WO2025100263A1 - Corps moulé en alliage d'aluminium et son procédé de production - Google Patents

Corps moulé en alliage d'aluminium et son procédé de production Download PDF

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Publication number
WO2025100263A1
WO2025100263A1 PCT/JP2024/038101 JP2024038101W WO2025100263A1 WO 2025100263 A1 WO2025100263 A1 WO 2025100263A1 JP 2024038101 W JP2024038101 W JP 2024038101W WO 2025100263 A1 WO2025100263 A1 WO 2025100263A1
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Prior art keywords
aluminum alloy
mass
molded body
modulus
young
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PCT/JP2024/038101
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English (en)
Japanese (ja)
Inventor
渉一 廣澤
片岡　隆一
一真 西尾
隆史 長尾
継治 田代
潤 楠井
勇夫 村上
直輝 森内
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Toyo Aluminum KK
Nippon Light Metal Co Ltd
Yokohama National University NUC
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Toyo Aluminum KK
Nippon Light Metal Co Ltd
Yokohama National University NUC
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Publication of WO2025100263A1 publication Critical patent/WO2025100263A1/fr
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/01—Extruding metal; Impact extrusion starting from material of particular form or shape, e.g. mechanically pre-treated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • 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
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium

Definitions

  • the present invention relates to an aluminum alloy molded body and a manufacturing method thereof, and in particular to a high Young's modulus aluminum alloy molded body that can be suitably used for automobile parts, etc., and a simple and efficient manufacturing method thereof.
  • Aluminum alloys are used in automobile parts, machine parts, structural materials, etc., but their Young's modulus is around 70 to 75 GPa. This Young's modulus is significantly smaller than the 200 GPa of steel and the 110 GPa of titanium alloys, which has limited the uses of aluminum alloys.
  • Patent Document 1 proposes an aluminum alloy for plastic processing that has high tensile strength, high Young's modulus, and high ductility and is useful for high-performance components such as bicycle parts, fishing tackle, golf clubs, and snowboards, and a manufacturing method thereof, proposing "a solidified formed material that is a mixture of aluminum alloy powder containing 0.4 to 2.0 wt.% Si, 0.4 to 2.0 wt.% Mg, and a total of 0.5 to 2.0 wt.% of one or more elements selected from Fe, Mn, and Cr, with the balance being Al containing unavoidable impurities, and 10 to 25 wt.% alumina, the aluminum alloy for plastic processing being characterized in that it has a Young's modulus of 80 GPa or more at room temperature, a tensile strength at room temperature after water quenching of 300 MPa or more, and an elongation of 5% or more.”
  • the aluminum alloy for plastic processing described in Patent Document 1 has high tensile strength and a high Young's modulus, making it useful for high-performance components such as bicycle parts, fishing tackle, golf clubs, and snowboards.
  • this invention has an elongation of 8% even when the alumina content is 10% by weight or more, and is said to have excellent ductility and be suitable for plastic processing.
  • Non-Patent Document 1 in order to obtain a molded body with excellent properties such as a high Young's modulus by additive manufacturing, a molded body using an AlSi10Mg-10% wtSiC mixed powder as the raw material was investigated, and a Young's modulus of 75 to 90 GPa was obtained.
  • Non-Patent Document 1 has a low elongation of 1.2% or less, so if the size of the molded object becomes large, there is a risk of cracks occurring due to thermal stress during molding.
  • Young's modulus can be increased by adding large amounts of elements such as iron (Fe) and silicon (Si) to the aluminum, but this reduces the ductility of the molded object, making it prone to cracks for the same reasons as above and difficult to commercialize.
  • the object of the present invention is to provide an aluminum alloy molded body that exhibits a Young's modulus of 80 GPa or more using aluminum alloy alone, without mixing with ceramics such as alumina or silicon carbide, and is suitable for use as industrial materials such as automobile parts, machine parts, and structural materials, and an efficient method for manufacturing the same.
  • the inventors have conducted extensive research into the relationship between the composition and microstructure of an aluminum alloy and the Young's modulus of an aluminum alloy formed body. As a result, they have discovered that it is extremely effective to optimize the Mn and Cr contents and perform an appropriate heat treatment to form a G phase, which is an Al 12 (Mn, Cr) compound, and have arrived at the present invention.
  • the present invention provides: Contains 4 to 11 mass% Mn and 1 to 4 mass% Cr, and satisfies the relationship 1.9 x Cr mass% ⁇ Mn mass% ⁇ 5.3 x Cr mass%,
  • An aluminum alloy formed body the balance of which is composed of unavoidable impurities and aluminum, Young's modulus at room temperature (25°C) is 80 GPa or more;
  • the present invention provides an aluminum alloy formed body, characterized by:
  • the volume fraction of the G phase which is an Al 12 (Mn, Cr) compound, is 10 to 90%.
  • the G phase is an Al 12 (Mn, Cr) compound.
  • the aluminum alloy molded body of the present invention has a layered structure consisting of a layer containing particles with a particle size of 1 to 3 ⁇ m and a fine-grain layer consisting of particles with a particle size of less than 1 ⁇ m.
  • the formation of this layered structure can increase the Young's modulus of the aluminum alloy molded body.
  • the present invention also provides a method for producing a semiconductor device comprising the steps of: A method for producing the aluminum alloy formed product of the present invention, comprising the steps of: a molding step of molding an aluminum alloy powder containing 4 to 11 mass% Mn and 1 to 4 mass% Cr, satisfying the relationship of 1.9 x Cr mass% ⁇ Mn mass% ⁇ 5.3 x Cr mass%, with the remainder being unavoidable impurities and aluminum; a heat treatment step of heat treating the aluminum alloy formed body obtained in the forming step at a temperature of 350 to 550°C; Also provided is a method for producing an aluminum alloy formed product, comprising the steps of:
  • an aluminum alloy powder containing the Mn and Cr necessary for forming the G phase is molded, and the resulting aluminum alloy compact is subjected to a heat treatment at a temperature of 350 to 550°C, thereby precipitating a large amount of the G phase in the aluminum alloy compact.
  • the manufacturing method of the aluminum alloy molded body of the present invention it is preferable to use an additive manufacturing method in the molding process.
  • an additive manufacturing method it is possible to efficiently manufacture aluminum alloy molded bodies having any shape, such as a complex shape or a hollow shape.
  • the as-built material according to the present invention has high ductility, the possibility of cracks occurring during molding is extremely low, and a sound molded body can be obtained.
  • an extrusion molding method in the forming step it is preferable to use an extrusion molding method in the forming step.
  • an extrusion molding method in the forming step by performing hot extrusion at 350 to 550°C, the temperature history of the hot extrusion can also serve as a heat treatment step.
  • the extrusion molding method it is possible to efficiently manufacture aluminum alloy molded bodies having simple shapes.
  • the present invention provides an aluminum alloy molded body that exhibits a Young's modulus of 80 GPa or more using aluminum alloy alone without mixing with ceramics such as alumina or silicon carbide, and is suitable for industrial materials such as automobile parts, machine parts, and structural materials, as well as an efficient method for manufacturing the same.
  • FIG. 2 is a schematic diagram showing the shape of a test piece for measuring Young's modulus.
  • 13 is a microscope image of a cross section of an additive manufacturing body having the alloy composition of Example 2. 1 shows an SEM image and EDS mapping results of an extruded material having the alloy composition of Example 4.
  • 13 is a photograph showing the appearance of an additive manufacturing body having the alloy composition of Comparative Example 2.
  • 13 is a photograph showing the appearance of an additive manufacturing body having the alloy composition of Comparative Example 6.
  • the manufacturing method of the aluminum alloy compact of the present invention is characterized by comprising a molding step of molding an aluminum alloy powder containing 4 to 11 mass % Mn and 1 to 4 mass % Cr, satisfying the relationship of 1.9 ⁇ Cr mass % ⁇ Mn mass % ⁇ 5.3 ⁇ Cr mass %, with the balance being unavoidable impurities and aluminum, and a heat treatment step of heat treating the aluminum alloy compact obtained in the molding step at a temperature of 350 to 550° C.
  • the aluminum alloy powder used as a raw material and each step will be described in detail below.
  • Aluminum alloy powder used as the raw material for the aluminum alloy compact (hereinafter also simply referred to as the "compact") can be produced, for example, by gas atomization (spraying medium is air, nitrogen gas, Ar gas, He gas, etc.) or water atomization. In addition, it can also be produced by rotating electrode method, plasma atomization method, centrifugal atomization method, mechanical alloying method, chemical process, etc. Among these, production by gas atomization method and centrifugal atomization method is preferable.
  • the composition of the aluminum alloy powder may contain 4-11 mass% Mn and 1-4 mass% Cr, satisfying the relationship 1.9 ⁇ Cr mass% ⁇ Mn mass% ⁇ 5.3 ⁇ Cr mass%, with the remainder being unavoidable impurities and aluminum.
  • Mn is an element that forms the G phase (Al 12 (Mn,Cr)) together with Cr, and Mn alone contributes to improving strength.
  • the Mn content may be 4-11 mass%, preferably 5-10 mass%, and more preferably 5-8 mass%.
  • Cr is an element that forms the G phase (Al 12 (Mn,Cr)) together with Mn, and Cr alone also contributes to improving strength.
  • the Cr content is preferably 1 to 4 mass%, more preferably 1.5 to 3.5 mass%, and even more preferably 1.8 to 3.2 mass%. If the Cr content is less than 1 mass%, the strength of the compact is poor and it is difficult to form a sufficient amount of G phase to obtain a high Young's modulus. If the Cr content exceeds 4 mass%, the toughness and ductility are poor and the melting point (liquidus temperature) of the alloy is high, which may make it difficult to manufacture the aluminum alloy powder.
  • unavoidable impurity elements include iron (Fe), silicon (Si), magnesium (Mg), copper (Cu), zinc (Zn), lithium (Li), nickel (Ni), titanium (Ti), calcium (Ca), sodium (Na), strontium (Sr), yttrium (Y), niobium (Nb), molybdenum (Mo), tungsten (W), antimony (Sb), beryllium (Be), phosphorus (P), vanadium (V), tin (Sn), lead (Pb), bismuth (Bi), cobalt (Co), silver (Ag), gallium (Ga), scandium (Sc), cerium (Ce), boron (B), carbon (C), nitrogen (N), and oxygen (O).
  • unavoidable impurity elements may be present inevitably in aluminum ingots, may be mixed in unavoidably during the production of aluminum alloy powder, or may be modifier elements when grain refining elements such as titanium, boron, and zirconium are intentionally added.
  • the content of these unavoidable impurity elements is not particularly limited as long as it does not impair the effects of the present invention, but each of them is preferably 0.5 mass% or less, more preferably 0.3 mass% or less, and particularly preferably 0.2 mass% or less.
  • the content of each element in the aluminum alloy powder and aluminum alloy compact can be measured by ICP atomic emission spectrometry and inert gas fusion-infrared absorption method, etc.
  • the average particle diameter of the aluminum alloy powder is not particularly limited, but the volume-based average particle diameter (median diameter d 50 ) is preferably 5 ⁇ m or more, more preferably 10 ⁇ m or more, and even more preferably 15 ⁇ m or more. If the average particle diameter is less than 5 ⁇ m, the fluidity of the powder decreases, and a uniform powder layer may not be formed in the manufacturing process of the molded body. On the other hand, the average particle diameter is preferably 200 ⁇ m or less, more preferably 150 ⁇ m or less, even more preferably 100 ⁇ m or less, and particularly preferably 80 ⁇ m or less. If the average particle diameter exceeds 200 ⁇ m, the powder may get caught by the squeegee during layered manufacturing, making it difficult to spread it.
  • the average circularity (sphericity) of the aluminum alloy powder is not particularly limited, but is preferably 0.9 or more and 1.0 or less. If the average circularity is less than 0.9, the fluidity of the powder decreases, and there is a risk that a uniform powder layer cannot be formed in the manufacturing process of the compact.
  • the circularity is a value not exceeding 1 obtained by dividing the equivalent circle diameter calculated from the area by the equivalent circle diameter calculated from the circumference, and can be determined by image analysis of a photograph of the particles taken with a microscope. If the average circularity of about 1,000 particles is 0.90 or more, the necessary fluidity is ensured and the content of oxides that cause defects tends to be reduced. As an example of the measurement results, the photograph and actual measurement value of Al-8Mn-2Cr powder are shown in Figure 1, and the circularity of this powder was 0.94 on average for about 1,000 particles.
  • the additive manufacturing method is a method of processing molten and solidified regions by stacking them up one layer at a time, based on two-dimensional (slice) data obtained from 3D-CAD data.
  • the aluminum alloy molded body includes a first step of forming a powder layer containing aluminum alloy powder, and a second step of forming a metal layer in the powder layer by melting and solidifying the aluminum alloy powder at a predetermined position. These first and second steps are repeated in sequence, and multiple metal layers are stacked and joined to produce the aluminum alloy molded body.
  • powder bed fusion can be used for the additive manufacturing method
  • other additive manufacturing methods can also be used, such as directed energy deposition.
  • additive manufacturing methods using indirect methods such as binder jetting and fused deposition modeling can also be used.
  • Laser light can be used as a heat source for melting and solidifying the metal powder, but the means for this is not limited to laser light, and for example, electron beams, plasma, etc. can also be used.
  • the metal layer and the powder layer may be preheated.
  • the preheating temperature is preferably 30°C or higher, more preferably 150°C or higher. It is also preferably 500°C or lower, more preferably 400°C or lower, and even more preferably 250°C or lower. Preheating to 150°C or higher fully suppresses cracks (delamination), while preheating to a temperature above 500°C tends to cause the microstructure of the aluminum alloy compact to disappear and the mechanical properties to deteriorate.
  • an electric heater attached to the lower part of the modeling platform or base plate is usually used, but a ceramic heater or high-frequency heating may also be used. Heating may also be performed by scanning a heat source such as a laser beam or an electron beam.
  • the aluminum alloy powder As a preliminary step before extrusion molding, it is preferable to cold mold the aluminum alloy powder.
  • Cold pressing, cold isostatic pressing (CIP), etc. can be used as a method of cold molding.
  • the density of the cold molded body is preferably about 60 to 80%. If it is less than 60%, it will be fragile, and high pressure will be required to solidify it to a density of more than 80%, which will increase costs. To achieve a density of 60% or more, it is preferable to apply a pressure of 9.8 x 10 MPa or more.
  • the cold molded body may be degassed in a vacuum at 300 to 500°C for about 10 minutes to 24 hours.
  • the cold-formed body can be hot-extruded at a temperature of preferably 350 to 550°C, more preferably 400 to 550°C, and even more preferably 450 to 550°C to obtain an aluminum alloy formed body.
  • a temperature preferably 350 to 550°C, more preferably 400 to 550°C, and even more preferably 450 to 550°C to obtain an aluminum alloy formed body.
  • extrusion resistance is high and extrusion may become difficult.
  • intermetallic compounds such as crystallized substances may become coarse, which may reduce mechanical properties.
  • the holding time at 350 to 550°C can be set appropriately and may be adjusted appropriately depending on the size of the cold-formed body. Usually, it is about 5 minutes to about 10 hours.
  • the extrusion ratio may be adjusted appropriately depending on the shape and size of the desired formed body, but usually it is about 5 to 25.
  • the aluminum alloy molded body molded by the additive manufacturing method can be further precipitated with the G phase by heat treatment to improve the Young's modulus. Also, in the aluminum alloy molded body molded by the extrusion molding method, when the precipitation of the G phase is insufficient, the aluminum alloy molded body can be further precipitated with the G phase by heat treatment to improve the Young's modulus.
  • the heat treatment temperature is preferably 350°C or higher, more preferably 375°C or higher, even more preferably 400°C or higher, and particularly preferably 450°C or higher.
  • the upper limit is preferably 550°C or lower, and if it exceeds 550°C, precipitates and crystal grains may become coarse, which may impair mechanical properties.
  • the time for heat treatment is preferably 0.1 hour or more, more preferably 0.5 hour or more, and even more preferably 1 hour or more. Also, it is preferably 100 hours or less, and more preferably 24 hours or less. If it is shorter than 0.1 hour, the Young's modulus of the aluminum alloy molded body may not be improved sufficiently. On the other hand, if it is longer than 100 hours, the strength of the aluminum alloy molded body may be reduced due to overaging.
  • the furnace used for heat treatment is usually an atmospheric furnace, but it may also be used in an atmospheric furnace, for example, in an inert gas atmosphere such as nitrogen or argon, or in a reducing gas atmosphere such as hydrogen.
  • Aluminum alloy molded body The composition of the aluminum alloy molded body of the present invention is approximately the same as that of the aluminum alloy powder.
  • the aluminum alloy powder described above melts temporarily and resolidifies (rapidly solidifies), but the alloy components of the aluminum alloy powder used in the present invention are hardly volatilized, so the composition of the obtained aluminum alloy molded body is the same as that of the original aluminum alloy powder within the margin of error.
  • the relative density of the aluminum alloy molded body of the present invention is preferably 98% or more, more preferably 99% or more, and even more preferably 99.5% or more. If the relative density is less than 98%, the mechanical properties of the molded body may be significantly degraded.
  • This relative density is calculated as the area ratio of the metal part excluding void parts by binarizing an image (magnification of about 100 times) obtained by an optical microscope or a microscope of an arbitrary cross section near the center of the molded body. The higher the relative density, the more desirable it is for improving the mechanical strength, ductility, and thermal and electrical conductivity of the layered product.
  • the Young's modulus of the aluminum alloy molded body is 80 GPa or more.
  • the Young's modulus is preferably 90 GPa or more, more preferably 95 GPa or more, and even more preferably 100 GPa or more.
  • the Young's modulus correlates to a certain extent with the volume fraction of the G phase, and a Young's modulus of 80 GPa or more is easily obtained when the volume fraction of the G phase is 10% or more.
  • the volume fraction of the G phase is preferably 20% or more, more preferably 30% or more, and even more preferably 35% or more.
  • the upper limit of the volume fraction of the G phase is preferably 90% or less, more preferably 85% or less, and even more preferably 80% or less. If it exceeds 90%, the molded body becomes brittle, becomes difficult to process, and tends to have reduced toughness, so it is preferable to avoid this.
  • the aluminum alloy molded body preferably has a layered structure consisting of a layer containing particles with a particle size of 1 to 3 ⁇ m and a fine-grain layer consisting of particles with a particle size of less than 1 ⁇ m.
  • the formation of this layered structure can increase the Young's modulus of the aluminum alloy molded body.
  • the layered structure can be easily observed by SEM observation, etc.
  • the breaking elongation at room temperature of the as-built material of the molded body obtained by the additive manufacturing method is 10% or more.
  • This breaking elongation is more preferably 12% or more, and even more preferably 14% or more.
  • Alloys with the nominal compositions shown in Table 1 as examples and comparative examples were prepared, heated to above the melting point (liquidus temperature) in a high-frequency induction furnace until fully melted, and then powdered using a nitrogen gas atomization method to obtain aluminum alloy powder.
  • each aluminum alloy powder obtained were measured by ICP emission spectrometry, and the results are shown in Table 1.
  • the particle size distribution of the powder was measured by a laser diffraction scattering method using a microtrack, and the particle size of the cumulative 50% from the fine particle side in the volume-based particle size distribution was taken as the average particle size of the aluminum alloy powder.
  • the average particle size is also expressed as the median diameter "d 50 ".
  • the circularity was measured as follows using a Morphologi G3 manufactured by Spectris Co., Ltd. First, about 1,000 particles were selected from each aluminum alloy powder, and the circularity of each particle was read from the appearance shape photograph of each particle, and the average value was taken as the circularity of the aluminum alloy powder. The obtained average particle size and circularity are shown in Table 1.
  • the aluminum alloy powders having the nominal compositions shown as examples contain 4 to 11 mass% Mn and 1 to 4 mass% Cr, and satisfy the relationship 1.9 x Cr mass% ⁇ Mn mass% ⁇ 5.3 x Cr mass%.
  • the obtained powder was classified by passing it through a sieve with an opening of 63 ⁇ m, and 100 g of this powder was placed in a rubber mold and cold molded with a cold isostatic press (CIP) at a surface pressure of 3000 kg/ cm2 to obtain a green compact with a length of about 70 mm and a diameter of about 30 mm.
  • This green compact was made into a billet, heated in an atmospheric furnace at 500°C for 30 minutes, and then placed in a container (diameter 32 mm) of an extrusion molding machine with a maximum load of 100 tons maintained at 450°C to obtain an extrusion molded product with a width of 20 mm and a thickness of 4 mm (extrusion ratio 10).
  • the aluminum alloy powder was used to produce an aluminum alloy compact by additive manufacturing.
  • the aluminum alloy compact was obtained using the aluminum alloy powder as a raw material by powder bed fusion additive manufacturing using a laser.
  • the molding machine used for additive manufacturing was a LUMEX Avance-25 manufactured by Matsuura Machinery Works or an EOSINT M280 manufactured by EOS.
  • the aluminum alloy molded body was obtained under the following lamination conditions: laser output: 280-480 W, scanning speed: 800-2200 mm/s, scanning pitch: 0.10-0.16 mm, atmosphere: inert gas.
  • the "molding temperature” shown in Table 2 is the preheating temperature of the base plate during additive manufacturing.
  • the tensile strength, 0.2% yield strength, and breaking elongation of the laminated molded body were evaluated according to JIS Z 2241 Tensile Test Method for Metallic Materials.
  • No. 14A test pieces (parallel part ⁇ 6 mm, original gauge length 30 mm) specified in the same standard were taken from the obtained molded body in a direction perpendicular to the molding direction, and tensile tests were performed at room temperature using a Shimadzu 100k NXplus autograph.
  • the crosshead speed during the tensile test was 0.5 mm/min up to 0.2% yield strength, and 5 mm/min after 0.2% yield strength.
  • the obtained tensile strength, 0.2% yield strength, and breaking elongation are shown in Table 2.
  • the breaking elongation was calculated according to Section 20.2 of the above JIS standard, using the final gauge length and original gauge length after fracture, which were measured by butting two test pieces together after fracture.
  • cracks were evaluated as a measure of the moldability of the layered molded bodies.
  • the obtained molded bodies were visually observed, and for 12 or more molded bodies, the crack occurrence rate was calculated by multiplying the number of molded bodies with cracks / (number of molded bodies with cracks + number of molded bodies without cracks) by 100.
  • the obtained crack occurrence rate is shown in Table 2.
  • the additively manufactured bodies having the alloy compositions of Examples 1 to 3 did not have any cracks and had good ductility in the as-built state. Furthermore, the relative density calculated by image analysis from cross-sectional observation was 99.5% or more. A cross section of the additively manufactured body of Example 2 is shown in Figure 3.
  • the Young's modulus of the additively manufactured bodies having the alloy compositions of Examples 2 and 3 is significantly increased by heat treatment at 400°C or 500°C. According to the results of X-ray diffraction measurement, a new G phase is formed by the heat treatment, which is thought to be the reason for the increase in Young's modulus. On the other hand, the Young's modulus of the extruded material having the alloy composition of Example 3 is even higher, reaching 111 GPa.
  • the Young's modulus of the extruded material having the alloy composition of Comparative Example 1 exceeds 80 GPa, but the extruded body is very brittle and it is difficult to process test specimens, so it cannot be used as a practical alloy.
  • Comparative Example 6 is an alloy with added Fe, but the Young's modulus of the extruded material is low and it cannot be used suitably in applications where rigidity is required. In additive manufacturing, residual stress causes cracks to form in the molded body, making it problematic as a practical alloy. Figure 6 shows the cracks in the additive manufactured body of Comparative Example 6.

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  • Powder Metallurgy (AREA)

Abstract

Le problème décrit par la présente invention est de fournir : un corps moulé en alliage d'aluminium qui est approprié pour des matériaux industriels tels que des pièces automobiles, des pièces mécaniques et des matériaux structuraux, et présente un module de Young supérieur ou égal à 80 GPa par un alliage d'aluminium seul sans mélange avec des céramiques telles que l'alumine ou le carbure de silicium ; et un procédé efficace de production du corps moulé en alliage d'aluminium. La solution selon l'invention porte sur un corps moulé en alliage d'aluminium qui contient de 4 à 11 % en masse de Mn et de 1 à 4 % en masse de Cr et satisfait la relation 1,9 × Cr % en masse ≤ Mn % en masse ≤ 5,3 × Cr % en masse, le reste étant des impuretés inévitables et de l'aluminium, le corps moulé en alliage d'aluminium étant caractérisé en ce que le module de Young à température ambiante (25 °C) est supérieur ou égal à 80 GPa.
PCT/JP2024/038101 2023-11-08 2024-10-25 Corps moulé en alliage d'aluminium et son procédé de production Pending WO2025100263A1 (fr)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022080319A1 (fr) * 2020-10-12 2022-04-21 地方独立行政法人大阪産業技術研究所 Poudre métallique pour fabrication additive, procédé de fabrication d'un article fabriqué par fabrication additive l'utilisant, et article fabriqué par fabrication additive
WO2022122670A1 (fr) * 2020-12-10 2022-06-16 Höganäs Ab (Publ) Nouvelle poudre, procédé de fabrication additive de composants faits de la nouvelle poudre et article fabriqué à partir de celle-ci

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022080319A1 (fr) * 2020-10-12 2022-04-21 地方独立行政法人大阪産業技術研究所 Poudre métallique pour fabrication additive, procédé de fabrication d'un article fabriqué par fabrication additive l'utilisant, et article fabriqué par fabrication additive
WO2022122670A1 (fr) * 2020-12-10 2022-06-16 Höganäs Ab (Publ) Nouvelle poudre, procédé de fabrication additive de composants faits de la nouvelle poudre et article fabriqué à partir de celle-ci

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
KIMURA NORIHITO, JUNICHI KANEKO, MAKOTO SUGAMATA: "Structure and properties of rapidly solidified Al–6∼8 mass%Mn–1∼3 mass%Cr alloys", JOURNAL OF JAPAN INSTITUTE OF LIGHT METALS, KEIKINZOKU GAKKAI, JP, vol. 50, no. 1, 1 January 2000 (2000-01-01), JP , pages 12 - 17, XP093313701, ISSN: 0451-5994 *

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