EP0592665A1 - Poudre a base d'un alliage aluminium/silicium hypereutectique et production de cette poudre - Google Patents

Poudre a base d'un alliage aluminium/silicium hypereutectique et production de cette poudre Download PDF

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Publication number
EP0592665A1
EP0592665A1 EP91918937A EP91918937A EP0592665A1 EP 0592665 A1 EP0592665 A1 EP 0592665A1 EP 91918937 A EP91918937 A EP 91918937A EP 91918937 A EP91918937 A EP 91918937A EP 0592665 A1 EP0592665 A1 EP 0592665A1
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EP
European Patent Office
Prior art keywords
alloy powder
silicon
aluminum
percent
weight
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.)
Granted
Application number
EP91918937A
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German (de)
English (en)
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EP0592665B1 (fr
EP0592665A4 (fr
Inventor
Yoshinobu Itami Works Of Sumitomo Elect. Takeda
Tetsuya Itami Works Of Sumitomo Electr. Hayashi
Toshihiko Itami Works Of Sumitomo Electri. Kaji
Yusuke Itami Works Of Sumitomo Electric Odani
Kiyoaki Itami Works Of Sumitomo Electric Akechi
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.)
Toyo Aluminum KK
Sumitomo Electric Industries Ltd
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Toyo Aluminum KK
Sumitomo Electric Industries Ltd
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Application filed by Toyo Aluminum KK, Sumitomo Electric Industries Ltd filed Critical Toyo Aluminum KK
Publication of EP0592665A4 publication Critical patent/EP0592665A4/fr
Publication of EP0592665A1 publication Critical patent/EP0592665A1/fr
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Publication of EP0592665B1 publication Critical patent/EP0592665B1/fr
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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
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent

Definitions

  • the present invention relates to hyper-eutectic aluminum-silicon alloy powder and a method of preparing the same, and more particularly, it relates to hyper-eutectic aluminum-silicon alloy powder which stably contains fine silicon primary crystals and a method of preparing the same.
  • Al-Si alloys a cast material is classified as AC or ADC under the Japanese Industrial Standards, and employed in plenty as an aluminum alloy casting such as an engine block.
  • An Al-Si alloy prepared as an wrought material is classified in the 4,000 series, and worked from a cast billet into various parts by extrusion, forging or the like.
  • a hyper-eutectic Al-Si alloy is prepared by a casting method.
  • a hyper-eutectic Al-Si alloy casting obtained by the casting method which has excellent properties such as a low thermal expansion coefficient, a high Young's modulus and high wear resistance, is expected for employment in various fields.
  • a hyper-eutectic Al-Si alloy casting contains coarse primary crystals of silicon, however, its mechanical properties and machinability in machine work are deteriorated.
  • a refiner particularly phosphorus (P)
  • P phosphorus
  • a refiner may be added in order to refine primary crystals of silicon contained in a hyper-eutectic Al-Si alloy casting. Even if such a refiner is added when a hyper-eutectic Al-Si alloy is cast, however, refinement of silicon primary crystals is restricted. Particularly when the Al-Si alloy contains silicon in excess of 20 percent by weight, coarse primary crystals of silicon still remain even if the refiner is added, and hence the alloy is still deteriorated in mechanical properties and machinability in machine work.
  • Powder metallurgical alloys such as Al-17Si-X, Al-20Si-X and Al-25Si-X, having properties further superior to those of cast alloys, have been put into practice as alloys prepared by a powder metallurgical method using such powder materials.
  • the particle sizes of silicon primary crystals contained in the overall powder are extremely dispersed so far as the as-obtained powder has particle size distribution of a constant width, since the cooling rate depends on the particle size of the powder.
  • powder of about 400 ⁇ m in particle size has generally unavoidably contained coarse silicon primary crystals of about 20 ⁇ m in particle size.
  • an object of the present invention is to provide a composition of hyper-eutectic Al-Si alloy powder containing fine and homogeneous primary crystals of silicon and being capable of suppressing primary crystallization of coarse primary crystals of silicon in particular by atomizing, and a method of preparing the same.
  • hyper-eutectic aluminum-silicon alloy powder containing extremely fine primary crystal silicon can be obtained by atomizing a molten metal of an aluminum-silicon alloy to which a primary crystal silicon refiner containing phosphorus is added, or an alloy molten metal obtained by melting an aluminum-silicon alloy ingot previously containing a primary crystal silicon refiner containing phosphorus, with air or an inert gas.
  • Hyper-eutectic aluminum-silicon alloy powder in accordance with a first aspect of the present invention contains at least 12 percent by weight and not more than 50 percent by weight of silicon, and at least 0.0005 percent by weight and not more than 0.1 percent by weight of phosphorus.
  • the particle size of primary crystal silicon contained in the inventive hyper-eutectic aluminum-silicon alloy powder is by far smaller than the size of primary crystal silicon contained in a conventional hyper-eutectic aluminum-silicon alloy obtained by a casting method, and is not more than 10 ⁇ m in general.
  • the content of silicon in the inventive aluminum-silicon alloy powder is at least 12 percent by weight and not more than 50 percent by weight, preferably at least 20 percent by weight and not more than 30 percent by weight. If the content of silicon is less than 12 percent by weight, no primary crystal silicon is formed. If the content of silicon exceeds 50 percent by weight, on the other hand, the amount of primary crystal silicon is too much however primary crystals of silicon are refined, and hence consolidates prepared from the as-obtained powder are inferior in machinability while its mechanical strength is deteriorated.
  • the molten metal of a hyper-eutectic aluminum-silicon alloy containing phosphorus may be prepared from a molten metal of an aluminum-silicon alloy to which a primary crystal silicon refiner containing phosphorus is added, or an alloy molten metal obtained by melting an aluminum-silicon alloy ingot previously containing a primary crystal silicon refiner containing phosphorus.
  • the primary crystal silicon refiner containing phosphorus is prepared from a primary crystal silicon refiner employed in a conventional casting method, such as Cu-8wt.%P, Cu-15wt.%P, PCl5 or mixed salt mainly composed of red phosphorus, or an Al-Cu-P refiner.
  • the primary crystal silicon refiner is generally used in an amount of at least 0.0005 percent by weight and not more than 0.1 percent by weight, preferably at least 0.002 percent by weight and not more than 0.05 percent by weight. If the amount of the primary crystal silicon refiner is less than 0.0005 percent by weight, no sufficient effect is attained by addition of the primary crystal silicon refiner. On the other hand, no further improvement of the effect is recognized even if the primary crystal silicon refiner is added in an amount exceeding 0.1 percent by weight.
  • the aluminum-silicon alloy molten metal is atomized according to a well-known method.
  • the alloy molten metal is preferably atomized in a state being at a temperature of at least a level exceeding the liquidus temperature of the aluminum-silicon alloy by 100°C and not more than 1300°C. Also when the primary crystal silicon refiner is added to the aluminum-silicon alloy, the alloy is preferably held at the aforementioned temperature.
  • liquidus temperature indicates a temperature at which the alloy of the composition is completely molten.
  • the liquidus temperature of an aluminum-silicon alloy containing 25 percent by weight of silicon is about 780°C.
  • hyper-eutectic aluminum-silicon alloy powder in which extremely fine primary crystal silicon is homogeneously dispersed.
  • hyper-eutectic aluminum-silicon alloy powder having a desired composition.
  • Consolidates prepared from the inventive hyper-eutectic aluminum-silicon alloy powder have extremely superior machinability and mechanical properties.
  • a molten metal of a hyper-eutectic aluminum-silicon alloy containing phosphorus is prepared previously. This molten metal is atomized with air and quench-solidified, thereby preparing hyper-eutectic aluminum-silicon alloy powder. Only alloy powder of not more than 400 ⁇ m in particle size is selected.
  • the maximum crystal grain size of the primary crystal silicon can be controlled to be not more than 10 ⁇ m.
  • the maximum crystal grain size of the primary crystal silicon can be controlled to be not more than 7 ⁇ m when the particle size of the as-obtained alloy powder is selected to be not more than 200 ⁇ m. More preferably, the maximum crystal grain size of the primary crystal silicon can be controlled to be not more than 5 ⁇ m when the particle size of the as-obtained alloy powder is selected to be not more than 100 ⁇ m. Further, the maximum crystal grain size of the primary crystal silicon can be controlled to be not more than 3 ⁇ m when the particle size of the as-obtained alloy powder is selected to be not more than 50 ⁇ m.
  • the third aspect of the present invention it is possible to refine and homogenize primary crystal silicon contained in hyper-eutectic aluminum-silicon alloy powder prepared by atomizing, as well as to remarkably reduce dependency of the particle size of the primary crystal silicon on the grain size of the alloy powder as compared with the prior art. Consequently, it is possible to prepare consolidates of powder which are more improved in mechanical properties as compared with the prior art, with no restriction of powder grain size in a high yield by employing the as-obtained hyper-eutectic aluminum-silicon alloy powder.
  • Fig. 1 is an optical micrograph, showing the micro-structure of primary crystal silicon contained in aluminum alloy powder obtained in Example 1 (magnification: x 400).
  • Fig. 3 is an optical micrograph, showing the structure of primary crystal silicon contained in an aluminum cast alloy (magnification: x 400).
  • Fig. 4 is an optical microphotograph showing the metallographic structure of hyper-eutectic aluminum-25wt.%silicon alloy powder obtained in Example 3 and inoculated with phosphorus (magnification: x 400).
  • Fig. 5 is an optical microphotograph showing the metallographic structure of hyper-eutectic aluminum-25wt.%silicon alloy powder obtained in Example 3 and inoculated with no phosphorus (magnification: x 400).
  • Fig. 6 is a graph showing relation between the maximum particle size of silicon primary crystals contained in the hyper-eutectic aluminum-25wt. %silicon alloy powder in Example 3 and tensile strength of consolidates obtained from the powder at the room temperature.
  • Molten metals of aluminum alloys having compositions shown in Table 1 were held at a temperature of 950°C, and Cu-8wt.%P was added to the molten metals to attain contents of phosphorus shown in Table 1. The molten metals were held at the temperature of 950°C for 1 hour, and then powdered by air atomizing (refer to alloy powder samples No. 1 to No. 4 in Table 1).
  • the as-obtained alloy powder samples were classified in -42 to -80 meshes (particle sizes of 175 to 350 ⁇ m), and thereafter sizes of primary crystal silicon particles contained in the powder samples were measured through structure observation with an optical microscope. The results are shown in Table 1.
  • Fig. 1 shows a structure photograph of the alloy powder No. 1 through an optical microscope.
  • Alloy powder No. 5 was prepared under the same conditions as the alloy powder No. 1. In this case, however, no Cu-8wt.%P was added to the molten metal of the aluminum alloy.
  • a molten metal of an aluminum alloy having the same composition as the alloy powder No. 1 was held at a temperature of 950°C, and Cu-8wt.%P was added to attain the content of phosphorus shown in Table 1. This molten metal was held at the temperature of 950°C for 1 hour, and thereafter cast in a metal mold of 30 mm in diameter by 80 mm in height, to prepare an alloy casting (No. 6).
  • the as-obtained alloy powder samples were classified in -100 meshes (particle sizes of not more than 147 ⁇ m), and thereafter sizes of primary crystal silicon particles contained in the powder samples were measured through structure observation with an optical microscope. The results are shown in Table 3.
  • the as-obtained alloy powder samples were classified in -100 meshes (particle sizes of not more than 147 ⁇ m), and sizes of primary crystal silicon particles contained in the powder samples were measured through micro-structure observation with an optical microscope. The results are shown in Table 3. Table 3 Alloy No.
  • hyper-eutectic aluminum-silicon alloys were prepared from ingots: A-17: 2024 ingot + 17wt.%Si A-20: 2024 ingot + 20wt.%Si A-25: 2024 ingot + 25wt.%Si B-25: 2024 ingot + 25wt.%Si + 5wt.%Fe C-25: 2024 ingot + 25wt.%Si + 5wt.%Fe + 2wt.%Ni D-25: Al + 25wt.%Si + 2.5wt.%Cu + 1wt.%Mg + 0.5wt.%Fe + 0.5wt.%Mn E-25: Al ingot of 99.9 % purity + 25wt.%Si Molten metals of the aforementioned respective alloys were inoculated with phosphorus at the rates shown in Table 5 or inoculated with no phosphorus, atomized under conditions of air pressures of 5 to 10 kg/mm2 by open air atomizing, and quench-solidified
  • Table 5 shows relations between powder grain sizes D p and the maximum particle sizes D si of Si primary crystals as the results of deciding particle sizes of silicon primary crystals contained in these alloy powder samples with a image analysis microscope.
  • the two types of powder samples obtained by inoculating the aforementioned A-25 alloys with phosphorus and with no phosphorus were cold-formed at pressure with no classification. These compacts were degassed and heated at a temperature of 450°C for 30 minutes. The compacts were preheated at the same temperature, thereafter forged/formed at a surface pressure of 6 ton/cm2, and subjected to T6 heat treatment.
  • a consolidate or hot worked product prepared from the inventive hyper-eutectic aluminum-silicon alloy powder has extremely superior machinability and mechanical strength. Thus, it is usefully applied to various parts for machine structural use.
  • the inventive method of preparing hyper-eutectic aluminum-silicon alloy powder further, it is possible to refine and homogenize primary crystal silicon contained in the hyper-eutectic aluminum-silicon alloy powder, thereby remarkably reducing dependency of the particle size of the primary crystal silicon on the powder grain size as compared with the prior art. As the result, it is possible to prepare consolidates of powder which is improved in mechanical properties as compared with the prior art with a high yield.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Powder Metallurgy (AREA)

Abstract

On produit une poudre à base d'un alliage aluminium/silicium hypereutectique, dans laquelle un cristal primaire de silicium possède un tout petit grain dont le diamètre est inférieur ou égal à 10 mum, grâce au processus de l'atomisation, lequel consiste à préparer un bain de fusion d'un alliage aluminium/silicium hypereutectique contenant du phosphore et à vaporiser le bain de fusion à l'aide d'air ou d'un gaz inactif pour produire un refroidissement rapide permettant la solidification. La poudre d'alliage ainsi obtenue contient 12 à 50 % en poids de silicium et 0,0005 à 0,1 % en poids de phosphore. Cette poudre peut constituer une poudre solidifiée ayant des propriétés mécaniques améliorées avec un rendement élevé sans aucune restriction de granulométrie.
EP91918937A 1990-10-31 1991-10-31 Poudre a base d'un alliage aluminium/silicium hypereutectique et production de cette poudre Expired - Lifetime EP0592665B1 (fr)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
JP29509990 1990-10-31
JP295018/90 1990-10-31
JP29501890 1990-10-31
JP295099/90 1990-10-31
JP295019/90 1990-10-31
JP29501990 1990-10-31
PCT/JP1991/001488 WO1992007676A1 (fr) 1990-10-31 1991-10-31 Poudre a base d'un alliage aluminium/silicium hypereutectique et production de cette poudre

Publications (3)

Publication Number Publication Date
EP0592665A4 EP0592665A4 (fr) 1993-11-19
EP0592665A1 true EP0592665A1 (fr) 1994-04-20
EP0592665B1 EP0592665B1 (fr) 1996-06-12

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EP91918937A Expired - Lifetime EP0592665B1 (fr) 1990-10-31 1991-10-31 Poudre a base d'un alliage aluminium/silicium hypereutectique et production de cette poudre

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EP (1) EP0592665B1 (fr)
DE (1) DE69120299T2 (fr)
WO (1) WO1992007676A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997003775A1 (fr) * 1995-07-19 1997-02-06 Osprey Metals Limited Alliages de silicium utilises dans l'encapsulation de composants electroniques
WO1997009458A1 (fr) * 1995-09-01 1997-03-13 Erbslöh Aktiengesellschaft Procede de fabrication de tuyaux minces
WO1997009459A1 (fr) * 1995-09-01 1997-03-13 Erbslöh Aktiengesellschaft Procede de fabrication de tuyaux minces
WO1997009457A1 (fr) * 1995-09-01 1997-03-13 Erbslöh Aktiengesellschaft Procede de fabrication de tubes de faible epaisseur
EP0747494B1 (fr) * 1995-06-06 2002-03-13 Toyota Jidosha Kabushiki Kaisha Matériau composite à base d'aluminium, ayant une propriété de résistance à l'adhésion, et procédé pour sa production

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2703840B2 (ja) * 1991-07-22 1998-01-26 東洋アルミニウム 株式会社 高強度の過共晶Ａ１―Ｓｉ系粉末冶金合金
CN114101689B (zh) * 2021-11-15 2023-11-03 河北新立中有色金属集团有限公司 气雾化制粉用高硅铝合金熔体流动性、纯净度控制方法
CN116970831A (zh) * 2023-09-13 2023-10-31 四川航天职业技术学院(四川航天高级技工学校) 一种高硅铝合金细化方法

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3953202A (en) * 1975-02-10 1976-04-27 Kawecki Berylco Industries, Inc. Phosphorus-bearing master composition for addition to hyper-eutectic silicon-aluminum casting alloys and process therefor
JPS5937339B2 (ja) * 1977-04-15 1984-09-08 昭和電工株式会社 高ケイ素アルミニウム合金焼結体の製造方法
JPS55145134A (en) * 1979-04-27 1980-11-12 Aikoorosuborou Kk Grain refiner for hyper-eutectic aluminum-silicon alloy
EP0185540A3 (fr) * 1984-12-18 1987-05-27 Sumitomo Light Metal Industries Limited Procédé pour l'affinage du grain de silicium primaire dans les alliages hypereutectiques Al-Si
FR2604186A1 (fr) * 1986-09-22 1988-03-25 Peugeot Procede de fabrication de pieces en alliage d'aluminium hypersilicie obtenu a partir de poudres refroidies a tres grande vitesse de refroidissement
JPS63108945A (ja) * 1986-10-27 1988-05-13 Nippon Light Metal Co Ltd 初晶珪素微細化用フラツクス
JPS63266004A (ja) * 1987-11-10 1988-11-02 Showa Denko Kk 耐熱耐摩耗性高力アルミニウム合金粉末
JPH01147038A (ja) * 1987-12-02 1989-06-08 Honda Motor Co Ltd 粉末冶金用耐熱Ａｌ合金
JPH02213401A (ja) * 1989-02-13 1990-08-24 Toyota Motor Corp 粉末冶金用アルミニウム合金粉末
JP2703840B2 (ja) * 1991-07-22 1998-01-26 東洋アルミニウム 株式会社 高強度の過共晶Ａ１―Ｓｉ系粉末冶金合金

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0747494B1 (fr) * 1995-06-06 2002-03-13 Toyota Jidosha Kabushiki Kaisha Matériau composite à base d'aluminium, ayant une propriété de résistance à l'adhésion, et procédé pour sa production
WO1997003775A1 (fr) * 1995-07-19 1997-02-06 Osprey Metals Limited Alliages de silicium utilises dans l'encapsulation de composants electroniques
GB2317900A (en) * 1995-07-19 1998-04-08 Osprey Metals Ltd Silicon alloys for electronic packaging
GB2317900B (en) * 1995-07-19 2000-03-01 Osprey Metals Ltd Silicon alloys for electronic packaging
WO1997009458A1 (fr) * 1995-09-01 1997-03-13 Erbslöh Aktiengesellschaft Procede de fabrication de tuyaux minces
WO1997009459A1 (fr) * 1995-09-01 1997-03-13 Erbslöh Aktiengesellschaft Procede de fabrication de tuyaux minces
WO1997009457A1 (fr) * 1995-09-01 1997-03-13 Erbslöh Aktiengesellschaft Procede de fabrication de tubes de faible epaisseur
US6030577A (en) * 1995-09-01 2000-02-29 Erbsloh Aktiengesellschaft Process for manufacturing thin pipes
US6086819A (en) * 1995-09-01 2000-07-11 Erbsloh Aktiengesellschaft Process for manufacturing thin-walled pipes
US6136106A (en) * 1995-09-01 2000-10-24 Erbsloh Aktiengesellschaft Process for manufacturing thin pipes

Also Published As

Publication number Publication date
DE69120299D1 (de) 1996-07-18
EP0592665B1 (fr) 1996-06-12
WO1992007676A1 (fr) 1992-05-14
DE69120299T2 (de) 1997-01-23
EP0592665A4 (fr) 1993-11-19

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