WO2017209720A2 - Procédé de production de composite avec matrice métallique coulée par compression continue - Google Patents

Procédé de production de composite avec matrice métallique coulée par compression continue Download PDF

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Publication number
WO2017209720A2
WO2017209720A2 PCT/TR2017/050228 TR2017050228W WO2017209720A2 WO 2017209720 A2 WO2017209720 A2 WO 2017209720A2 TR 2017050228 W TR2017050228 W TR 2017050228W WO 2017209720 A2 WO2017209720 A2 WO 2017209720A2
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WO
WIPO (PCT)
Prior art keywords
production
composite
continuous
matrix
metal
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Ceased
Application number
PCT/TR2017/050228
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English (en)
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WO2017209720A3 (fr
Inventor
Bahattin AGADAY
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Dokuz Eylül University
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Dokuz Eylül University
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Publication date
Application filed by Dokuz Eylül University filed Critical Dokuz Eylül University
Publication of WO2017209720A2 publication Critical patent/WO2017209720A2/fr
Publication of WO2017209720A3 publication Critical patent/WO2017209720A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/006—Continuous casting of metals, i.e. casting in indefinite lengths of tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • B22F5/106—Tube or ring forms
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1073—Infiltration or casting under mechanical pressure, e.g. squeeze casting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/08—Making alloys containing metallic or non-metallic fibres or filaments by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould
    • C22C47/12—Infiltration or casting under mechanical pressure
    • 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
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • B22F2007/042—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal characterised by the layer forming method
    • B22F2007/045—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal characterised by the layer forming method accompanied by fusion or impregnation
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention describes a continuously squeezed metal matrix composite (MMK) material production method and a machine developed to carry out said continuous production .
  • MMK continuously squeezed metal matrix composite
  • the homogenous distribution structuring and solidification control under pressure, inside a rotational moving compressor and under atmospheric and thermal controlled conditions of continuous, non-continuous and powder reinforcement materials into a liquid metal matrix is carried out by means of the system that has been developed ; and as a result continuous production having plate, cylindrical and tube formed items with variable wall thicknesses is performed.
  • Products with high added value are provided by using high quality materials during production .
  • improved materials are used in advanced technology products.
  • the rapid development of technology has also increased the anticipated performance requirements from materials.
  • This demand has significantly accelerated the developments of new materials.
  • Another field where developments can be observed is the field of composite materials.
  • properties of classical materials have been increased by up to 100% .
  • silver-diamond materials have become cooling platforms in technology products with a value of 600 W/mK
  • aluminium-ceramic fibre materials have provided high thermal resistance
  • fourth generation nanocomposite applications have already started to be used in defence sector. Thanks to new mixing applications and new production techniques that are developed day by day; new features and performances have been achieved with the use of highly qualified materials in sectors such as the defence sector, air transportation , automotive and health sectors and in information systems.
  • Metal matrix composites (Low density, high strength , thermal advantage, thermal stability, etc.) have been used increasingly due to their superior properties as mentioned above. For example; it has been used in many applications such as space shuttles, ballistic missile applications, highly destructive explosives, high speed aircraft applications, advanced auto brake discs, pistons and aircraft landing gears.
  • the present shape of the product is differentiated by means of secondary processes etc.; therefore they also show differences in terms of their internal structures and strengths.
  • the liquid, liquid- solid phase metal matrix composite forming techniques have been listed as liquid casting matrix composite production methods such as pressurized or non pressurized infiltration, semi solid composite casting (compocasting), mixing (vortex), reinforcement of liquid by gas injection, squeezing casting and liquid spray.
  • Liquid matrix has been used in these techniques and the application method shows differences. Squeezing is carried out at a certain mass in single shaped moulds.
  • the production is carried out basically in liquid phase, liquid-solid and solid (reaction in situ) form.
  • the applications of the known state of the art are as follows:
  • Solid phase production techniques These are mechanisms where the matrix and reinforcement materials are generally solid at the beginning and heat is used during combining such as sintering.
  • Powder metal applications Conventional sintering, plasma sintering, hot press, hot extrusion , deformation processing, semi solid powder processing,
  • Plasma spraying Plasma spraying, HVOF spraying, cold kinetic spraying.
  • Electro deposition Types of electro chem ical deposition , electro precipitation and non flow deposition .
  • the matrix is initially a classic cast liquid metal, and this is a simple and cheap method that is applied with the addition of adm ixture materials. This method enables to produce complex shaped items. Good results may not be able to be obtained if parameters such as temperature, pressure, contact time, solidification rate are not controlled.
  • the low wetting ability of the ceramic phase with many metals is one of the most significant problems.
  • the solution is directed to overcoming wetting in processes such as coating and pre-mixing or overcom ing and removing surface energy with an external force. Thermal expansion compliance, shrinkage upon solidification and gas cavities are also important. Either the matrix alloy or the reinforcement agent needs to be selected properly and mixing and casting must be performed under suitable conditions.
  • Squeeze casting method The liquid matrix material does not enable proper contact with reinforcement agents such as boron, carbide, graphite and silicon carbide. Wetting creates a cavity effect in this matrix and leads to significant strength losses.
  • I n squeeze casting fibres that have been heated and purified from gas with partial metal absorption are placed into a mould, external force is applied in order to increase interfacial surface binding strength by the effect of pressure. The force that is applied is continued until solidification is completed.
  • This technique which has found a significant application field in metal matrix composite production enables to obtain products with smooth surfaces and low porosity.
  • the system is continued to be developed in the automotive, defence and aviation sector.
  • the disadvantage of the application is that the product per unit time is low. Deformation can be observed in the fibres and production difficulty increases with large sized parts and continuous production cannot be provided.
  • Mix (vortex) casting method This is a method which depends on m ixing of liquid metal with a mixer, and adding particle and short fibre admixtures during the mixing process. The m ixing process is continued until the mixture is poured into the moulds. This method especially increases the wetting ability of ceramic surfaces. The tendency of porosity formation in the system is high and the reasons for this is that the liquid is in contact with the atmosphere due to the position of the m ixer during m ixing and the gas dissolved metal cannot be cleaned and the reinforcement agents are added without being heated.
  • Reinforcement method by means of gas injection to the fluid This is an application that is generally developed in order to add particles.
  • the system generally is a nitrogen gas carrier.
  • the matrix flows from the metal pot base and the particles are mixed by means of gas and at this instant homogenous m ixture and small particles are formed.
  • - Plasma spraying (Osprev) method The liquid metal is atomized with inert gas and as a result it is accumulated at the desired thickness on the mobile base.
  • the system has been com worthalized by Osprey Metals developed by Singer. Complex m ixtures and special allow matrices can be used with this system .
  • the thickness of the piece is determined by controlling the accumulation at the base. I f solidification is fast, the interfacial reaction of some oxides will be limited. This situation may lim it the solubility rate and surface binding force will be weak.
  • Liquid metal infiltration method A matrix will be formed by infiltration of the liquid matrix material under pressure or vacuum to the structure that has been formed by fibre, whisker and particles. Moreover liquid pressure infiltration with nitrogen gas, and liquid pressure vacuum or non vacuum applications are also present.
  • the invention is related to an apparatus which enables to produce metal matrix composites that have been reinforced with a multiple component phase.
  • TR 201 4 07923 B The invention describes a metal matrix composite casting method that has been developed in order to increase the abrasion resistance of steel allows cast parts that are subj ected to abrasion and impact.
  • the invention describes a metal matrix composite production method comprising processes such as hot-process isotactic compression of products related to the prior step and the cold press isotactic compression of powders.
  • ceram ic and graphite reinforcement materials display problems such as floating and m ixing. This limits the production of improved quality materials.
  • Agglomeration is formed when the reinforcement material is not distributed homogenously inside a matrix and when the materials aggregate among themselves. The problem is tried to be overcome by means of lim iting reinforcement material amounts, particle size and form .
  • Type of product Most of the applications are carried out as continuous production (part) . This also increases production costs in unit basis. Moreover it does not provide widespread usage as a sem i-manufactured product.
  • Continuous production Continuous production in cast metal matrix composites is limited with product type and section . Generally part forming in a mould is used.
  • I ndustrial usage Many of the production methods have been developed according to requirements and they may not be used extensively and this limits production . However if the method has several controllable production parameters, this increases product variability.
  • the developed method aims to provide continuously squeezed metal matrix composite material production and to eliminate factors that reduce strength during production.
  • the system enables continuous production, by means of an induction coil, a pot and a mould, around which thermal control is provided wherein an intermittent cylinder, is placed into the cylindrical mould, and is rotated around its axis, between phases of the cylinder liquid under atmosphere controlled conditions is allowed to flow and solid matrix and reinforcement materials are added; pressure is applied with the radial opening and cool grinding base, the materials are squeezed and pushed with a rotational motion and the solidified section is released from the bottom of the mould.
  • the method that has been carried out enables the economical and continuous production of products such as, hollow cylinder, plate, non-hollow cylinders by benefiting from parameters like the temperature, pressure, rotational movement rate, and reinforcement types of liquid, semisolid, solid (powder) products under controlled atmosphere conditions.
  • I t shall be possible to carry out continuous squeezed metal matrix composite (MMK) production .
  • I t is possible to increase quality by applying secondary processes.
  • Cast MMK production with density problems such as graphite and ceramic can be performed easily and rapidly.
  • the solid-solid powder metal reinforced composites are continuously produced by induction sintering and axial squeezing.
  • the system shall prevent flotation by means of radial and vertical squeezing and shall provide homogenous distribution .
  • the system provides controlled solidification and distribution .
  • Pressurized squeeze controlled solidification of the system enables to overcome wetting problems.
  • the unit weight costs shall be reduced in comparison to present applications.
  • Fig. 1 Continuous squeeze cast, metal matrix composite production system .
  • Fig. 2 I nternal mould channel system for a pipe or non-hollow cylinder.
  • the invention is an (where the temperature of the flowing metal or squeezed material is controlled) composite production system comprising an induction system and a production method used in said system , wherein the distribution and spreading of flowing metal flowing out of a feeder pot, between two mould membranes with an axial rotation movement (matrix and reinforcement material) is carried out and where structural characteristics are also developed by squeezing with a vertically applied force.
  • the system is fed by charging the grooved channel which rotates at the axial centre, with liquid metal delivered from heat and flow controlled pots.
  • the squeezing rotating cylinder can be fed from a single point or from multiple points depending on its size. Physical layers are formed by delivering different metal phases from the second pot, to the metal flow channel (4) .
  • Metal is delivered to the radial squeezer, in solid (powder sinter solid-liquid, and liquid form depending on rotation and cooling rate and is m ixed and squeezed with reinforcement materials.
  • Squeezing does not only provide structural improvement (wetting, particle size reduction , degassing, reinforcement rate, preventing aggregation , and floatation etc.) but it also allows to solidify the product and enables it to be pushed and released out of the bottom of the mould and ensures continuous production .
  • Powder and fibre reinforcement materials besides matrix materials can be poured into the mould together or separately.
  • Matrix or reinforcement materials can be fed from a single point or from a plurality of points depending on the size of the product. The amount of squeezing is controlled with dynamic brakes during loading and mould exit.
  • Temperature control is provided both in the pot and the mould by means of an induction coil. Pressurized nitrogen application controls the cooling of the mould and metal.
  • the system performs continuous production by means of powder metal application in a mould with induction heating and sintering.
  • the system allows the flat metal and alloys to be obtained as a compressed structure.
  • metals which are difficult to produce such as magnesiu m can be mass produced in different forms (cylinder, tube, plate) .
  • Secondary metallurgical processes can be applied to the products.
  • the system also enables to efficiently produce polymer type materials.
  • the walls are covered with separating gels, the fibres are contacted by compression with resin, the gas cavities are removed and homogenous spreading is provided ; solidification is provided by the heat of the mould during extraction.
  • one of the single unit dual induction coil heating systems controls the temperature of the liquid in the charging pot while the other controls the heat in the production mould.
  • the opening at the rotation direction of the squeezer in the form of an intermittent cylinder which applies vertical squeezing force and carries out an axial rotation motion between the two telescopic and cylindrical stationary moulds containing liquid metal, has a wide angle and it spreads and then squeezes the materials received from the charge channels to the base of the mould by a rotation motion.
  • the opening at the rotation direction of the squeezer in the form of an intermittent cylinder which applies vertical squeezing force and carries out an axial rotation motion between the two telescopic and cylindrical stationary moulds containing liquid metal, has a wide angle and it spreads and then squeezes the materials received from the charge channels to the base of the mould by a rotation motion.
  • the rotation speed determines the speed of solidification, the dendrite and particles that are solidified by squeezing, are homogenously distributed and besides this, shrinking due to wetting and solidification and gas cavities are reduced and a thinner and denser structure is formed.
  • the homogenous distribution of dense graphite and ceramic particles is carried out.
  • the thickness formed as a result of the solidification following rotation motion increases squeezing at the vertical direction and the section that is to be released from the mould is obtained. If the charge is continuous than the production of the product (20) from the mould is also continuous.
  • the induction coil which is placed outside of the mould, controls the temperature of the squeezed material when desired and maintains the temperature at a semi solid or sintering temperature. The cooling is carried out during the discharge of the mould and from the inside of the mould. Cylindrical (hollow or non hollow) plate production having small diameters and lower thicknesses can be carried by means of the system.
  • the liquid metal that is charged to the induction heating pot under an atmosphere controlled medium ( 18) is poured in a controlled manner into the metal flow channel (4) having a radial opening.
  • the liquid metal flows to the front section of the semi cylinder with radial edge, which rotates between the two telescopic cylindrical moulds intermittently.
  • powder reinforcement or strip reinforcement is laid in front of the squeezer.
  • Vertical pressure is applied to the material by means of a motor and roll bearing system .
  • the rotation rate of the squeezer, the cooling gas and mould heating rate, the amount of reinforcement materials, the liquid, liquid-solid, solid-solid structure of the matrix, form the composition parameters.
  • the solidified metal is released out of the mould and continuous production is performed.
  • the continuous squeeze cast composite production method used in said system comprises the following steps:
  • Liquid, liquid-solid, solid matrix and reinforcement materials are allowed to flow under controlled atmosphere conditions,
  • Said MMK system is suitable especially for semi finished products. These products can also be industrialized and can be utilized extensively such as rolling and extrusion methods used nowadays in iron-steel production . Moreover this system can also be used in specific productions directed to reach a certain aim .

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

Abstract

L'invention concerne un procédé de production de matériau composite à matrice métallique comprimée en continu (MMK) et une machine développée pour réaliser ladite production continue. La structuration par répartition homogène et le contrôle de la solidification sous pression, à l'intérieur d'un compresseur à mouvement rotatif et dans des conditions atmosphériques et thermiques contrôlées, de matériaux de renforcement continus, non continus et en poudre dans une matrice métallique sont effectués au moyen du système qui a été développé. En conséquence, une production continue d'articles en forme de plaque, de cylindre et de tube ayant des épaisseurs de paroi variables est réalisée.
PCT/TR2017/050228 2016-06-01 2017-05-30 Procédé de production de composite avec matrice métallique coulée par compression continue Ceased WO2017209720A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2016/07371 2016-06-01
TR201607371 2016-06-01

Publications (2)

Publication Number Publication Date
WO2017209720A2 true WO2017209720A2 (fr) 2017-12-07
WO2017209720A3 WO2017209720A3 (fr) 2018-01-04

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118080748A (zh) * 2023-12-07 2024-05-28 中国航空油料集团有限公司 地井阀筒形阀体的半固态旋挤锻复合成形工艺

Citations (4)

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Publication number Priority date Publication date Assignee Title
US6547850B1 (en) 1998-03-11 2003-04-15 Mc21 Incorporated Method for mixing particles into a liquid medium
CN101020973A (zh) 2006-02-14 2007-08-22 丁刚 多元相增强金属复合材料制造工艺及设备
CN101142045A (zh) 2005-03-14 2008-03-12 博洛涅锻造公司 用于制备金属基体复合材料的改进方法及使用该方法的装置
CN101829777A (zh) 2010-03-18 2010-09-15 丁家伟 纳米颗粒增强金属基复合材料制备工艺及设备

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US3844332A (en) * 1971-11-05 1974-10-29 R Bucci Making seamless tubing by continuous process
US4775000A (en) * 1986-08-27 1988-10-04 Ayers Jack D Continuous casting of tubular shapes by incremental centrifugal material deposition
US7105235B2 (en) * 2002-05-17 2006-09-12 Her Majesty The Queen In Right Of Canada As Represented By The Minister Of Natural Resources Isotropic zero CTE reinforced composite materials
JP5185178B2 (ja) * 2009-03-31 2013-04-17 トヨタ自動車株式会社 Mmcシリンダーライナー及びその製造方法
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Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6547850B1 (en) 1998-03-11 2003-04-15 Mc21 Incorporated Method for mixing particles into a liquid medium
CN101142045A (zh) 2005-03-14 2008-03-12 博洛涅锻造公司 用于制备金属基体复合材料的改进方法及使用该方法的装置
CN101020973A (zh) 2006-02-14 2007-08-22 丁刚 多元相增强金属复合材料制造工艺及设备
CN101829777A (zh) 2010-03-18 2010-09-15 丁家伟 纳米颗粒增强金属基复合材料制备工艺及设备

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118080748A (zh) * 2023-12-07 2024-05-28 中国航空油料集团有限公司 地井阀筒形阀体的半固态旋挤锻复合成形工艺

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