EP0408257B1 - Procédé de fabrication d'un matériau composite à matrice métallique avec les composés intermétalliques et sans les micropores - Google Patents

Procédé de fabrication d'un matériau composite à matrice métallique avec les composés intermétalliques et sans les micropores Download PDF

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Publication number
EP0408257B1
EP0408257B1 EP19900307379 EP90307379A EP0408257B1 EP 0408257 B1 EP0408257 B1 EP 0408257B1 EP 19900307379 EP19900307379 EP 19900307379 EP 90307379 A EP90307379 A EP 90307379A EP 0408257 B1 EP0408257 B1 EP 0408257B1
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EP
European Patent Office
Prior art keywords
volume
pure
powder
nickel
aluminum
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP19900307379
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German (de)
English (en)
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EP0408257A2 (fr
EP0408257A3 (en
Inventor
Tetsuya Nukami
Tetsuya Suganuma
Atsuo Tanaka
Jun Ohkijima
Yoshiaki Kajikawa
Masahiro Kubo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
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Toyota Motor Corp
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Publication date
Priority claimed from JP28225089A external-priority patent/JPH03177524A/ja
Application filed by Toyota Motor Corp filed Critical Toyota Motor Corp
Publication of EP0408257A2 publication Critical patent/EP0408257A2/fr
Publication of EP0408257A3 publication Critical patent/EP0408257A3/en
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Publication of EP0408257B1 publication Critical patent/EP0408257B1/fr
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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
    • C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
    • C22C49/04—Light metals
    • C22C49/06—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
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F3/26—Impregnating

Definitions

  • the present invention relates to a composite material, and more particularly, to a method of manufacture of a metal matrix composite material having high integrity of microstructure available by high affinity between materials to compose the composite material and generation of intermetallic compounds therein.
  • the third powder material expedites the infiltration of the molten matrix metal into the interstices of the porous preform not only by the good affinity or wettability of the third material itself with the molten matrix metal but also by increased fluidization of the molten matrix metal due to the heat generated by the reaction between the third powder material and the molten matrix metal.
  • micropores in the composite material there were formed micropores in the composite material.
  • a composite material was manufactured by forming a preform consisting of 5% by volume SiC particles (10 microns average particle diameter), 30% by volume aluminum alloy powder (Al - 12% Si, 40 microns average particle diameter) and 30% by volume pure copper powder (30 microns average particle diameter) and immersing the preform in a melt of aluminum alloy (JIS standard AC8A) at 575 C° for 15 seconds, inspection of its section under the optical microscope revealed micropores in the composite structure which are guessed to have been caused by imperfect wetting of the aluminum alloy.
  • JIS standard AC8A melt of aluminum alloy
  • a porous preform is formed of 60% to 80% by volume aluminum or aluminum alloy, 1% to 10% by volume nickel, copper, nickel alloy or copper alloy and 1% to 10% by volume titanium or titanium alloy so that the total percent by volume of such fragments is 62% to 95%, and such preform is infiltrated with molten matrix metal such as aluminum, aluminum alloy, magnesium or magnesium alloy by at least a part of said preform being contacted with a melt of such matrix metal, a highly integrated metal matrix composite material having reinforcing nuclei made of intermetallic compounds and including no micropores is obtained with no application of pressure to the melt of the matrix metal.
  • a conventional reinforcing material such as fibers, whisker or particles
  • the above-mentioned first object is accomplished according to the present invention by a method of manufacture of a metal matrix composite material comprising the steps of forming a porous preform including 60% to 80% by volume fine fragments essentially made of aluminum, 1% to 10% by volume fine fragments essentially made of nickel, copper or both, and 1% to 10% by volume fine fragments essentially made of titanium so that these fine fragments occupy in total 62% to 95% by volume of said preform, and contacting at least a part of said preform with a melt of a matrix metal selected from aluminum, aluminum alloy, magnesium and magnesium alloy, thereby infiltrating said porous preform with said melt under no substantial application of pressure to said melt.
  • said preform is formed further to include dispersed reinforcing material.
  • the fine fragments essentially made of aluminum such as pure aluminum or aluminum alloy have excellent affinity to the melt of aluminum, aluminum alloy, magnesium or magnesium alloy
  • the fine fragments essentially made of nickel, copper or both such as pure nickel, pure copper, nickel alloy or copper alloy have low tendency to form oxides
  • these two kinds of fine fragments cooperate to provide excellent wetting for the melt of aluminum, aluminum alloy, magnesium or magnesium alloy in contacting with the fragments of pure aluminum or aluminum alloy while protecting surfaces of the fine fragments of pure aluminum or aluminum alloy from forming oxide layer.
  • the aluminum in the fine fragments of pure aluminum or aluminum alloy and the aluminum or magnesium in the melt of matrix metal reacts with the nickel or copper in the fine fragments of pure nickel, pure copper, nickel alloy or copper alloy so that intermetallic compounds are produced with generation of heat which fuses those fine fragments of pure aluminum or aluminum alloy and pure nickel, nickel alloy, pure copper or copper alloy.
  • the titanium in the fine fragments of pure titanium or titanium alloy which is highly reactive with nitrogen and oxygen at elevated temperature absorbs air existing in the interstices of the preform so as to change it into volumeless liquid nitrides and oxides, thereby expediting intimate contact of the fine fragments of aluminum, etc with the melt of aluminum, etc..
  • the volume proportion of the fine fragments of pure aluminum or aluminum alloy is selected to be 60% to 80% so as to leave a relatively low ratio of cavity in the preform
  • the fine fragments of pure nickel, pure copper, nickel alloy or copper alloy and the fine fragments of pure titanium or titanium alloy at such ratio as 1% to 10% by volume operate most effectively in protecting the fine fragments of pure aluminum or aluminum alloy from oxidization while decreasing the volume of air remaining in the spaces between the fine fragments of aluminum, etc. so that the melt of aluminum, etc can easily enter the spaces between such fine fragments.
  • the temperature of the melt of matrix metal is, expressing the melting point of the matrix metal by T C°, in a range of the temperature for coexistence of liquid and solid such as T - T+50 C°.
  • the solid phase proportion of the melt is not more than 70%, particularly not more than 50%.
  • the fine fragments of metals used in the present invention may be in the form of powder, short fibers or whisker, and it is desirable that their sizes are, in the case of powder, an average particle diameter of 1 to 500 microns, particularly 3 to 200 microns, and in the case of short fibers or whisker, an average fiber diameter of 0.1 micron to 1 mm, particularly 1 to 200 microns and an average fiber length of 1 micron to 10 mm, particularly 1 to 200 microns.
  • the reinforcing material used in the present invention may be in the form of short fibers, whisker or particles, and it is desirable that their sizes are, in the case of short fibers or whisker, an average fiber diameter of 0.1 to 20 microns, particularly 0.3 to 10 microns and an average fiber length of 5 microns to 10 mm, particularly 10 microns to 3 mm, and in the case of particles, an average particle diameter of 0.1 to 100 microns, particularly 1 to 30 microns.
  • the content of nickel in the nickel alloy when it is used in the present invention is at least 50% by weight, particularly more than 80% by weight, and, although any elements other than nickel, excepting inevitable impurities, may be included, they are particularly silver, aluminum, boron, cobalt, chromium, copper, iron, magnesium, manganese, molybdenum, lead, silicon, tin, tantalum, titanium, vanadium, zinc and zirconium.
  • the content of copper in the copper alloy when it is used in the present invention is at least 50% by weight, particularly more than 80% by weight, and, although any elements other than copper, excepting inevitable impurities, may be included, they are particularly silver, aluminum, boron, cobalt, iron, magnesium, manganese, nickel, lead, silicon, tin, tantalum, titanium, vanadium, zirconium and zinc.
  • the content of titanium in the titanium alloy when it is used in the present invention is at least 50% by weight, particularly more than 80% by weight, and, although any elements other than titanium, excepting inevitable impurities, may be included, they are particularly aluminum, vanadium, tin, iron, copper, manganese, molybdenum, zirconium, chromium, silicon, and boron.
  • Alumina-silica short fibers having 3 microns average fiber diameter and 1.5 mm average fiber length manufactured by Isolite Kogyo KK
  • aluminum alloy powder JIS standard AC8A
  • aluminum alloy powder JIS standard AC7A
  • pure titanium powder having 20 microns average particle diameter
  • pure nickel powder having 20 microns average particle diameter
  • each preform 18 was immersed in a melt 22 of aluminum alloy (JIS standard AC8A) maintained at 570 C° by a heater 20, was held there for 10 seconds, and then was removed from the melt, and then the molten metal infiltrated in the preform was solidified without further treatment.
  • JIS standard AC8A aluminum alloy
  • Table 1 shows the results when the volume proportion of the alumina-silica short fibers was 0%, 5%, 10%, 15% or 20%, and the volume proportion of the pure nickel powder was 0% or 15%
  • Table 2 shows the results when the volume proportion of the alumina-silica short fibers was 0%, 5%, 10%, 15% or 20%, and the volume proportion of the pure nickel powder was 1%, 3%, 5%, 7% or 10%.
  • the volume proportion of the aluminum alloy powder is between 60% and 80%, and the volume proportions of the pure nickel powder and the pure titanium powder are between 1% and 10%, respectively.
  • alumina short fibers (“Safil RF" manufactured by ICI, 3 microns average fiber diameter, 1 mm average fiber length) as a reinforcing material, 65% by volume aluminum alloy fibers (manufactured by Aisin Seiki KK, Al - 5% Mg, 60 microns average fiber diameter, 3 mm average fiber length), 5% by volume pure nickel fibers (manufactured by Tokyo Seiko KK, 20 microns average fiber diameter, 1 mm average fiber length), and 10% by volume pure titanium fibers (manufactured by Tokyo Seiko KK, 20 microns average fiber diameter, 1 mm average fiber length) were mixed and subjected to compression forming to produce a preform.
  • Safil RF manufactured by ICI, 3 microns average fiber diameter, 1 mm average fiber length
  • this preform was disposed within a die (JIS standard No. 10) at 400C°, molten magnesium alloy (SAE standard AZ91) at 650C° was poured into this die, and the preform infiltrated with the molten magnesium alloy was cooled to room temperature under supply of sulfur hexafluoride gas over the surface of the melt to prevent oxidation of the magnesium alloy.
  • molten magnesium alloy SAE standard AZ91
  • the composite material thus formed was sectioned, and by observation of sections of this material, the penetration of the melt was investigated. As a result, it was confirmed that also in this embodiment a satisfactory composite material including no micropores was formed.
  • the matrix at a central portion was an aluminum alloy while the matrix at peripheral portions was a magnesium alloy, that the nickel fibers had reacted with aluminum so as to produce intermetallic compounds such as NiAl3 and NiAl, that particularly at peripheral portions the pure nickel fibers had reacted also with magnesium so as to produce intermetallic compounds such as Mg2Ni and MgNi2, such intermetallic compounds being higher in density toward outer peripheral portions, and the matrix was compositely reinforced not only by the reinforcing material but also by these intermetallic compounds.
  • the melt of matrix metal was replaced by a pure magnesium melt at 680C°, the composite material formed in the same way had again a satisfactory composite structure including no micropores.
  • Composite materials were formed in the same manner and under the same conditions as in Embodiment 1, except in that the pure nickel powder was replaced by pure copper powder having 30 microns average particle diameter, and by investigation of sections of the composite materials thus formed, the penetration of the melt was investigated.
  • the results obtained were similar to those obtained in Embodiment 1.
  • the volume proportion of the aluminum alloy powder is between 60 and 80%, and the volume proportion of each of the pure copper powder and the pure titanium powder is between 1 and 10%, respectively.
  • Composite materials were formed in the same manner and under the same conditions as in Embodiment 2, except that the pure nickel powder was replaced by pure copper powder having 30 microns average particle diameter.
  • Composite materials were manufactured in the same manner and under the same conditions as in Embodiment 3, except that the pure nickel powder was replaced by pure copper powder having 30 microns average particle diameter.
  • a composite material was manufactured in the same manner and under the same conditions as in Embodiment 4, except that the pure nickel fibers were replaced by pure copper fibers (manufactured by Tokyo Seiko KK, 20 microns average fiber diameter, and 1 mm average fiber length), and by observation of sections of the composite material thus formed, the penetration of the melt was investigated.
  • the composite material was formed in the same manner except that the pure copper fibers were replaced by the pure copper powder used in Embodiment 8 or the melt of magnesium alloy was replaced by a melt of pure magnesium at 680C°, in both cases satisfactory composite materials including no micropores were obtained.
  • Composite materials were formed in the same manner and under the same conditions as in Embodiment 5, except that the pure nickel powder was replaced by pure copper powder having 30 microns average particle diameter.
  • Alumina-silica short fibers having 3 microns average fiber diameter and 1.5 mm average fiber length manufactured by Isolite KK
  • aluminum alloy powder JIS Standard AC8A
  • aluminum alloy powder JIS Standard AC7A
  • pure titanium powder having 30 microns average particle diameter
  • pure nickel powder having 30 microns average particle diameter
  • pure copper powder having 30 microns average particle diameter
  • preforms having 45 x 25 x 10 mm dimensions and including the alumina-silica short fibers at 0%, 5%, 10%, 15% or 20% by volume
  • the aluminum alloy powder at 40%, 50%, 60%, 70% or 80% by volume, the pure titanium powder at 0%, 1%, 5%, 10% and 15% by volume, the pure copper powder at 0.5% by volume, and the pure nickel powder at 0.5% to 15% (in steps of 0.5%) by volume, respectively, except such cases that the total volume proportion would exceed 95%.
  • preforms were prepared in the same manner as above to have 45 x 25 x 10 mm dimensions except that the volume proportion of nickel powder was 0.5% and the volume proportion of pure copper powder was 0.5% to 15% (in steps of 0.5%).
  • composite materials were formed in the same manner and under the same conditions as in Embodiment 1, except that the above preforms were used, and by examination of sections thereof the penetration of the melt was investigated.
  • the volume proportion of the aluminum alloy powder is between 60 and 80%, for the volume proportion of the pure nickel powder plus the pure copper powder to be between 1 and 10%, and for the volume proportion of the pure titanium powder to be between 1 and 10%.
  • Composite materials were formed in the same manner and under the same conditions as in Embodiment 2, except that the pure nickel powder was replaced by 2.5% by volume pure nickel powder (5 microns average particle diameter) and 2.5% by volume pure copper powder (30 microns average particle diameter).
  • Composite materials were manufactured in the same manner and under the same conditions as in Embodiment 3, except that the pure nickel powder was replaced by 3% by volume pure nickel powder (10 microns average particle diameter) and 3% by volume pure copper powder (20 microns average particle diameter).
  • a composite material was manufactured in the same manner and under the same conditions as in Embodiment 4, except that the pure nickel fibers were replaced by 5% by volume pure nickel fibers (30 microns average fiber diameter and 3 mm average fiber length) and 5% by volume pure copper fibers (20 microns average fiber diameter and 1 mm average fiber length), and by examination of sections of the composite material thus formed, the penetration of the melt was investigated.
  • Composite materials were formed in the same manner and under the same conditions as in Embodiment 3, except that the pure nickel powder was replaced by 4% by volume pure nickel powder (15 microns average particle diameter) and 4% by volume pure copper powder (25 microns average particle diameter).
  • Composite materials were formed in the same manner and under the same conditions as in Embodiment 5, except that the pure nickel powder was replaced by 5% by volume pure nickel powder (15 microns average particle diameter) and 5% pure copper powder (25 microns average particle diameter).
  • melt of matrix metal was replaced by a melt of pure magnesium at 680C° and composite materials were formed in the same manner, satisfactory composite materials including no micropores were also obtained.
  • the fine fragments of some particular compositions were used in the various embodiments described above, in the present invention the fine fragments may have other compositions.
  • the composition of the aluminum alloy may be, for example, JIS Standard AC7A, JIS Standard ADC12, JIS Standard ADT17, or 8% Al - 3.5% Mg, and so forth
  • the composition of the nickel alloy may be, for example, Ni - 50% Al, Ni - 30% Cu, Ni - 39.5% Cu - 22.1% Fe, 8.8% B, and so forth
  • the composition of the copper alloy may be, for example, Cu - 50% Al, Cu - 29.6% Ni - 22.1% Fe - 8.8% B, and so forth, and particularly when the nickel alloy or the copper alloy is a nickel-copper alloy, the nickel and copper contents may have any proportions
  • the titanium alloy may be, for example, Ti - 1% B.
  • the molten matrix metal satisfactorily infiltrates into the preform, and by the reaction of titanium with oxygen and nitrogen in the preform, air is substantially removed from the preform, and as a result an even more satisfactory composite material including no micropores is manufactured.
  • the temperature of the molten matrix metal may be relatively low, and since the time duration for the preform to be in contact with the molten metal is shortened as compared with the case where no fragments of nickel, copper, nickel alloy, copper alloy, titanium or titanium alloy is included in the preform, a composite material can be manufactured at lower cost and at higher efficiency as compared with the above-mentioned prior proposal.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Claims (8)

  1. Procédé de fabrication d'un matériau composite à matrice métallique comprenant les étapes de formation d'une préforme poreuse contenant 60% à 80% en volume de fragments fins essentiellement faits d'aluminium, 1% à 10% en volume de fragments fins essentiellement faits de nickel, de cuivre ou des deux et de 1% à 10% en volume de fragments fins essentiellement faits de titane, de telle sorte que ces fragments fins occupent au total 62% à 95% en volume de la préforme, et de mise en contact d'au moins une partie de cette préforme avec un bain fondu d'un métal de matrice choisi parmi l'aluminium, un alliage d'aluminium, le magnésium et un alliage de magnésium, de façon telle que cette préforme poreuse s'infiltre dans ce bain fondu sans exercer de pression sensible sur ledit bain fondu.
  2. Procédé de fabrication d'un matériau composite à matrice métallique suivant la revendication 1, dans lequel ladite préforme est formée de plus de façon à comprendre un matériau de renforcement dispersé.
  3. Procédé de fabrication d'un matériau composite à matrice métallique suivant la revendication 1, dans lequel ces fragments fins essentiellement faits de nickel, cuivre ou les deux, comprennent au moins 50% en volume de nickel.
  4. Procédé de fabrication d'un matériau composite à matrice métallique suivant la revendication 3, dans lequel ces fragments fins essentiellement faits de nickel, de cuivre ou des deux comprennent plus de 80% en volume de nickel.
  5. Procédé de fabrication d'un matériau composite à matrice métallique suivant la revendication 1, dans lequel ces fragments fins essentiellement faits de nickel, de cuivre ou des deux comprennent au moins 50% en volume de cuivre.
  6. Procédé de fabrication d'un matériau composite à matrice métallique suivant la revendication 5, dans lequel ces fragments fins essentiellement faits de nickel, de cuivre ou des deux comprennent plus de 80% en volume de cuivre.
  7. Procédé de fabrication d'un matériau composite à matrice métallique suivant la revendication 1, dans lequel ces fragments fins essentiellement faits de titane comprennent au moins 50% en volume de titane.
  8. Procédé de fabrication d'un matériau composite a matrice métallique suivant la revendication 7, dans lequel ces fragments fins essentiellement faits de titane comprennent plus de 80% en volume de titane.
EP19900307379 1989-07-10 1990-07-05 Procédé de fabrication d'un matériau composite à matrice métallique avec les composés intermétalliques et sans les micropores Expired - Lifetime EP0408257B1 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
JP17772189 1989-07-10
JP177721/89 1989-07-10
JP244158/89 1989-09-20
JP24415889 1989-09-20
JP28225089A JPH03177524A (ja) 1989-07-10 1989-10-30 金属基複合材料の製造方法
JP282250/89 1989-10-30

Publications (3)

Publication Number Publication Date
EP0408257A2 EP0408257A2 (fr) 1991-01-16
EP0408257A3 EP0408257A3 (en) 1992-04-29
EP0408257B1 true EP0408257B1 (fr) 1995-05-31

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EP19900307379 Expired - Lifetime EP0408257B1 (fr) 1989-07-10 1990-07-05 Procédé de fabrication d'un matériau composite à matrice métallique avec les composés intermétalliques et sans les micropores

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EP (1) EP0408257B1 (fr)
AU (1) AU626435B2 (fr)
CA (1) CA2020335C (fr)
DE (1) DE69019783T2 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2675063B1 (fr) * 1991-04-09 1996-01-12 Renault Procede d'elaboration de pieces metalliques composites a renforts metalliques.
EP0732415A1 (fr) * 1995-03-14 1996-09-18 Deritend Advanced Technology Limited Procédé de préparation d'un composé intermétallique
DE19750600A1 (de) * 1997-11-14 1999-05-20 Nils Claussen Metallverstärktes Konstruktionselement
US6599466B1 (en) 2002-01-16 2003-07-29 Adma Products, Inc. Manufacture of lightweight metal matrix composites with controlled structure
DE102010061960A1 (de) * 2010-11-25 2012-05-31 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur endkonturnahen Fertigung von hochtemperaturbeständigen Triebwerksbauteilen

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6029431A (ja) * 1983-07-28 1985-02-14 Toyota Motor Corp 合金の製造方法
BR8407153A (pt) * 1983-11-24 1985-10-08 Cegedur Ligas a base de al contendo litio,magnesio e cobre
DE68913800T2 (de) * 1988-04-30 1994-07-14 Toyota Motor Co Ltd Verfahren zur Herstellung von Verbundmetall unter Beschleunigung der Infiltration des Matrix-Metalls durch feine Teilchen eines dritten Materials.

Also Published As

Publication number Publication date
EP0408257A2 (fr) 1991-01-16
AU626435B2 (en) 1992-07-30
DE69019783T2 (de) 1995-11-16
DE69019783D1 (de) 1995-07-06
CA2020335C (fr) 2001-03-20
CA2020335A1 (fr) 1991-01-11
EP0408257A3 (en) 1992-04-29
AU5802090A (en) 1991-01-10

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