EP0213528A2 - Matériau composite contenant des fibres courtes d'alumine-silice comme matériau de renforcement et avec une matrice en alliage d'aluminium contenant du cuivre avec une corrélation entre les différentes teneurs - Google Patents

Matériau composite contenant des fibres courtes d'alumine-silice comme matériau de renforcement et avec une matrice en alliage d'aluminium contenant du cuivre avec une corrélation entre les différentes teneurs Download PDF

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Publication number
EP0213528A2
EP0213528A2 EP86111395A EP86111395A EP0213528A2 EP 0213528 A2 EP0213528 A2 EP 0213528A2 EP 86111395 A EP86111395 A EP 86111395A EP 86111395 A EP86111395 A EP 86111395A EP 0213528 A2 EP0213528 A2 EP 0213528A2
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EP
European Patent Office
Prior art keywords
alumina
approximately
composite material
copper content
silica
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EP86111395A
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German (de)
English (en)
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EP0213528A3 (fr
Inventor
Masahiro Kubo
Tadashi Dohnomoto
Atsuo Tanaka
Hidetoshi Hirai
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Toyota Motor Corp
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Toyota Motor Corp
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
    • C22C49/14—Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
    • C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
    • C22C49/04—Light metals
    • C22C49/06—Aluminium

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  • the present invention relates to a composite material made up from reinforcing fibers embedded in a matrix of metal, and more particularly relates to such a composite material utilizing alumina - silica short fiber material as the reinforcing fiber material and aluminum alloy including some copper as the matrix metal.
  • JIS standard 6061 (0.4 to 0.8% Si, 0.15 to 0.4% Cu, 0.8 to 1.2% Mg, 0.04 to 0.35% Cr, remainder substantially Al)
  • JIS standard 5056 (not more than 0.3% Si, not more than 0.4% Fe, not more than 0.1% Cu, 0.05 to 0.2% Mn, 4.5 to 5.6% Mg, 0.05 to 0.2% Cr, not more than 0.1% Zn, remainder substantially Al)
  • JIS standard 7075 (not more than 0.4% Si, not more than 0.5% Fe, 1.2 to 2.0% Cu, not more than 0.3 Mn, 2.1 to 2.9% Mg, 0.18 to 0.28% Cr, 5.1 to 6.1% Zn, 0.2% Ti, remainder substantially Al)
  • the inventors of the present application have considered the above mentioned problems in composite materials which use such conventional aluminum alloys as matrix metal, and in particular have considered the particular case of a composite material which utilizes alumina - silica short fibers as reinforcing fibers, since such alumina - silica short fibers, among the various reinforcing fibers used conventionally in the manufacture of a fiber reinforced metal composite material, have particularly high strength, and are exceedingly effective in improving the high temperature stability and strength, as well as being available in numerous convenient varieties.
  • alumina - silica type short fibers which are related by the following inequalities: and: and having substantially no content of other elements such as silicon, magnesium, nickel, zinc, or the like in its aluminum alloy matrix metal, is optimal in view of its bending strength characteristics as well as in view of others of its characteristics such as its mechanical characteristics.
  • the present invention is based on the knowledge obtained from the results of the various experimental researches carried out by the inventors of the present application, as will be detailed later in this specification.
  • a composite material comprising alumina - silica type short fibers embedded in a matrix of metal, the percentage fiber volume proportion X% of said alumina - silica type short fibers being between approximately 5% and approximately 50%, and said metal being an alloy consisting essentially of a percentage Y% of copper and remainder substantially aluminum, said values X% and Y% approximately satisfying the following inequalities: Y S - 0.00092 X 2 - 0.0094 X + 7.85 and Y 1 - 0.00092 X 2 - 0.0094 X + 3.55; and, more particularly, the fiber volume proportion of said alumina - silica type short fibers may be between approximately 5% and approximately 40%; and said alumina - silica type short fibers may be alumina short fibers, or alternatively may be crystalline alumina - silica short fibers, of which the mullite crystalline amount of said alumina - silica
  • alumina - silica short fibers which have high strength, and are exceedingly effective in improving the high temperature stability and strength of the resulting composite material
  • matrix metal there is used an aluminum alloy with a copper content such as in concert with the volume proportion of the reinforcing alumina - silica short fibers to satisfy the inequalities detailed above and with the remainder thereof being substantially only aluminum, and the volume proportion of the alumina - silica short fibers is from 5% to 50%, whereby, as is clear from the results of experimental research carried out by the inventors of the present application as will be described below, a composite material with superior mechanical characteristics such as strength can be obtained.
  • the volume proportion of alumina - silica short fibers in a composite material according to the present invention may be set to be lower than the value required for such a conventional composite material, and therefore, since it is possible to reduce the amount of alumina - silica short fibers used, the machinability and workability of the composite material can be improved, and it is also possible to reduce the cost of the composite material. Further, the characteristics with regard to wear on a mating member will be improved.
  • the strength of the aluminum alloy matrix metal is increased and thereby the strength of the composite material is improved, but that effect is not sufficient if the copper content is small, whereas if the copper content is too high the composite material becomes very brittle, and has a tendency to rapidly disintegrate.
  • the volume proportion of the alumina - silica short fibers used is increased, the strength of the aluminum alloy matrix metal is increased and thereby the strength of the composite material is improved, but its toughness is reduced, and again there is a tendency for the composite material to become very brittle. Therefore the copper content of the aluminum alloy used as matrix metal in the composite material of the present invention is required to satisfy the two inequalities detailed above.
  • alumina - silica short fibers are less than 5%, a sufficient strength cannot be obtained; when the volume proportion of the alumina - silica short fibers is between about 5% and about 30% the strength of the composite material increases substantially linearly along with increase in said short fiber volume proportion; and if the volume proportion of alumina - silica short fibers exceeds 40% and particularly if it exceeds 50% even if the volume proportion of the alumina - silica short fibers is increased, the strength of the composite material is not very significantly improved.
  • the wear resistance of the composite material increases with the volume proportion of the alumina - silica short fibers, but when the volume proportion of the alumina - silica short fibers is in the range from zero to approximately 5% said wear resistance increases rapidly with an increase in the volume proportion of the alumina - silica short fibers, whereas when the volume proportion of the alumina - silica short fibers is in the range of at least approximately 5%, the wear resistance of the composite material does not very significantly increase with an increase in the volume proportion of said alumina - silica short fibers. Therefore, according to one characteristic of the present invention, the volume proportion of the alumina - silica short fibers is required to be in the range of from approximately 5% to approximately 50%, and preferably is required to be in the range of from approximately 5% to approximately 40%.
  • the copper content of the aluminum alloy used as matrix metal of the composite material of the present invention has a relatively high value, if there are unevennesses in the concentration of the copper within the aluminum alloy, the portions where the copper concentration is high will be brittle, and it will not therefore be possible to obtain a uniform matrix metal or a composite material of good and uniform quality.
  • such a composite material of which the matrix metal is aluminum alloy of which the copper content is less than approximately 3.5% is subjected to liquidizing processing for from about 2 hours to about 8 hours at a temperature of from about 480°C to about 520°C, and is preferably further subjected to aging processing for about 2 hours to about 8 hours at a temperature of from about 150°C to 200°C, while on the other hand such a composite material of which the matrix metal is aluminum alloy of which the copper content is at least approximately 3.5% and is less than approximately 6.5% is subjected to liquidizing processing for from about 2 hours to about 8 hours at a temperature of from about 460°C to about 510°C, and is preferably further subjected to aging processing for about 2 hours to about 8 hours at a temperature of from about 150°C to 200°C.
  • alumina - silica short fibers in the composite material of the present invention may be either alumina - silica continuous fibers cut to a predetermined length or may be or alumina - silica non continuous fibers.
  • These alumina - silica short fibers either may be alumina short fibers having a composition of about 80% to about 100% A1203 and remainder substantially Si02, or may be crystalline or amorphous alumina - silica short fibers having a composition of not less than about 35% and not greater than about 80% A1203 and remainder substantially Si02; and, in the case that said alumina - silica short fibers are alumina short fibers the crystalline structure of the A1203 may be any of the alpha, the gamma, or the delta types.
  • the alumina - silica type short fibers are crystalline alumina - silica short fibers, as will be described in detail below: if the mullite crystalline amount in the crystalline alumina - silica short fibers is in the range of from about 0% to about 10%, even if the mullite crystalline amount increases the strength of the composite material is not significantly increased, but remains substantially constant; if the mullite crystalline amount in the crystalline alumina - silica short fibers is in the range of from about 10% to about 20%, then as the mullite crystalline amount increases the strength of the composite material increases gradually and substantially linearly with said mullite crystalline amount; if the mullite crystalline amount in the crystalline alumina - silica short fibers is in the range of from about 20% to about 40%, then even if the mullite crystalline amount increases the strength of the composite material is not significantly improved, but remains substantially constant; if the mullite crystalline amount in the crystalline alumina -
  • the mullite crystalline amount of these crystalline alumina - silica short fibers is set at to be at least about 45%.
  • the fiber length of the alumina - silica short fibers is preferably from approximately 10 microns to approximately 7 cm, and particularly is preferably from approximately 10 microns to approximately 5 cm, and the fiber diameter thereof is preferably from approximately 1 micron to approximately 30 microns, and particularly is preferably from approximately 1 micron to approximately 25 microns.
  • substantially Si02 means that, apart from the A1203 and the Si02 forming the reinforcing alumina - silica type short fibers, other constituents are present only to the extent of being impurities.
  • the present inventors manufactured by using the high pressure casting method samples of various composite materials, utilizing as reinforcing material alumina - silica fiber material of type "KaoWool" (this is a trademark) made by Isolite Babcock Taika K.K., which were approximately 48% A1203 and remainder substantially Si02, and which had average fiber length 1 mm and average fiber diameter 3 microns, and utilizing as matrix metal Al-Cu type aluminum alloys of various compositions. Then the present inventors conducted evaluations of the bending strength of the various resulting composite material sample pieces.
  • KaoWool this is a trademark
  • a set of aluminum alloys designated as A1 through A15 were produced, having as base material aluminum and having various quantities of copper mixed therewith, with substantially no impurities, as shown in the appended Table 1.
  • six preforms were made of amorphous, in this case, alumina - silica short fiber material by, in each case, subjecting a quantity of the above specified alumina - silica short fiber material to compression forming without using any binder.
  • Each of these six alumina - silica fiber material preforms was, as schematically illustrated in perspective view in Fig.
  • an exemplary such preform is designated by the reference numeral 2 and the alumina - silica fibers therein are generally designated as 1, about 38 x 100 x 16 mm in dimensions, and the individual alumina - silica fibers 1 in each of said preforms 2 were oriented substantially randomly in two dimensions, i.e. in the x-y plane parallel to the 38 x 100 mm face of the preform, and were overlapped in a two dimensionally random manner in the axis perpendicular to this plane. And the approximate fiber volume proportions in these six preforms 2 were respectively 5%, 10%, 15%, 20%, 30%, and 40%.
  • each of these alumina - silica fiber material preforms 2 was subjected to high pressure casting together with an appropriate quantity of one of the aluminum alloys A1 through A15 described above, in the following manner.
  • the preform 2 was inserted into a stainless steel case 2a, as shown in Fig. 2; this stainless steel case 2a was a rectangular parallelopiped and was open at both its ends.
  • the preform 2 and the stainless steel case 2a were together heated up to a temperature of approximately 600°C, and then said preform 2 and the enclosing case 2a were placed within a mold cavity 4 of a casting mold 3, which itself had previously been preheated up to a temperature of approximately 250°C.
  • the results of these bending strength tests were as shown in the appended Table 2, and as summarized in the graph of Fig. 4.
  • the numerical values in Table 2 indicate the bending strengths (in kg/mm 2 ) of the composite material bending strength test pieces having as matrix metals aluminum alloys as shown down the left edge of the table and having reinforcing alumina - silica short fiber volume proportions as shown along the upper edge of the table.
  • the graph of Fig. 4 is based upon the data in Table 2, and shows the relation between copper content and the bending strength (in kg/mm 2 ) of the composite material test pieces, for reinforcing amorphous alumina - silica short fiber volume proportion X fixed along the various lines thereof.
  • the reinforcing amorphous alumina - silica short fiber volume proportion X was approximately 40%: when the copper content was in the range from approximately 0% to approximately 4.5% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range from approximately 1% to approximately 4.5%; when the copper content reached approximately 4.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 4.5% the bending strength of the composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of from approximately 6% to approximately 6.5%.
  • the reinforcing amorphous alumina - silica short fiber volume proportion X was approximately 30%: when the copper content was in the range from approximately 0% to approximately 4.5% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range from approximately 2% to approximately 4 .5%; when the copper content reached approximately 4.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 4.5% the bending strength of the composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of being greater than approximately 6.5%.
  • the reinforcing amorphous alumina - silica short fiber volume proportion X was approximately 20%: when the copper content was in the range from approximately 0% to approximately 5.5% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range from approximately 2.5% to approximately 4 %; when the copper content reached approximately 5.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 5.5% the bending strength of the composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of being greater than approximately 7%.
  • the reinforcing amorphous alumina - silica short fiber volume proportion X was approximately 15%, or 10%, or 5%: when the copper content was in the range from approximately 0% to approximately 6% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the respective ranges of from approximately 3% to approximately 6%, from approximately 3% to approximately 5.5%, and from approximately 3% to approximately 4.5%; when the copper content reached approximately 6% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 6% the bending strength of the composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of being greater than approximately 7.5%.
  • These preferable ranges for the copper content of the Al-Cu type aluminum alloy matrix metal are values which, if X (in percent) represents the volume proportion of the amorphous type alumina - silica short fibers and Y (likewise in percent) represents the copper content of the matrix metal, satisfy the two inequalities detailed previously, i.e.: and:
  • Fig. 5 is a graph in which the reinforcing alumina - silica fiber volume proportion X in percent in the composite material is shown along the horizontal axis and copper content Y of the aluminum alloy matrix metal thereof in percent is shown along the vertical axis, such values of X and Y as satisfy the two inequalities (1) and (2) detailed above fall within the area defined by the two quadratic curves shown.
  • alumina - silica fiber material made by subjecting a quantity of the same type of alumina - silica fiber material as before - i.e. a quantity of alumina - silica fiber material of type "KaoWool" (this is a trademark) made by Isolite Babcock Taika K.K., which were approximately 48% A1203 and remainder substantially Si02, and which had average fiber length 1 mm and average fiber diameter 3 microns - to heat procesing so that the percentage of the mullite crystalline form included therein was about 60%.
  • matrix metal there were utilized the same Al-Cu type aluminum alloys as before, i.e.
  • alumina - silica fiber material preforms were made as before, without using any binder, said six alumina - silica fiber material preforms 2 again having approximate fiber volume proportions of respectively 5%, 10%, 15%, 20%, 30%, and 40%; and these preforms 2 had substantially the same dimensions as the preforms 2 of the first set of preferred embodiments.
  • each of these alumina - silica short fiber material preforms 2 was subjected to high pressure casting while included in a stainless steel case, together with an appropriate quantity of one of the aluminum alloys described above, utilizing operational parameters substantially as before, and, after machining away the peripheral portions of the resulting solidified aluminum alloy masses and extraction from the cases, sample pieces of composite material which had alumina - silica short fiber material as reinforcing material in the appropriate fiber volume proportion and the appropriate one of the above described aluminum alloys as matrix metal were obtained.
  • Post processing steps were performed on the composite material samples, substantially as before, and from each of the composite material sample pieces manufactured as described above, to which heat treatment had been applied, there was cut a bending strength test piece of dimensions substantially as in the case of the first set of preferred embodiments, and for each of these composite_material bending strength test pieces a bending strength test was carried out, again substantially as before.
  • Table 4 and Fig. 6 correspond respectively to Table 2 and Fig. 4 relating to the first set of preferred embodiments.
  • the numerical values in Table 4 indicate the bending strengths (in kg/mm 2 ) of the composite material bending strength test pieces having as matrix metals aluminum alloys as shown down the left edge of the table and having reinforcing alumina - silica short fiber volume proportions as shown along the upper edge of the table.
  • the reinforcing mullite crystalline alumina - silica short fiber volume proportion X was approximately 40%: when the copper content was in the range from approximately 0% to approximately 4.5% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range from approximately 1% to approximately 4 .5%; when the copper content reached approximately 4.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 4.5% the bending strength of the composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of from approximately 6% to approximately 6.5%.
  • the reinforcing mullite crystalline alumina - silica short fiber volume proportion X was approximately 30%: when the copper content was in the range from approximately 0% to approximately 4.5% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range from approximately 2% to approximately 4.5%; when the copper content reached approximately 4.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 4.5% the bending strength of the composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range from approximately 6.5% to approximately 7%.
  • the reinforcing mullite crystalline alumina - silica short fiber volume proportion X was approximately 20%: when the copper content was in the range from approximately 0% to approximately 5.5% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range from approximately 2.5% to approximately 4%; when the copper content reached approximately 5.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 5.5% the bending strength of the - composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of from approximately 7% to approximately 7.5%.
  • the reinforcing mullite crystalline alumina - silica short fiber volume proportion X was approximately 15%, or 10%, or 5%: when the copper content was in the range from approximately 0% to approximately 6% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range of from approximately 3% to approximately 6%; when the copper content reached approximately 6% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 6% the bending strength of the composite material had a tendency to reduce relatively rapidly along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of being greater than approximately 7.5 % .
  • the present inventors manufactured further samples of various composite materials, again utilizing as matrix metal the fifteen Al-Cu type aluminum alloys Al through A15 detailed above, but this time using as reinforcing material a different type of alumina - silica fiber material, consisting of alumina short fibers. Then the present inventors again conducted evaluations of the bending strength of the various resulting composite material sample pieces.
  • a set of aluminum alloys again designated as A1 through A15 were produced in the same manner as before, again having as base material aluminum and having various quantities of copper mixed therewith, as before.
  • six alumina - silica fiber material preforms were made similarly to what was done before by, in each case, subjecting a quantity of a fiber material, this time being alumina short fibers of type "Saffil RF" (this is a trademark) manufactured by ICI KK and being composed of approximately 95% delta A1203 and remainder substantially Si02 and having average fiber length approximately 2 cm and average fiber diameter approximately 3 microns, to compression forming without using any binder, the six said alumina - silica fiber material preforms 2 for each aluminum alloy sample as before having approximate fiber volume proportions of respectively 5%, 10%, 15%, 20%, 30%, and 40%, as before.
  • These preforms 2 had substantially the same dimensions as the preforms 2 of the first and second sets of preferred embodiments.
  • each of these alumina - silica fiber material preforms 2 was subjected to high pressure casting in a stainless steel case together with an appropriate quantity of the appropriate one of the aluminum alloys Al through A15 described above, utilizing operational parameters substantially as before.
  • the solidified aluminum alloy mass with the preform 2 included therein was then removed from the casting mold, and the peripheral portion of said solidified aluminum alloy mass was machined away, leaving, after extraction from the stainless steel case, a sample piece of composite material which had alumina - silica short fiber material as reinforcing material in the appropriate fiber volume proportion and the appropriate one of the aluminum alloys A1 through A15 as matrix metal.
  • post processing steps were performed on the composite material samples, substantially as before.
  • Table 5 and Fig. 7 correspond respectively to Table 2 and Fig. 4 relating to the first set of preferred embodiments, and also respectively to Table 4 and Fig. 6 relating to the second set of preferred embodiments.
  • the numerical values in Table 5 indicate the bending strengths (in kg/mm 2 ) of the composite material bending strength test pieces having as matrix metals aluminum alloys as shown down the left edge of the table and having reinforcing alumina - silica short fiber volume proportions as shown along the upper edge of the table.
  • the reinforcing delta alumina type alumina - silica short fiber volume proportion X was approximately 15%, or 10%, or 5%: when the copper content was in the range from approximately 0% to approximately 6% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range of from approximately 3% to approximately 6%; when the copper content reached approximately 6% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 6% the bending strength of the composite material had a tendency to reduce along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of being greater than approximately 7.5%.
  • alumina - silica type short fibers there were used alumina short fibers obtained by cutting alumina short fiber material of the type "Sumi-Ka alumina fibers" manufactured by Sumitomo Kagaku Kogyo KK, which were composed approximately of 85% gamma type A1203, the remainder being substantially Si02, and which had average fiber diameter 17 microns, to a length of approximately 1 cm.
  • the results of these tests showed a similar trend to that of the results for the third set of preferred embodiments detailed above and shown in Fig. 7.
  • the present inventors manufactured by using the high pressure casting method samples of various composite materials, again utilizing as matrix metal the fifteen Al-Cu type aluminum alloys A1 through A15 detailed above, but this time using as reinforcing material a different type of alumina - silica fiber material, the alumina of which consisted of alpha alumina and mullite crystals. Then the present inventors again conducted evaluations of the bending strength of the various resulting composite material sample pieces.
  • a set of aluminum alloys again designated as Al through A15 were produced in the same manner as before, again having as base material aluminum and having various quantities of copper mixed therewith, as before.
  • six alumina - silica fiber material preforms were made similarly to what was done before by, in each case, subjecting a quantity of a fiber material, this time being alumina short fibers of type "Arusen” (this is a trademark) manufactured by Denki Kagaku Kogyo KK and being composed of approximately 80% A1203 - which consisted of alpha A1203 crystals and mullite crystals - and remainder substantially Si02 and having average fiber length approximately 2 cm and average fiber diameter approximately 3 microns, to compression forming without using any binder, the six said alumina - silica fiber material preforms 2 for each aluminum alloy sample as before having approximate fiber volume proportions of respectively 5%, 10%, 15%, 20%, 30%, and 40%, as before.
  • each of these six alumina - silica fiber material preforms was again, as schematically illustrated in perspective view in Fig. 8 wherein an exemplary such preform is designated by the reference numeral 8 and the alumina - silica fibers therein are generally designated as 7, about 38 x 100 x 16 mm in dimensions, while the individual alumina - silica fibers 7 in each of said preforms 8 were oriented substantially randomly in three dimensions.
  • each of these alumina - silica fiber material preforms 2 was subjected to high pressure casting in a stainless steel case together with an appropriate quantity of the appropriate one of the aluminum alloys A1 through A15 described above, utilizing operational parameters substantially as before.
  • the solidified aluminum alloy mass with the preform 2 included therein was then removed from the casting mold, and the peripheral portion of said solidified aluminum alloy mass was machined away, leaving, after extraction from the stainless steel case, a sample piece of composite material which had alumina - silica short fiber material as reinforcing material in the appropriate fiber volume proportion and the appropriate one of the aluminum alloys A1 through A15 as matrix metal.
  • post processing steps were performed on the composite material samples, substantially as before.
  • Table 6 and Fig. 9 correspond respectively to Table 2 and Fig. 4 relating to the first set of preferred embodiments, respectively to Table 4 and Fig. 6 relating to the second set of preferred embodiments, and also to Table 5 and Fig. 7 relating to the third set of preferred embodiments.
  • the numerical values in Table 6 indicate the bending strengths (in kg/mm 2 ) of the composite material bending strength test pieces having as matrix metals aluminum alloys as shown down the left edge of the table and having reinforcing alumina - silica short fiber volume proportions as shown along the upper edge of the table.
  • the reinforcing alpha alumina type alumina - silica short fiber volume proportion X was approximately 30%: when the copper content was in the range from approximately 0% to approximately 4.5% the bending strength of the composite material increased relatively rapidly along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the range from approximately 2% to approximately 3.5%; when the copper content reached approximately 4.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 4.5%, the bending strength of the composite material reduced along with an increase in the copper content, and particularly said bending strength reduced rapidly along with an increase in the copper content when the copper content was in the range of from approximately 6.5% to approximately 7%.
  • the reinforcing alpha alumina type alumina - silica short fiber volume proportion X was approximately 20%: when the copper content was in the range from approximately 0% to approximately 5.5% the bending strength of the composite material increased along with an increase in the copper content, and particularly that when the copper content was in the range from approximately 2.5% to approximately 3.5% the bending strength of the composite material increased relatively rapidly along with an increase in the copper content; when the copper content reached approximately 5.5% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 5.5% the bending strength of the composite material reduced along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of being between approximately 7% and approximately 7.5%.
  • the reinforcing alpha alumina type alumina - silica short fiber volume proportion X was approximately 15%, or 10%, or 5%: when the copper content was in the range from approximately 0% to approximately 6% the bending strength of the composite material increased along with an increase in the copper content, and particularly increased relatively rapidly along with an increase in the copper content when the copper content was in the ranges, respectively, of from approximately 3% to approximately 3.5%, from approximately 3% to approximately 5%, and from approximately 3% to approximately 3.5%; when the copper content reached approximately 6% the bending strength of the composite material reached a substantially maximum value; and, when the copper content was in the range of being greater than approximately 6% the bending strength of the composite material had a tendency to reduce along with an increase in the copper content, and particularly reduced rapidly along with an increase in the copper content when the copper content was in the range of being greater than approximately 7.5%.
  • the copper content of the aluminium alloy is a value satisfying the inequalities (1) and (2) above, with respect to any particular fiber volume proportion for the reinforcing alumina - silica short fiber material, next, in order to assess what value of the volume proportion of the alumina-silica type short fibers which are the reinforcing fibers was most appropriate, the following set of experiments was performed.
  • composite material sample sets B1 to B7, Cl to C7, D1 to D7 and El to E7 were manufactured, with, in each said set of seven samples, the fiber volume proportions being variously 5%, 10%, 15%, 20%, 30%, 40%, and 50%.
  • This manufacture was carried out in the same manner and under the same conditions as in the first set of preferred embodiments detailed above (except that in the case of the composite material sample set El to E7 the same process and conditions were utilized as in the fourth set of preferred embodiments detailed above), and the various resulting composite material samples were subjected to liquidizing processing and artificial aging processing in the same manner and under the same conditions as in the various sets of preferred embodiments detailed above. Then, bending test pieces were cut in the same manner and of the same dimensions as in the first or the fourth sets of preferred embodiments detailed above from each composite material sample piece, and for each bending test sample piece a bending test was carried out in the same manner and under the same conditions as in the first set of preferred embodiments detailed above.
  • the fiber volume proportion of the alumina - silica type short fiber material utilized as reinforcing fibers is, irrespective of the type of said reinforcing fiber material, in the range of from about 5% to about 50%, and more preferably in the range of from about 5% to about 40%.
  • the preferable range for the copper content of the aluminium alloy which is the matrix metal is the range indicated by hatching in Fig. 5, and the particularly preferable range is that indicated by cross hatching.
  • crystalline alumina - silica short fiber material is used as the alumina - silica type short fiber material
  • amorphous alumina - silica type short fiber material used in Embodiment 1 above were subjected to heat treatment under various conditions not particularly detailed here because they are per se known in the art, whereby crystalline alumina - silica type short fiber material samples were formed with mullite crystalline amounts of 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60 and 65%, and then, from each of these crystalline alumina - silica type short fiber material samples, a preform with a fiber volume proportion of approximately 15% was formed in the same manner and under the same conditions as in the first set of preferred embodiments detailed above, and then,
  • Fig. 11 The results of these bending tests are shown in Fig. 11. It should be noted that in Fig. 11 the mullite crystalline amount ( in percent) of the crystalline alumina - silica short fiber material which was the reinforcing fiber material is shown along the horizontal axis .
  • the mullite crystalline amount is in the range from about 0% to about 10% the bending strength of the composite material is a substantially constant low value; in the case that the mullite crystalline amount is in the range from about 10% to about 20% the bending strength of the composite material increases gradually and substantially linearly with an increase in the mullite crystalline amount; in the case that the mullite crystalline amount is in the range from about 20% to about 40% the bending strength of the composite material increases only extremely slightly with an increase in the mullite crystalline amount; in the case that the mullite crystalline amount is in the range from about 40% to about 45% the bending strength of the composite material increases extremely rapidly with an increase in the mullite crystalline amount; and in the case that the mullite crystalline amount is in the range of greater than about 45% the bending strength of the composite material has an extremely high value and increases slightly and substantially linearly with an increase in the mullite crystalline amount.
  • the value of the mullite crystalline amount therein is at least 45%.

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
EP86111395A 1985-09-02 1986-08-18 Matériau composite contenant des fibres courtes d'alumine-silice comme matériau de renforcement et avec une matrice en alliage d'aluminium contenant du cuivre avec une corrélation entre les différentes teneurs Withdrawn EP0213528A3 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP193415/85 1985-09-02
JP19341585A JPS6254044A (ja) 1985-09-02 1985-09-02 アルミナ−シリカ系短繊維強化アルミニウム合金

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EP0213528A2 true EP0213528A2 (fr) 1987-03-11
EP0213528A3 EP0213528A3 (fr) 1988-01-13

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EP86111395A Withdrawn EP0213528A3 (fr) 1985-09-02 1986-08-18 Matériau composite contenant des fibres courtes d'alumine-silice comme matériau de renforcement et avec une matrice en alliage d'aluminium contenant du cuivre avec une corrélation entre les différentes teneurs

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2248629A (en) * 1990-09-20 1992-04-15 Daido Metal Co Sliding material
EP0624657A1 (fr) * 1993-05-13 1994-11-17 Toyota Jidosha Kabushiki Kaisha Pièce coulissante en alliage d'aluminium
US20170142859A1 (en) * 2014-07-04 2017-05-18 Denka Company Limited Heat-dissipating component and method for manufacturing same

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3441392A (en) * 1967-03-27 1969-04-29 Melpar Inc Preparation of fiber-reinforced metal alloy composites by compaction in the semimolten phase
US4152149A (en) * 1974-02-08 1979-05-01 Sumitomo Chemical Company, Ltd. Composite material comprising reinforced aluminum or aluminum-base alloy

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2248629A (en) * 1990-09-20 1992-04-15 Daido Metal Co Sliding material
US5128213A (en) * 1990-09-20 1992-07-07 Daido Metal Company Limited Sliding material of single substance and composite sliding material
GB2248629B (en) * 1990-09-20 1995-03-29 Daido Metal Co Sliding material
EP0624657A1 (fr) * 1993-05-13 1994-11-17 Toyota Jidosha Kabushiki Kaisha Pièce coulissante en alliage d'aluminium
AU667159B2 (en) * 1993-05-13 1996-03-07 Toyota Jidosha Kabushiki Kaisha A slide member made of an aluminium alloy
US6358628B1 (en) 1993-05-13 2002-03-19 Toyota Jidosha Kabushiki Kaisha Slide member made of an aluminum alloy
US20170142859A1 (en) * 2014-07-04 2017-05-18 Denka Company Limited Heat-dissipating component and method for manufacturing same
US10869413B2 (en) * 2014-07-04 2020-12-15 Denka Company Limited Heat-dissipating component and method for manufacturing same

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EP0213528A3 (fr) 1988-01-13
JPS6254044A (ja) 1987-03-09

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