and unavoidable impurities, it provides an aluminum alloy material with high ductility, high tensile strength and better heat resistance, which can be used for multilayer manufacturing (3D printing, powder metallurgy), casting, etc.
  • the tensile strength is better than common aluminum-silicon (Al-Si), aluminum-magnesium (Al-Mg), aluminum-copper (Al-Cu), aluminum-magnesium-silicon (Al-Mg-Si), aluminum-zinc-magnesium-copper ( Al-Zn-Mg-Cu) and other alloys.
  • the present invention provides an aluminum alloy powder and a manufacturing method thereof.
  • an aluminum alloy material with high ductility, high tensile strength and better heat resistance can be manufactured, which can be used for laminated manufacturing , Such as 3D printing, powder metallurgy, casting and other methods to prepare aluminum alloy products, so it has industrial applicability.

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Abstract

一种铝合金粉末及其制造方法、铝合金制品及其制造方法，其中以其总重为100wt.％计算，该铝合金粉末或铝合金制品包括下列元素：镍：3.0～5.0wt.％，铜：2.0～3.0wt.％，铁：1.0～2.0wt.％，锰：0.5～1.0wt.％，锆：0.4～1.0wt.％，铬：0.40～1.0wt.％，硅：0.05～4.0wt.％，其余部分为铝及不可避免的杂质。使用镍、铜、铁作为主要合金元素，锰、锆、铬及硅作为次要合金元素，从而提供一种具有高延展性、高抗拉强度及较佳耐热性的铝合金材料，可用于积层制造，如3D打印、粉末冶金、铸造等方法制备铝合金制品。

Description

铝合金粉末及其制造方法、铝合金制品及其制造方法 技术领域
本发明是有关于一种合金粉末及其制造方法、合金制品及其制造方法，且特别是有关于一种铝合金粉末及其制造方法、铝合金制品及其制造方法。
背景技术
中国专利申请公布号CN109175350A公开一种用于增材制造的Al-Mg-Mn-Sc-Zr铝合金粉末的制备方法，其包括以下步骤：向中频炉内的坩埚中加入纯铝锭，并对铝锭进行预热；将熔炼室的温度升高至700～850℃，纯铝熔化开始后向熔炼室通入氩气，使熔炼室压力为0.6～0.9MPa；使坩埚内熔体温度达到1150～1300℃，加入纯锰、纯锆，保温15～25min；调高坩埚降温至800～900℃，熔炼室压力调节至0.3～0.7MPa，加入Al-Sc中间合金熔化后，保温5～15min；使坩埚内熔体温度降低至700～790℃，熔炼室压力调节至0.05～0.15MPa，加入纯镁锭；待镁锭完全熔化后，将坩埚保持在780～820℃；采用气雾化制粉方式进行制粉。
依已知的铝合金粉末以硅(Si)、镁(Mg)、锰(Mn)、锌(Zn)或铜(Cu)作为主要合金元素，并将镍(Ni)、铁(Fe)等元素视为杂质元素。利用铝合金粉末以积层制造方法制备的铝合金制品的抗拉强度大部分皆低于500MPa，除了航空应用的铝合金，如:7075、7050、2024等能高于500MPa，但这些高强度的铝合金需经由繁杂的热处理制程而得，且延展性及耐热性不佳，延展性(断裂伸长量)皆低于10％，无法在300℃以上使用。
因此，便有需要提供一种具有高延展性、高抗拉强度及较佳耐热性的铝合金材料，解决前述的问题。
发明内容
本发明的一目的是提供一种铝合金制品，其具有高延展性、高抗拉强度及较佳耐热性。
依据上述的目的，本发明提供一种铝合金粉末，以其总重为100wt.％计算，该铝合金粉末包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
本发明还提供一种铝合金粉末，以其总重为100wt.％计算，该铝合金粉末只由下列元素所构成：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
本发明更提供一种铝合金粉末的制造方法，包括下列步骤：进行一熔炼制程，使含有铝 (Al)、镍(Ni)、铜(Cu)、铁(Fe)、锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)的各个材料熔化成一铝合金熔汤；以及进行一制粉制程，使该铝合金熔汤形成一铝合金粉末；其中该铝合金粉末包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
在一些实施例中，该熔炼制程包括下列步骤：
将一纯铝锭置入一熔炼炉中，并对该纯铝锭进行预热；
该纯铝锭熔化后，依序投入纯铜锭(或铝铜中间合金或铜剂)、纯镍锭(或铝镍中间合金或镍剂)、纯铁锭(或铝铁中间合金或铁剂)、纯锰锭(或铝锰中间合金或锰剂)、纯锆锭(或铝锆中间合金)、纯铬锭(或铝铬中间合金或铬剂)及纯硅锭(或铝硅中间合金)；以及
加大熔炼功率，升温至850～950℃，持续搅拌约15～20分钟，使含有铝(Al)、镍(Ni)、铜(Cu)、铁(Fe)、锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)的各个材料熔化成该铝合金熔汤；以及
该制粉制程包括下列步骤：
开启雾化气体，进行气雾化制粉，使该铝合金熔汤形成该铝合金粉末。
本发明另提供一种铝合金制品，以其总重为100w％计算，该铝合金制品包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
在一些实施例中，该铝合金制品的抗拉强度大于500Mpa，且延展性大于10％。
本发明又提供一种铝合金制品的制造方法，包括：将所述的铝合金粉末进行3D打印制程或粉末冶金制程，使该铝合金粉末形成一铝合金制品。
在一些实施例中，该3D打印制程包括下列步骤：
将该铝合金粉末经由气旋分选及震动分选进行粉末筛分，将粉末粒径筛选至20～63μm后，加热至70～90℃约0.5～1.0小时，去除湿气，并将该铝合金粉末抽真空保存；以及
以激光选区熔化设备进行3D打印而得该铝合金制品；以及
待3D打印完成后，将该铝合金制品取下，并施以表面处理。
在一些实施例中，该粉末冶金制程包括下列步骤：
将体积百分比65～90％的铝合金粉末与黏结剂10～35％混合；
以粉浆浇注、带材浇注及静压方式制成一铝合金生胚；以及
将该铝合金生胚经由高温烧结或锻造而得该铝合金制品。
本发明再提供一种铝合金制品的制造方法，包括：
进行一熔炼制程：使含有铝(Al)、镍(Ni)、铜(Cu)、铁(Fe)、锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)的各个材料熔化成一铝合金熔汤；以及
进行一浇铸制程：使该铝合金熔汤形成一铝合金制品，其中该铝合金制品包括下列元素：
镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
本发明主要使用镍(Ni)、铜(Cu)、铁(Fe)作为主要合金元素，锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)作为次要合金元素，其余部分为铝(Al)及不可避免的杂质，而提供一种具有高延展性、高抗拉强度及较佳耐热性的铝合金材料，可用于积层制造(3D打印、粉末冶金)、铸造等方法制备，抗拉强度优于常见的铝硅(Al-Si)、铝镁(Al-Mg)、铝铜(Al-Cu)、铝镁硅(Al-Mg-Si)、铝锌镁铜(Al-Zn-Mg-Cu)等合金。
附图说明
图1为本发明一实施例的铝合金粉末的制造方法流程图；
图2为本发明一实施例的熔炼炉及气体雾化设备的剖面示意图；
图3为本发明第一实施例的铝合金制品的制造方法流程图；
图4为本发明第二实施例的铝合金制品的制造方法流程图；
图5为本发明第三实施例的铝合金制品的制造方法流程图。
附图中的符号说明：
10    承载坩埚；
11    铝合金熔汤；
12    下舱体；
13    集粉桶；
G     雾化气体；
P     铝合金粉末；
S11   熔炼制程；
S12   制粉制程；
S21   步骤；
S22   步骤；
S23   步骤；
S31   步骤；
S32   步骤；
S33   步骤；
S41   熔炼制程；
S42   浇铸制程。
具体实施方式
为让本发明的上述目的、特征和特点能更明显易懂，配合附图将本发明相关实施例详细说明如下。
图1为本发明一实施例的铝合金粉末的制造方法流程图。该铝合金粉末的制造方法包括下列步骤：(1)进行一熔炼制程S11：使含有铝(Al)、镍(Ni)、铜(Cu)、铁(Fe)、锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)的各个材料熔化成一铝合金熔汤；以及(2)进行一制粉制程S12：使该铝合金熔汤形成一铝合金粉末。
请参考图2，举例，本发明的熔炼制程包括下列步骤：将纯铝锭置入熔炼炉(例如真空感应熔炼炉)的承载坩埚10中，并对该纯铝锭进行预热；该纯铝锭熔化后，依序投入纯铜锭(或铝铜中间合金或铜剂)、纯镍锭(或铝镍中间合金或镍剂)、纯铁锭(或铝铁中间合金或铁剂)、纯锰锭(或铝锰中间合金或锰剂)、纯锆锭(或铝锆中间合金)、纯铬锭(或铝铬中间合金或铬剂)及纯硅锭(或铝硅中间合金)；以及加大熔炼功率，升温至850～950℃，持续搅拌约15～20分钟，使含有铝(Al)、镍(Ni)、铜(Cu)、铁(Fe)、锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)的各个材料熔化成该铝合金熔汤11。该铝合金熔汤包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
本发明的制粉制程包括下列步骤：搅拌完成后，将该铝合金熔汤11除渣精炼，并调整下舱体12压力控制于0.07～0.10MPa，承载坩埚温度控制于850～880℃，开启雾化气体G(例如氩气或氮气)，进行气雾化制粉，使该铝合金熔汤11形成该铝合金粉末P，并收集在集粉桶13内。例如以高速冷却气体将该铝合金熔汤11冲击雾化后而快速凝固成铝合金粉末P。该铝合金粉末P包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其馀部分为铝(Al)及不可避免的杂质。
图3为本发明第一实施例的铝合金制品的制造方法流程图。该铝合金制品的制造方法包括：将本发明的铝合金粉末进行3D打印制程，使该铝合金粉末形成一铝合金制品。该3D打印制程包括下列步骤：在步骤S21中，将该铝合金粉末经由气旋分选及震动分选进行粉末筛分，将粉末粒径筛选至20～63μm后，加热至70～90℃约0.5～1.0小时，去除湿气，并将该铝合金粉末抽真空保存；在步骤S22中，以选区激光熔化(Selective laser melting；SLM)技 术进行3D打印而得该铝合金制品(选区激光熔化技术是以原型制造技术为基本原理发展起来的一种先进的激光增材制造技术，通过专用软件对零件三维数模进行切片分层，获得各截面的轮廓资料后，利用高能量激光射束根据轮廓数据逐层选择性地熔化金属粉末，通过逐层铺粉，逐层熔化凝固堆积的方式，制造三维实体零件。例如，以德国SLM Solutions 280激光选区熔化设备进行铝合金3D打印)；以及，在步骤S23中，待3D打印完成后，将该铝合金制品取下，并施以表面处理，其中该铝合金制品包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
请参考表一，本发明实施例1～3的铝合金制品的配方成分及其比例。请参考表二，实施例1～3的铝合金制品的抗拉强度可大于500MPa，其断裂伸长量大于10％及适用于300℃以上的环境。
  Al Ni Cu Fe Mn Zr Cr Si
实施例1. 余量 4.11 2.22 1.44 0.72 0.55 0.53 0.12
实施例2. 余量 3.80 2.10 1.63 0.74 0.50 0.55 0.11
实施例3. 余量 4.30 2.30 1.45 0.80 0.68 0.52 0.18
表一
Figure PCTCN2019121428-appb-000001
表二
机械性能测试根据ISO 6892-1:2009(B)annex D
拉伸试棒：直径5mm圆棒，标距长度25mm
本发明的铝合金制品添加大量的镍、铜、铁及少量的锰、锆及铬至铝合金中，借由Cu、Mn、Si及Cr元素在Al中溶解度，产生部分固溶强化，及其元素间形成的分散强化相(CrFe)Al 7、(CrMn)Al 12、(FeMn)Al 6、(Fe2Si)Al 8、FeSiAl 5、Al 3Zr提升铝合金的强度及耐热性。热处理后，使时效硬化相Al 3Ni及Al 2Cu析出，进一步提升抗拉强度及延展性。
本发明铝合金制品具备高延展性的原因在于Al 3Ni及Al 3Fe的分散强化相，此类析出相 为杆状结构，在裂痕扩展时，此结构与裂痕平行，不易造成应力集中，另外添加Cr及Mn元素可调整Fe在铝合金中的微结构，形成(CrFe)Al 7、(CrMn)Al 12及(FeMn)Al 6，可同时提升延展性及抗拉强度。
另外，本发明铝合金制品的硅(Si)含量只介于0.05～4.0wt.％，若Si在此铝合金含量过高会造成Al 5FeSi(alpha phase,script-like phase)增加，容易形成裂缝，降低延展性。在热处理上Si含量过高也容易形成Si聚集，可能会有粗大的硅颗粒(Si particle)或是片状硅(Si sheet)产生，降低铝合金的抗拉强度。
图4为本发明第二实施例的铝合金制品的制造方法流程图。该铝合金制品的制造方法包括：将本发明的铝合金粉末进行粉末冶金制程，使该铝合金粉末形成一铝合金制品。该粉末冶金制程包括下列步骤：在步骤S31中，将体积百分比65～90％的铝合金粉末与黏结剂10～35％混合；在步骤S32中，以粉浆浇注、带材浇注及静压方式制成一铝合金生胚；以及，在步骤S33中，将生胚经由高温烧结或锻造而得该铝合金制品，其中该铝合金制品包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5-1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
图5为本发明第三实施例的铝合金制品的制造方法流程图。该铝合金制品制造方法包括下列步骤：(1)进行一熔炼制程S41：使含有铝(Al)、镍(Ni)、铜(Cu)、铁(Fe)、锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)的各个材料熔化成一铝合金熔汤；以及(2)进行一浇铸制程S42：使该铝合金熔汤形成一铝合金制品。
举例，该熔炼制程S41包括：将一纯铝锭置入一熔炼炉中，并对该纯铝锭材料进行预热；该纯铝锭熔化后，依序投入纯铜锭(或铝铜中间合金或铜剂)、纯镍锭(或铝镍中间合金或镍剂)、纯铁锭(或铝铁中间合金或铁剂)、纯锰锭(或铝锰中间合金或锰剂)、纯锆锭(或铝锆中间合金)、纯铬锭(或铝铬中间合金或铬剂)及纯硅锭(或铝硅中间合金)；以及，加大熔炼功率，升温至850～950℃，持续搅拌约15～20分钟，使含有铝(Al)、镍(Ni)、铜(Cu)、铁(Fe)、锰(Mn)、锆(Zr)、铬(Cr)及硅(Si)的各个材料熔化成该铝合金熔汤。
该浇铸制程S42包括：搅拌完成后，将该铝合金熔汤表面熔渣扒除，调整该铝合金熔汤的温度在850～870度，浇铸至一模具中，使该铝合金熔汤形成该铝合金制品，其中该铝合金制品包括下列元素：镍(Ni)：3.0～5.0wt.％，铜(Cu)：2.0～3.0wt.％，铁(Fe)：1.0～2.0wt.％，锰(Mn)：0.5～1.0wt.％，锆(Zr)：0.4～1.0wt.％，铬(Cr)：0.40～1.0wt.％，硅(Si)：0.05～4.0wt.％，其余部分为铝(Al)及不可避免的杂质。
本发明主要使用镍(Ni)、铜(Cu)、铁(Fe)作为主要合金元素，锰(Mn)、锆(Zr)、铬(Cr)及 硅(Si)作为次要合金元素，其余部分为铝(Al)及不可避免的杂质，而提供一种具有高延展性、高抗拉强度及较佳耐热性的铝合金材料，可用于积层制造(3D打印、粉末冶金)、铸造等方法制备，抗拉强度优于常见的铝硅(Al-Si)、铝镁(Al-Mg)、铝铜(Al-Cu)、铝镁硅(Al-Mg-Si)、铝锌镁铜(Al-Zn-Mg-Cu)等合金。
综上所述，仅记载本发明为呈现解决问题所采用的技术手段的较佳实施方式或实施例而已，并非用来限定本发明专利实施的范围。即凡与本发明专利申请范围文义相符，或依本发明专利范围所做的均等变化与修饰，皆为本发明专利范围所涵盖。
工业实用性
本发明提供了一种铝合金粉末及其制造方法，利用该铝合金粉末为原料能够制造出具有高延展性、高抗拉强度及较佳耐热性的铝合金材料，能够用于积层制造，如3D打印、粉末冶金、铸造等方法制备铝合金制品，因此，具有工业实用性。

Claims (10)

  1. 一种铝合金粉末，其中，以其总重为100wt.％计算，该铝合金粉末包括下列元素：
    镍：3.0～5.0wt.％，铜：2.0～3.0wt.％，铁：1.0～2.0wt.％，锰：0.5～1.0wt.％，锆：0.4～1.0wt.％，铬：0.40～1.0wt.％，硅：0.05～4.0wt.％，其余部分为铝及不可避免的杂质。
  2. 一种铝合金粉末，其中，以其总重为100wt.％计算，该铝合金粉末只由下列元素所构成：
    镍：3.0～5.wt.％，铜：2.0～3.0wt.％，铁：1.0～2.0wt.％，锰：0.5～1.0wt.％，锆：0.4～1.0wt.％，铬：0.40～1.0wt.％，硅：0.05～4.0wt.％，其余部分为铝及不可避免的杂质。
  3. 一种铝合金粉末的制造方法，其中，包括下列步骤：
    进行一熔炼制程，使含有铝、镍、铜、铁、锰、锆、铬及硅的各个材料熔化成一铝合金熔汤；以及
    进行一制粉制程，使该铝合金熔汤形成一铝合金粉末；
    其中该铝合金粉末包括下列元素：
    镍：3.0～5.0wt.％，铜：2.0～3.0wt.％，铁：1.0～2.0wt.％，锰：0.5～1.0wt.％，锆：0.4～1.0wt.％，铬：0.40～1.0wt.％，硅：0.05～4.0wt.％，其余部分为铝及不可避免的杂质。
  4. 如权利要求3所述的铝合金粉末的制造方法，其中，该熔炼制程包括下列步骤：
    将一纯铝锭置入一熔炼炉中，并对该纯铝锭进行预热；
    该纯铝锭熔化后，依序投入纯铜锭或铝铜中间合金或铜剂、纯镍锭或铝镍中间合金或镍剂、纯铁锭或铝铁中间合金或铁剂、纯锰锭或铝锰中间合金或锰剂、纯锆锭或铝锆中间合金、纯铬锭或铝铬中间合金或铬剂及纯硅锭或铝硅中间合金；以及
    加大熔炼功率，升温至850～950℃，持续搅拌15～20分钟，使含有铝、镍、铜、铁、锰、锆、铬及硅的各个材料熔化成该铝合金熔汤；以及
    该制粉制程包括下列步骤：
    开启雾化气体，进行气雾化制粉，使该铝合金熔汤形成该铝合金粉末。
  5. 一种铝合金制品，其中，以其总重为100wt.％计算，该铝合金制品包括下列元素：
    镍：3.0～5.0wt.％，铜：2.0～3.0wt.％，铁：1.0～2.0wt.％，锰：0.5～1.0wt.％，锆：0.4～1.0wt.％，铬：0.40～1.0wt.％，硅：0.05～4.0wt.％，其余部分为铝及不可避免的杂质。
  6. 如权利要求5所述的铝合金制品，其中，该铝合金制品的抗拉强度大于500Mpa，且延展性大于10％。
  7. 一种铝合金制品的制造方法，其中，包括：将如权利要求1或2所述的铝合金粉末进行3D打印制程或粉末冶金制程，使该铝合金粉末形成一铝合金制品。
  8. 如权利要求7所述的铝合金制品的制造方法，其中，该3D打印制程包括下列步骤：
    将该铝合金粉末经由气旋分选及震动分选进行粉末筛分，将粉末粒径筛选至20～63μm后，加热至70～90℃，0.5～1.0小时，去除湿气，并将该铝合金粉末抽真空保存；以及
    以激光选区熔化设备进行3D打印而得该铝合金制品；以及
    待3D打印完成后，将该铝合金制品取下，并施以表面处理。
  9. 如权利要求7所述的铝合金制品的制造方法，其中，该粉末冶金制程包括下列步骤：
    将体积百分比65～90％的铝合金粉末与黏结剂10～35％混合；
    以粉浆浇注、带材浇注及静压方式制成一铝合金生胚；以及
    将该铝合金生胚经由高温烧结或锻造而得该铝合金制品。
  10. 一种铝合金制品的制造方法，其中，包括：
    进行一熔炼制程：使含有铝、镍、铜、铁、锰、锆、铬及硅的各个材料熔化成一铝合金熔汤；以及
    进行一浇铸制程：使该铝合金熔汤形成一铝合金制品，其中该铝合金制品包括下列元素：
    镍：3.0～5.0wt.％，铜：2.0～3.0wt.％，铁：1.0～2.0wt.％，锰：0.5～1.0wt.％，锆：0.4～1.0wt.％，铬：0.40～1.0wt.％，硅：0.05～4.0wt.％，其余部分为铝及不可避免的杂质。
PCT/CN2019/121428 2019-09-23 2019-11-28 铝合金粉末及其制造方法、铝合金制品及其制造方法 WO2021056806A1 (zh)

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