Method of getting compound material with metallic matrix

专利摘要:

公开号:SU1831413A3
申请号:SU904830865
申请日:1990-07-17
公开日:1993-07-30
发明作者:Kempbell Kantner Robert；Antolin Stanislav；Kumar Dvivedi Ratnesh
申请人:Lanxide Technology Co Ltd；
IPC主号:

专利说明:

The invention relates to the formation of metal matrix composite bodies.
The purpose of this proposal is to increase the efficiency and simplify the method.
Composite products, including matrix metal and a hardening and reinforcing phase, such as ceramic particles, whiskers, fibers or the like, open up the possibility of a number of applications, due to the fact that they combine some rigidity and resistance to wear of the reinforcing phase with ductility and strength metal matrix. The metal matrix composite will show an improvement in properties such as strength, stiffness, contact wear resistance and strength retention at elevated temperature compared to the matrix metal in the form of a monolith, but the degree to which any given property can be improved is highly dependent on the specific components, their volumetric or weight fractions, and how they are introduced during molding of the composite. In some cases, the composite material may be lighter in weight than the matrix material
1831413 AZ in itself. Ceramic-reinforced aluminum matrix composites such as silicon carbide in the form of particles, plates (small size), or in the form of whiskers, for example, are of interest due to their higher stiffness, wear resistance and high temperature strength compared to aluminum.
In the present invention, a metal matrix composite body is produced by a self-generated vacuum technique. in which the molten matrix metal impregnates a permeable mass of filler or a preformed preform, which is placed in an impermeable container. In particular, the molten matrix metal and the reactive atmosphere are both bonded to the permeable mass at least at some stage during the processes in contact between the reactive atmosphere and the matrix metal and / or filler or preformed workpiece and / or impermeable container , a vacuum is generated leading to the molten metal being impregnated with the filler or preformed workpiece.
In a first preferred embodiment, the reaction system comprises incorporating an impermeable container and a filler contained therein, contacting the molten matrix metal in the presence of a reactive atmosphere, and sealing means for sealing the reaction system from the surrounding atmosphere. The reactive atmosphere interacts, either partially or completely, with the molten matrix metal and / or the filler and / or the impermeable container, forming a reaction product that can create a vacuum, thereby drawing the molten matrix metal at least partially into the filler. The interaction, including the reactive atmosphere and the molten matrix metal and / or filler and / or impermeable container, may continue over time. sufficient to allow the molten matrix metal to either partially or substantially completely impregnate the filler or preformed workpiece. An external sealing means may be provided for sealing the reaction system having a composition different from the matrix metal.
In another preferred embodiment, the matrix metal may react with the surrounding atmosphere to form an internal chemical sealant having a composition. different from matrix metal, which seals the reaction system from the surrounding atmosphere.
In yet another embodiment, instead of providing an external sealing means for sealing the reaction system, an internal physical insulating layer may be formed due to the matrix metal wetting the impermeable container, thereby sealing the reaction system from the surrounding atmosphere.
“In addition, you can include fusion additives a matrix metal, which facilitate the wettability of the impermeable container with a matrix metal, thereby sealing the reaction system from the surrounding atmosphere.
In another preferred embodiment, the filler can interact, at least in part, with a reactive atmosphere, creating a vacuum that draws the decomposed matrix metal into the filler or preformed workpiece. Furthermore, additives can be included in the filler, which can react, either partially or substantially completely with a reactive atmosphere, creating a vacuum and enhancing the properties of the resulting body. In addition, in addition to or instead of filler and matrix metal, the impermeable container can at least partially react with a reactive atmosphere to generate a vacuum.
Used in this description and multi-link claims, the terms below are defined as follows:
Alloy side refers to that side of the metal matrix composite material that originally contacted the molten matrix metal before this molten metal saturates the permeable mass of the filler or preformed mold.
Aluminum means and includes mainly pure metal (for example, relatively pure, commercially available unmelted aluminum) or other types of metal or metal alloys, such as commercially available metals having impurities and / or alloying components, such as iron, silicon , copper, magnesium, manganese, chromium, zinc, and so on.
Ambient atmosphere refers to the atmosphere outside the filler or preformed workpiece and the impermeable container. It may have substantially the same constituent parts as the reactive atmosphere, or it may have excellent constituents.
A barrier or barrier means in connection with metal matrix composite bodies means any suitable means that interferes, inhibits, prevents or restricts the migration, movement of molten matrix metal beyond the surface boundary of the permeable mass of the filler or preformed workpiece, where such a surface boundary is determined by the specified barrier means . A suitable barrier agent may be any such material, compound, element, composite material, etc., which, under the conditions of the process, maintains some integrity and is not substantially volatile (i.e., this barrier material is not volatile to such an extent that it appears to be non-functional as a barrier).
A suitable barrier agent includes materials that are either wettable or not wetted when the molten matrix metal migrates, since wetting of the barrier medium does not occur substantially beyond the surface of the barrier material (i.e., a wetting surface). Apparently, a barrier of this type exhibits a substantially small (or none) means to the molten matrix metal, and movement beyond a certain surface boundary of the mass of the filler or preformed workpiece is prevented or inhibited by the barrier means. The barrier reduces any final machining or grinding that may be required, and indicates at least a portion of the surface of the final metal matrix composite product.
Bronze means and includes an alloy rich in copper, which may include iron. tin, zinc, aluminum, silicon, beryllium, magnesium and / or lead. Certain bronze alloys include those alloys in which part of the copper is about 90 wt.%, Part of silicon is about 6 wt.% And part of iron is about 3 wt.%.
A carcass or Carcass matrix metal refers to any original body of the remaining matrix metal that is not consumed during the formation of the metal matrix composite body, when cooled, remains at least in partial contact with this metal matrix composite body that forms. It should be understood that the frame may also include a second or foreign metal.
Cast iron belongs to the family of ferrous alloys in which part of the carbon is at least about 2% by weight.
Copper refers to commercial grades of substantially pure metal, for example 99% by weight of copper with various amounts of impurities contained therein. Moreover, this also applies to metals, which are alloys or intermetallic compounds that do not fall within the definition of bronze, and which contain copper as the main component of it.
The filler includes either individual constituent parts, or mixtures of constituent parts, which are mainly non-reactive with the matrix metal and / or limited to solutions in the matrix metal and can be single-phase or multi-phase. Fillers can be presented in the form of a wide range of forms: powders, flakes, plates, microspheres, whiskers, bubbles, etc., and can be either dense or porous. The filler may also include ceramic fillers, such as alumina, or silicon carbide. In the form of fibers, particulate fibers, whiskers, bubbles, spheres, fiber mats or the like, and coated ceramic fillers, such as coated carbon fibers aluminum oxide or silicon carbide in order to protect carbon from exposure to, for example, molten aluminum base metal. Fillers may also include metals.
Impermeable container means a container that can enclose or contain a reactive atmosphere and a filler (or preformed workpiece) and / or molten matrix metal and / or a sealing agent under the conditions of the method, and which is sufficiently impermeable to transport gaseous or vapor-collected impurities through the container, so that the pressure difference between the surrounding atmosphere and the reaction atmosphere can be established:
Matrix metal or Matrix metal alloy ”used here means that metal that is used to form a metal matrix composite material (for example, before impregnation) and / or that metal which is mixed with a filler to form a metal matrix composite body ( for example, after soaking). When a certain metal is referred to as a matrix metal, it should be understood that such a matrix metal includes that metal as a substantially pure metal, a commercially available metal having impurities and / or alloying constituents therein, an intermetallic compound or alloy in which said metal represents a major or dominant component.
Metallic Matrix Composite Material ”(MMC) means a material comprising a two- or three-dimensionally bonded alloy or matrix metal that is embedded in a preformed blank or filler. The matrix metal may include various alloying elements in order to provide, in particular, the desired mechanical and physical properties in the resulting composite material.
A metal other than "matrix metal" means a metal that does not contain the same metal as the main component as the matrix metal) for example, if the main component of the matrix metal is aluminum, then the different metal could have the main component e.g. nickel).
Preformed billet or Permeable preformed billet ”means a porous mass of filler or filling material that is produced with at least one surface boundary that substantially defines the boundary for impregnation with matrix metal, which mass retains a sufficiently uniform shape and primary strength in order to ensure dimensional accuracy without any external support prior to impregnation with matrix metal, the mass should be sufficiently porous In order to allow matrix metal impregnation, the Preformed blank typically includes the associated order or arrangement of the filler, either homogeneous or heterogeneous, and may include any suitable material ^ (e.g. ceramic and / or metal particles, powders, fibers, whiskers, etc. .d.
in any combination of them). A preformed blank can exist either on its own or as an assembly.
A reactive system refers to said combination of materials that demonstrate the absorption of molten metal through a self-generated vacuum into a filling material or preformed workpiece. The reaction system includes at least an impermeable container having a permeable mass of filling material or a preformed blank, a reactive atmosphere, and matrix metal.
Reactive atmosphere means an atmosphere that can react with a matrix metal and / or filler (or preformed blank) and / or an impermeable container to form a self-generated vacuum, thereby causing molten matrix metal to penetrate the filler material or preformed blank to form a self-generated vacuum .
A reservoir means a separate matrix metal body located relative to the mass of the filler or preformed workpiece so that when the metal is melted, it can flow in order to replenish, or in some cases initially stock up and subsequently replenish that portion, section or source of matrix metal that is in contact with the filler or preformed workpiece.
Sealant or Sealant refers to a gas-tight sealant under the conditions of a method either formed independently (eg, external sealant) or formed by a reaction system (eg, internal sealant) that isolates the surrounding atmosphere from the reaction atmosphere. The sealant or sealing agent may have a composition different from that of the matrix metal.
The sealant reliever used herein is a material that facilitates the formation of a sealant during the reaction of the matrix metal with the surrounding atmosphere and / or impervious container and / or filling material or preformed blank. This material can be added to the matrix metal, and the presence of a sealant facilitator in the matrix metal can improve the properties of the resulting composite body.
A wetting enhancer refers to any material that, when added to the matrix metal and / or the filling material or preformed workpiece, enhances the wetting (for example, reduces the surface tension of the molten matrix metal) of the filling material or preformed workpiece by the molten matrix metal. The presence of a wetting enhancer can also improve the properties of the resulting metal matrix composite body, for example, by improving the bonding between the matrix metal and the filling material.
The matrix metal in the molten state is in contact with the filling material or the preformed preform in the presence of a reactive atmosphere in an impermeable container, there may be interactions between the reactive atmosphere and the molten matrix metal and / or filling material or the preformed preform and / or the impermeable container, which leads to a reaction product (e.g., solid, liquid, or steam) that occupies a smaller volume than the original volume. occupied by reacting components. When the reactive atmosphere is isolated from the surrounding atmosphere, a vacuum can be created in a permeable filling material or a preformed blank that draws the molten matrix metal into the voids of the space of the filling material. Additionally, creating a vacuum can enhance wetting. Continuous interaction between the reactive atmosphere and the molten matrix metal and / or the filling material or the preformed preform and / or the impermeable container can lead to the matrix metal that impregnates the filling material or the preformed preform as additional vacuum is generated.
The interaction can continue for a time sufficient to allow penetration of the molten matrix metal, either partially or substantially completely, into the mass of the filling material or preformed workpiece. The filling material or preformed preform must be sufficiently permeable to allow the reactive atmosphere to penetrate, at least partially, into the mass of the filling material or preformed preform.
In particular, the self-generated vacuum regime was observed in the aluminum / air system, in the aluminum / oxygen system, aluminum / nitrogen system, and bronze / air system. bronze / nitrogen system, copper / air system, copper / nitrogen system and cast iron / air system. However, it should be understood that the matrix metal / reactive atmosphere systems, in addition to those systems, in particular those discussed in this invention, can behave similarly.
In order to implement the self-generated vacuum technique of the present invention, it is necessary that the reactive atmosphere be isolated from the surrounding atmosphere, so that the low pressure of the reactive atmosphere that exists during the impregnation would not have a substantially harmful effect on any gas transported from the surrounding atmosphere. The impermeable container that can be used in the method of the present invention may be a container of any size, shape and / or composition, which may or may not be reactive with the matrix metal and / or reactive atmosphere and which is impermeable to the surrounding atmosphere under the conditions of the method . In particular, the impermeable container may include any material (e.g., ceramic, metal, glass, polymer, etc.) that can withstand the process conditions so that it retains its size and shape, and which prevents or substantially inhibits the transport of the surrounding atmosphere through the container. When using a container that is impervious enough to transport the atmosphere through this container, it is possible to form self-generated air inside this container. Further, depending on the particular reaction system used, an impermeable container that at least partially reacts with a reactive atmosphere and / or matrix metal and / or filling material can be used to create or help create a self-generated vacuum inside this container.
A distinctive feature of a suitable impermeable container is freedom from pores. cracks or capable of reducing oxides, each of which can adversely affect the development or maintenance of a self-generated vacuum. Thus, it should be appreciated that a variety of materials can be used to form impermeable containers. For example, molded or cast aluminum oxide or silicon carbide can be used, as well as brooms having limited or low solubility in the matrix metal, for example stainless steel for aluminum, copper and bronze matrix metals.
In addition, in other cases, unsuitable materials, such as porous materials (for example, ceramic bodies), can be made impermeable by forming a suitable coating on at least parts of them. Such impervious coatings may be any of a wide variety of glazes and gels suitable for bonding and sealing such porous materials. In addition, a suitable impermeable coating may be liquid at process temperatures, in which case the coating material must be stable enough to remain impermeable under conditions of self-generated vacuum, for example, due to viscous adhesion to the container or filling material or preformed workpiece. Suitable coating materials include glassy materials (e.g. (B ₂ 0z), chlorides, carbonates, etc., provided that the pore size of the filler or preform is small enough that the coating can effectively block the pores to form an impermeable coating .
The matrix metal used in the method of the present invention can be any matrix metal that, when molten under the conditions of the method, penetrates the filling material or preformed workpiece when creating a vacuum filling material. For example, the matrix metal can be any metal or component inside the metal that reacts with a reactive atmosphere under the process conditions, either partially or substantially completely thereby causing the molten matrix metal to penetrate the filling material or preformed workpiece due to at least partial emergence of a vacuum in it. Further, depending on the system used, the matrix metal can either partially or substantially be non-reactive with a reactive atmosphere, and a vacuum can be created due to the interaction of the reactive atmosphere with one or more other components of the reaction system, thereby allowing the matrix metal to penetrate the filling material.
In a preferred embodiment, the matrix material can be fused with a wetting enhancer to facilitate the wetting ability of the matrix metal, thus, for example, helping to form a bond between the matrix metal and the filler, reducing porosity in the formed metal matrix composite material, reducing the amount of time required for full impregnation, etc. In addition, a material that includes a wetting enhancer can also act as a sealant facilitator, as described below, to help isolate the reactive atmosphere from the surrounding atmosphere. However, in addition, in another preferred embodiment, the wetting enhancer can be incorporated directly into the filling material instead of being alloyed with the matrix metal.
Thus, wetting the filling material with a matrix metal can enhance the properties (for example, tensile strength, erosion resistance, etc.) of a composite body. In addition, the wetting of the filling material with molten matrix metal can favor uniform dispersion of the filler throughout the formed metal matrix composite material and improved binding of the filler to the matrix metal. Useful wetting enhancers for aluminum matrix metal include magnesium, bismuth, lead and tin, etc., and for bronze and copper include selenium, tellurium, sulfur, etc. Moreover, as discussed above, at least one wetting enhancer can be added to the matrix metal and / or filler material in order to impart the desired properties to the resulting metal matrix composite body.
Moreover, it is possible to use a matrix metal reservoir to ensure that the matrix metal is completely saturated with the filler material and / or to supply a second metal that has a different composition from the first matrix metal source. In particular, in some cases, it may be desirable to use the matrix metal in a reservoir that is different in composition from the first matrix metal source. For example, if an aluminum alloy is used as the first source of the matrix metal, then virtually any other metal or metal alloy that melts at the processing temperature could be used as the metal for the tank. The molten metals often mix very well with one another and this should lead to the mixing of the tank metal with the first source of the matrix metal, since sufficient time is given for mixing to take place. Thus, using the metal in the tank, which differs in composition from the original source of the matrix metal, it is possible to adapt the properties of the matrix metal to meet various operational requirements and thereby adjust the properties of the metal matrix composite body.
The temperature at which the reaction system is exposed (e.g., processing temperature) may vary depending on which matrix metals, filling materials or preformed workpieces, and reactive atmospheres are used. For example, for an aluminum matrix metal, this self-generated vacuum method usually occurs at a temperature of at least about 700 ° C and preferably about 850 ° C or more. Temperatures above 1000 ° C are usually not necessary and. in particular, a useful range is from 850 to 1000 ° C. Temperatures of about 1050 ° to about 1125 ° C are useful for bronze or copper matrix metal, and temperatures of 1250 to 1400 ° C are suitable for cast iron. In general, temperatures that are above the melting point but below the evaporation point of the matrix metal can be used.
The composition and / or microstructure of the metal matrix can be adjusted during the formation of the composite material to impart the desired characteristics to the resulting product. For example, for a given system, the conditions of the method can be selected to control the formation of, for example, intermetallic compounds, oxides, nitrides, etc. Further, in addition to adjusting the composition of the composite body, it is possible to modify other physical characteristics, for example, porosity, by controlling the cooling rate of the metal matrix composite body. In some cases, it may be desirable for the metal matrix composite material to be directly cured by placing, for example, a container containing the moldable metal matrix composite material on a cooled plate and / or selectively placing insulating materials near the container. In addition, additional properties (e.g. tensile strength) of the formed metal matrix composite material can be controlled by using heat treatment (e.g. standard heat treatment, which corresponds substantially to heat treatment for the matrix metal per se, or heat treatment that modifies partially or substantially).
Under the conditions used in the method of this invention, the mass of the filling material or preformed preform must be substantially permeable in order to allow the reactive atmosphere to soak or penetrate the filling material or preformed preform at some stage during the process prior to isolating the surrounding atmosphere from the reactive atmosphere. In the examples below, a sufficient amount of reactive atmosphere is contained within closely packed particles having particle sizes ranging from about 54 to about 220 grit. By providing such a filling material. a reactive atmosphere can either partially or substantially completely react after contact with the molten matrix metal and / or the filling material and / or the impermeable container, thereby creating a vacuum that draws the molten matrix metal into the filling material. Moreover, the distribution of the reactive atmosphere within the filling material still does not have to be substantially uniform, however, substantially uniform distribution of the reactive atmosphere can contribute to the formation of the desired metal matrix composite body.
The proposed method of forming a metal matrix composite body is applicable to a wide range of filling materials, and the choice of materials will depend to a large extent on such factors as matrix metal, processing conditions, reactivity of the molten matrix metal with a reactive atmosphere, reactivity of the filling material with a reactive atmosphere , the reactivity of molten matrix metal with an impermeable container and the properties laid mice for the target composite product. For example, when the matrix metal includes aluminum, the passing filler materials are (a) oxides (eg, aluminum oxide); (B) carbides (e.g. silicon carbide). (c) nitrides (e.g. titanium nitride). If there is a tendency for the filling material to interact harmfully with the molten matrix metal, then this interaction can be compensated by reducing the impregnation time and temperature or by providing non-reactive special coating on the filler. The filler material may include a substrate such as carbon or other non-ceramic material that is coated with ceramic to protect the substrate from exposure or degradation. Suitable ceramic coatings include oxides, carbides and nitrides. Creams that are preferred for use in this method include alumina and silicon carbide in the form of particles, plates, whiskers and fibers. The fibers can be continuous (in crushed form) or in the form of continuous filaments, such as multifilament bundles. In addition, the composition and / or shape of the filling material or preformed workpiece may be homogeneous or heterogeneous.
The size and shape of the filling material may be any that may be required in order to achieve the desired properties. In the composite. Thus, the material may be in the form of particles, whiskers, lamellae or fibers, since the impregnation is not limited to the shape of the filling material. Other forms may be used, such as spheres, cylinders, tablets, refractory fibrous weaves, and the like. In addition, the size of this material does not limit the impregnation, although a higher temperature or a longer period of time may be required in order to obtain a complete impregnation of the mass of smaller particles than for larger particles. An average filler material size ranging from less than 24 grit to about 500 grit is preferred for most technical applications. In addition, by controlling the size (e.g., particle diameter, etc.) of the impermeable mass of the filling material or the preformed blank, the physical and / or mechanical properties of the molded metal matrix composite material can be adjusted in order to satisfy an unlimited number of industrial applications.
By combining the filling material including the variable particle sizes of the filling material, it is possible to achieve a higher packing of the filling material to obtain a composite body with desired properties. It is also possible to obtain lower particle filling by mixing the filling material (eg, shaking the container) while soaking and / or by mixing the powdered matrix metal with the filling material for soaking.
The reactive atmosphere used in the method of this invention can be any atmosphere that can react, at least partially or substantially completely, with molten matrix metal and / or filling material and / or an impermeable container, forming a reaction product that occupies a volume, which is less than the volume occupied by this atmosphere and / or reaction components before the reaction. In particular, a reactive atmosphere in contact with the molten matrix metal and / or filler material and / or impermeable container can react with one or more components of the reaction system, forming a solid, liquid or vaporous reaction product that takes up less volume than the volume of the individual individual components thereby creating a void or vacuum that facilitates the retraction of the molten matrix metal into the filling material or preformed workpiece. The interaction between the reactive atmosphere and one or more matrix metal and / or the filling material and / or the impermeable container may continue for a time sufficient for the matrix metal to impregnate, at least partially or substantially completely, the filling material. For example, when air is used as a reactive atmosphere, the interaction between the matrix metal (eg aluminum) and air can lead to the formation of reaction products (eg alumina and / or aluminum nitride, etc.). Under the conditions of the method, reaction products tend to occupy a smaller volume than the total volume occupied by molten aluminum, which reacts with air. As a result of the reaction, a vacuum is generated, thereby causing the molten matrix metal to penetrate into the filling material or the preformed workpiece. Depending on the system used, the filling material and / or impermeable container can react with a reactive atmosphere in a similar way, generating a vacuum, thereby helping the molten matrix metal to penetrate the filling material. The reaction with a self-generated vacuum can continue for a time sufficient to lead to the formation of a metal matrix composite body.
In addition, it was found that the sealant or sealant should prevent or limit the gas flow from the surrounding atmosphere into the filling material or preformed workpiece blank (e.g., prevent the surrounding atmosphere from flowing into the reactive atmosphere).
The reactive atmosphere inside the impermeable container and the filling material must be sufficiently isolated from the surrounding atmosphere so that, as the interaction between the reactive atmosphere and the molten matrix metal and / or the filling material or the preformed blank and / or the impermeable container occurs, the pressure difference between the reactive and surrounding atmospheres until the desired impregnation is achieved. It should be understood that the isolation between the reactive and ambient atmospheres should not be perfect, but rather only sufficient, so that there is a difference in pressure in the grid (for example, the vapor phase could flow from the surrounding atmosphere to the reactive atmosphere as long as the speed the current would be lower than that necessary to immediately replenish the reactive atmosphere). Part of the necessary isolation of the surrounding atmosphere from the reactive atmosphere is provided by the impermeability of the container. Since most matrix metals are also impervious to the surrounding atmosphere, a reservoir with molten matrix metal provides another part of the necessary insulation. It is important to note, however, that the interface between the impermeable container and the matrix metal may provide a path for leakage between the surrounding and reactive atmospheres. Thus, the sealant must provide sufficient sealing to inhibit or prevent such leakage.
Suitable sealants or sealing agent can be classified as mechanical, physical, or chemical, and each of them can, in addition, be classified as either external or internal. By external they mean that the sealing action occurs independently of the molten parent metal, or in addition to any sealing action provided by the molten matrix metal (e.g., from a material added to other elements of the reaction system). By internal they mean that the sealing action arises exclusively from one or more characteristics of the matrix metal (eg, from the ability of the matrix metal to wet an impermeable container). An internal mechanical sealant can be molded simply by providing a sufficiently deep reservoir of molten matrix metal or a preformed workpiece.
However, it has been found that external mechanical sealants are ineffective in a number of applications and they may require excessively large amounts of molten matrix metal. In accordance with this invention, it was found that the external sealants and the physical and chemical classes of internal sealants overlap these disadvantages of the internal mechanical sealant. In a preferred embodiment of the external sealant, the sealing agent can be applied externally to the surface of the matrix metal in the form of a solid or liquid material, which under the conditions of the method can be substantially unreactive with the matrix metal. It is found that such an external sealant prevents. or at least sufficiently inhibits the transport of vapor-phase constituents from the surrounding atmosphere to the reactive atmosphere. Suitable materials for use as an external physical sealant may be either solids or liquids, including glass (e.g. boron or silicon glasses, B2O3, molten oxides, etc.) or any other material (s) that is sufficient inhibits the transport of the surrounding atmosphere to the reactive atmosphere at the conditions of this method.
'' The external mechanical sealant can be molded by pre-leveling or pre-polishing or by other means forming the inner surface of the impermeable container in contact with the matrix metal container, so that the gas transport between the surrounding atmosphere and the reactive atmospheric is sufficiently inhibited. Glazes and coatings, such BrOz. which can be used in the container to make it impermeable, can also provide lead-in sealing.
External chemical sealant can be obtained by placing the material on the surface of the molten matrix metal, which reacts with, for example, a permeable container. The reaction product may include an intermetallic compound. oxide, carbide, etc. In a preferred embodiment of the internal physical sealant, the matrix metal may react with the surrounding atmosphere to form a sealant or sealant having a composition different from that of the matrix metal. For example, in the reaction of a matrix metal with an ambient atmosphere, a reaction product (e.g., MgO and / or magnesium-aluminate spinel in the case of the interaction of an Al-Mg alloy with air or copper oxide in the case of interaction of a bronze alloy with air) may be formed, which can seal a reactive atmosphere from the surrounding atmosphere. In another embodiment of an internal physical sealant, a sealant facilitator may be added to the matrix metal to promote the formation of sealant during the reaction between the matrix metal and the surrounding atmosphere (e.g., by adding magnesium, bismuth, lead, etc. for aluminum matrix metals, or by adding selenium, tellurium, sulfur, etc. for copper and bronze matrix metals. When forming an internal chemical sealing agent, the matrix metal can interact with a container (e.g., by partially melting the container or coating it (internal) or by forming a reaction product or intermetallic compound, etc., which can seal the filling material from the environment.
In addition, it should be appreciated that the sealant must be able to correspond to volumetric (i.e., either expansion or reduction) or other changes in the reaction system, preventing the surrounding atmosphere from flowing into the filling material (e.g., flow into a reactive atmosphere). In particular, since the molten matrix metal is absorbed into the permeable mass of the filling material or the preformed preform, the depth of the molten matrix metal in the container tends to decrease. A suitable sealant for such a system should be sufficiently flexible to prevent the transport of gas from the surrounding amosphere into the filling material, since the level of molten matrix metal in the container is reduced.
A barrier agent may also be used in combination with this invention. In particular, the barrier agent that can be used in the method of this invention may be any suitable agent that interferes, inhibits, inhibits or restricts the migration, movement, or the like, of molten matrix metal beyond a certain surface boundary of the filling material. A suitable barrier agent may be any mineral, compound, element, composition or the like, which is under the conditions of the method of this invention. retains some structural integrity. It is non-volatile and capable of locally inhibiting, stopping, interfering. prevent, etc., continuous absorption or any other kind of movement beyond a certain surface boundary of the filling material. The barrier agent can be used during the impregnation using a self-generated vacuum or in any impermeable container used in connection with the self-generated vacuum technique to form metal matrix composite materials, as discussed in more detail below.
A suitable barrier agent includes materials that are either wettable or non-wettable during migration, melting on the matrix metal under the conditions of the method used, since wetting of the barrier means does not substantially occur outside the surface of the barrier material (i.e., wetting surface). Apparently, a barrier of this type exhibits little or no means to the molten matrix alloy, and movement beyond a certain boundary of the surface of the filling material or preformed workpiece is prevented or inhibited by barrier affinity. This barrier reduces any final machining or grinding. which may be required by the metal matrix composite product.
Suitable barriers, especially useful for aluminum matrix metals, are barriers containing carbon, especially the crystalline allotropic form of carbon, known as graphite. Graphite is not substantially wetted by the molten aluminum alloy under the conditions being measured. A particular preferred garfite is graphite tape, a GRAFOLlA product, which exhibits characteristics that prevent the migration of molten aluminum alloy over a defined surface boundary of the resembling material. This graphite tape is also heat resistant and is substantially chemically inert. Graphite tape is movable, compatible, accept-. It has various shapes and is resilient, and various shapes can be made from it that will fit most any barrier applications. A graphite barrier agent can be applied in the form of a suspension or paste, or even as a separating film around or at the boundary of the filling material or preformed blank. GRAFOLl ^ b tape in particular is preferred because it is in the form of a movable graphite sheet. One way to use this paper-like graphite sheet material is to wrap a filler material or preformed material to be impregnated with a layer of material. Alternatively, the graphite sheet material may be formed into the inverse configuration shape that is desired for the metal matrix composite body and this inverse shape may then be filled with filling material.
In addition, other finely divided particles of materials, such as 500 grit aluminum oxide, can function as a barrier in certain situations, since the impregnation of the barrier material from the particles must occur at a rate that is lower than the rate of impregnation of the filling material.
The barrier means can be applied in any suitable way, such as coating a certain surface boundary with a layer of barrier means. Such a layer of barrier agent can be applied by dyeing, dipping, sifting through silk, by evaporation, or in other cases applying a barrier agent in liquid form, in the form of a suspension or paste, or by spraying a vaporous barrier agent, or by simply applying a layer of solid barrier agent in in the form of particles, or by applying a solid thin sheet or film of a barrier agent to a specific surface boundary. In the case of a barrier agent in place, self-generated vacuum impregnation is substantially limited, in cases where the impregnating matrix metal reaches a certain surface boundary and is in contact with the barrier agent.
This method of forming a metal matrix composite material by the self-generation technique of vacuum, in combination with the use of a barrier means, provides significant advantages over the prior art. In particular, using the method of the present invention, a metal matrix composite body can be obtained without the need for expensive or complex technology. In one aspect of the invention, the impermeable container may comprise a filling material or preformed workpiece of a desired shape, a reactive atmosphere and a barrier means for stopping the impregnation of the metal matrix composite material beyond the surface of the resulting molded composite body. Upon contact of the reactive atmosphere with the matrix metal, which can be poured into an impermeable container and / or the filling material under the conditions of the method, a self-generated vacuum can be created, thereby causing the molten matrix metal to penetrate into the filling material. The instant method avoids the need for complex configurations, preserving molten metal baths, removing formed pieces from complex configurations, etc. Further, the movement of the filling material by the molten matrix metal is substantially reduced by providing a stable container that is not immersed in the molten metal bath.
Figure 1 A is a schematic cross-sectional view of typical stacked sheets in a bag, according to the method of the present invention, which uses an external sealing means;
Figure 1 B is a schematic cross-sectional view of comparative stacked sheets in a bag;
Figure 2 is a simplified flowchart of the method of the present invention applied to standard sheet stacking;
FIG. ZA is a photograph that corresponds to a product formed according to FIG. 1A:
FIG. 3B 'is a photograph that corresponds to a product molded according to FIG. 1 B;
Fig. 4A is a photograph that corresponds to a bronze metal matrix composite material obtained according to Fig. 1A;
FIG. 4 corresponds to the result that is achieved with a bronze matrix metal corresponding to FIG. 1B;
5 is a schematic cross-sectional view of stacked sheets in a bag used to make sample P;
6 is a schematic cross-sectional view of stacked sheets a bag used to make sample U;
7 shows a series of micrographs corresponding to samples made according to example 3;
Fig. 8 is a series of world photographs that correspond to Example 6;
Fig.9 'is a series of micrographs that correspond to example 7;
FIG. 10 is a series of micrographs that correspond to example 8;
Fig 11 is a series of micrographs that correspond to example 9;
12A and 12B are cross-sectional views of stacked sheets in bags used according to Example 10
Fig.13 is a graph of the magnitude of the vacuum as a function of time, according to the sample AK and sample AL;
Figa and 14B correspond to the products obtained according to samples AK and AL, respectively;
Fig is a graph of the magnitude of the vacuum against time for example 14;
FIG. 16 is a cross-sectional view of stacked sheets used in accordance with Example 18, Sample AU.
Example 1. This example demonstrates the feasibility and humidity of using an external sealant that is involved in the formation of an aluminum metal matrix composite material. In particular, two similar sheet packs were made. The only difference between the two sheet packs was that one sheet pack was provided with the material forming the external sealant, and the other was not provided with the material forming the external sealant.
FIGS. 1A and 1 show that the packs of sheets were identical, except that FIG. 1 A includes the use of an external sealing material 34. As shown in each of FIGS. 1 A and 1B, two impermeable containers 32 having an inner diameter of about 2 3/8 inches (60 mm) and a height of about 2 1/2 inches (64 mm) were constructed from 16 gauge (1.6 mm thick) stainless steel A1 1 Type 304. Each of the 32 containers was made by welding 16 caliber (1.6 mm thick) tubes, stainless steel 35, having about 2 3/8 inches (60 mm) inner diameter and about 2 1/2 inches mA (64 mm) length with a stainless steel plate 36 measuring 3 1/4 (83 mm) x 3 1/4 (83 mm) inches 16 gauge (1.5 mm thick). Each of the impermeable containers 32 was filled with about 150 g of filler material 31, including 90 grit of an alumina product known as Alundum 38A1 from Norton Co. Approximately 575 g of molten matrix metal 33, including a commercially available aluminum alloy, designated 170.1, is poured into a container 32. Each of which is at room temperature in order to cover the filling material 31. The molten matrix metal is at a temperature of about 900 ° C. The molten matrix metal 33 is then coated with a material forming a sealant 34 (FIG. 1 A). In particular, about 20 g of BrO3 powder from Aesar Co, of Seabrook, NH, is placed in molten aluminum matrix metal 33. Each of the experimental sheet packs is then placed in a chamber of a resistance furnace with heated atmospheric air, which is preheated to a temperature of 900 ° C. After 15 minutes at the temperature BrO3, material 34 is substantially completely melted, forming a glassy layer. In addition, any water that was in B2O3. substantially completely removed, thereby forming a gas-tight sealant. Each of the sheet packages shown in FIGS. 1 A and 1 B is kept in an oven for an additional 2 hours at 900 ° C. After that, both packages of sheets are removed from the furnace and the plate 36 of the container 32 is placed by direct contact on a copper plate cooled by cold water for directionally curing the matrix metal.
Each of the packs of sheets was cooled to room temperature and then a cross section was made in order to determine if the matrix metal 34 had infiltrated the filler material 31 to obtain a metal matrix composite material. It was observed that the stack of sheets shown in FIG. 1A, which used a sealing material, formed a metal matrix composite, while the lithium stack, shown in FIG. 1 B., which did not use a sealing material 34, did not form a metal, matrix composite material. In particular, FIG. 3A is a photograph that corresponds to the product formed according to FIG. 1A, while FIG. 3B is a photograph that corresponds to the result of FIG. 1B. FIG. 3A shows that the aluminum metal matrix body is a composite body 40 formed and a small amount of residual matrix metal 33 remains attached to it. In addition, FIG. 3B shows that no metallic matrix composite body is formed. In particular, FIG. 3B shows a cavity 41, which corresponds to the initial position of the filling material 31 shown in FIG. 1B. When the cross-section of the container 32 was made, the filling material 31 falls out of the container 32. because the filling material 31 was not impregnated with the matrix metal 33.
Example 2. This example demonstrates the feasibility and importance of using an external sealant that promotes the formation of a bronze metal matrix composite body. The experimental technique and stacking of sheets in packages discussed in Example 1 is basically repeated except that. that the matrix metal includes a bronze alloy with 93 wt.% Si, 6 wt.% SI and 1 wt.% Fe. The composition and amount of the filling material 31 were basically the same as those discussed in Example 1. In addition, the stainless steel container 32 and B2O3 sealant forming material were substantially identical to the same materials in Example 1. The bronze matrix metal 33 was previously heated to a temperature of 1025 ° C, to melt it before it is poured into a container 32 at room temperature. Each of the sheet packs, enclosed in stainless steel 32 containers, and their contents, are placed in the same chamber of the resistance furnace with the heated air of the atmosphere used in Example 1, except that the furnace is preheated to a temperature of 1025 ° €. The oven temperature is then raised to 1100 ° C for 20 minutes, and during which the B2O3 powder melts, degasses, and forms a gas-tight sealant. Both packs of sheets were then held at 1100 ° C for approximately 2 hours. Each of the packs of sheets was removed from the oven and plate 36 of container 32 was placed directly on a water-cooled copper cooling plate for directionally curing the matrix metal.
Each of the packs of sheets was cooled to room temperature and then a cross section was made to determine if the bronze matrix metal 33 penetrated into the filling material 31, forming a metal matrix composite material. Similar to what was observed in example 1, a sheet package using B2O3 sealing material 34 forms a bronze metal matrix composite material, while a container without B2O3 sealing material 34 does not form a metal matrix composite material. In particular, FIG. 4A shows a bronze metal matrix composite body 42, which is formed27 using the stack of sheets shown in FIG. 1 A; while FIG. 4B shows a cavity 43 that corresponds to the initial position of the material 31 shown in FIG. 1 B. Analogously to Example 1, the non-impregnated material 31 drops out of the container 32. when the container 32 is cut in the transverse direction.
EXAMPLE 3. This example demonstrates the importance of using a gas-tight container, which is involved in the formation of aluminum metal matrix composite materials. In particular, one gas permeable and four gas impermeable containers are compared. Four impermeable containers include a 16 gauge A1S1 impermeable type 304 stainless steel container, a commercially available glazed coffee cup. 16 gauge A1S1 type 304 stainless steel container, commercially available glazed coffee cup, 16 gauge AtSi type 304 stainless steel container, coated inside B2O3 and glazed AI2O3 body. The permeable container includes a porous clay crucible. Table 1 provides a summary of the relevant experimental parameters.
Sample A
A Type 304 stainless steel container, having an internal diameter of about 2 3/8 (60 mm) inches and a height of about 2 1/2 (64 mm) inches, fills approximately 150 g of 90 Nundon Co Alundum machine 38. An aluminum matrix metal having a composition (wt.%) Of 7.5-9.5% SI, 3.0-4.0 Cu, <2.9% Zn, 2.2-2.3% Mg. <1.5% Fe, <0.5 Μη, <0.35 Sn and balance A1. it melts in a resistance furnace chamber with heated atmospheric air at about 900 ° C and is poured into a stainless steel container. Powdered B2O3 by Aesar Co. Aesar Co. used to coat the surface of molten aluminum. (The package of sheets was the same as that shown in figa). A package of sheets, including the container and its contents, is placed in the chamber of a resistance furnace with heated atmospheric air at 900 ° C. After 15 minutes at a temperature of B2O3, the powder mostly melts and precipitates, forming a gas-tight sealant above the surface of the aluminum matrix metal. The packet of sheets is kept in the furnace for an additional 2 hours. The packet of sheets is removed from the furnace and placed on a water-cooled copper cooled plate for directionally curing the matrix metal.
Sample B.
The procedure presented for sample A is repeated, except that the container 32 (shown in FIG. 1 A) includes a commercially available glazed coffee cup.
Sample C.
An impermeable container having an inner diameter of about 1.7 inches (43 mm) and a height of about 2.5 inches (64 mm) and made of 16 gauges (1.6 mm thickness (A 1 1 Type 304 stainless steel, is coated on the inside with a layer of B2O3 powder from Aesar Co. of Johnson Matlhey In Seabrook. NH. In particular, about 1/2 inch (13 mm) of B2O3 powder is placed in a container. The container is then placed in a resistance furnace with a heated air atmosphere set at about 1000 ° C. Enough time is given for B2O3, so that it will mainly melt and leave. Immediately after melting , the stainless steel container with molten B2O3 is removed from the furnace and rotated so that the molten B2O3 spreads mainly throughout the inside of the stainless steel container.In the case of a surface that is mostly completely coated, filling material comprising 54 grit S1C 39 Crystolon from the Norton is placed inside the container, which is then at a temperature of about 90 ° C, to a depth of about 3/4 inch (19 mm). A molten matrix metal consisting of commercially pure aluminum and referred to as alloy 1100 is poured into a container to a depth of about 3/4 inch (19 mm) to cover the filling material. The B2O3-coated container and its contents are then placed in a chamber of a resistance furnace with heated atmosphere air, set at about 1000 ° C for about 15 minutes. About 20 g of B2O3 powder is then placed on the surface of the molten matrix metal. After holding for about 15 minutes at a temperature, the B2O3 powder is mostly completely melted and degassed to form a sealant. The package of sheets is kept additionally in the oven for one hour. The stainless steel container and its contents are then pulled out of the oven and allowed to cool to room temperature and cure.
Sample D.
An impermeable container of cylindrical shape with dimensions of about 6 inches (152 mm) in height and having an outer diameter of 2 inches (51 mm) is made. In particular. the container is made by casting an impression, which includes a mixture of about
84.2% by weight _of A120s (A1-7 from Alcoa. Pittsburg, RA), about 1% by weight of Darvan 821A ”(supplied by P.T. Vanderbilt and Company, Norwalk, CT) and about 14.8 wt. % distilled water. The impression is made by grinding balls in a vessel with a capacity of 5 gallons (18.9 L), which is about 1/4 filled with about 1/2 inch (13 mm) of oxide with an aluminum grinding medium, for about 2 hours.
The cast cylinder is dried at ambient temperature for about 1 day. subsequently heated to 1400 ° C at a rate of about 200 ° C / h and kept at about 1400 ° C for 2 hours and again cooled to ambient temperature. After annealing and cooling from the outside, the cylinder is impregnated with a coating mixture containing, by weight, about 60% 1T-79 cake (supplied by Fusion Ceramics Carrollton OP) and the rest is ethanol. The cake coating the cylinder is then heated and cooled at a rate of about 200 ° C./h to 1000 ° C. in a resistance heating furnace. To cover the cylinder with glaze AI2O3 and make it gas tight, immediately after cooling, the glaze-coated matrix is filled with 90 grit 39. A sheet package including the glaze-coated matrix and its contents are then placed in a furnace and heated to about 950 ° C at a speed of about 200 ° C / h While in the furnace, the molten matrix metal, including about 10% by weight of magnesium, about 10% silicon and the remainder of aluminum by weight, is poured into molds. Then, powdered B ₂ 0z poured onto the surface of the molten matrix metal. After about an hour of exposure at about 950 ° C, the furnace is cooled to about 850 ° C and at this time the matrix and its contents are removed from the furnace, cured and quenched with water. The matrix, including the body of aluminum oxide, coated with glaze, breaks and exfoliates during a sharp cooling. revealing a metal matrix composite material with a smooth surface.
After the room temperature is reached, each of the packs of sheets is cut in the transverse direction in order to determine whether the matrix metal is saturated with the filler material to form a metal matrix composite material. In each of the AD samples, a metallic matrix composite material is formed.
Sample E.
The procedures described above in sample A. are followed except that the container shown in FIG. 1A includes a porous clay crucible (DFC crucible No. 28-1000, from I.H. Borge Co., South Plainfield NT). A metal matrix composite body does not form. Thus, this example demonstrates the need for an impermeable container.
Example 4. This example demonstrates the importance of using a gas-tight container that is involved in the formation of bronze metal matrix composite materials. In particular, one gas permeable and two gas impermeable containers are compared. Two impermeable containers include A1S1 Type 304 stainless steel tanks and carbon steel containers coated with colloidal graphite. The permeable container includes a porous clay crucible. Table 1 provides a summary of the corresponding experimental techniques.
Sample F.
A Type 304 stainless steel container having an inner diameter of about 2 3/8 inches (60 mm) and a height of about 2 1/2 inches (64 mm) is filled with approximately 150 g of 90 mesh 38 Alundum from Notron Co. The matrix metal, comprising about 6% by weight of SI, 1% by weight of Fe and the remainder of Cu, is melted in a furnace chamber with atmospheric air of at least about 1025 ° C. and poured into a stainless steel container. Powdered B ₂ Oz from Aesar Co is used to coat the surface of molten bronze. A packet of sheets is placed in a heated chamber of a resistance furnace at about 1025 ° C. Then the furnace temperature is raised to about -1100 ° C over about 20 minutes and during this time the B2O3 powder melts substantially completely, degasses and forms a gas-tight sealant above the surface of the bronze matrix metal. After an additional 2 hours, a packet of sheets is transferred from the furnace and brought into contact with a water-cooled copper cooling plate. ^{1 1} to direction harden the matrix metal.
Sample C.
An impermeable container having a trapezoidal cross-section with a closed bottom measuring about 3 by 3 inches (76 by 76 mm) and an open end measuring about 3.75 by 3.75 inches (92 by 92 mm) and about 2.5 inches high mm), made of 14 gauge (2 mm thickness) carbon steel by welding the individual parts with each other. The inner surface of the container is coated with a graphite mixture comprising about 1.5 hours by volume of ethanol from Pharmo Products, inc., Boyonno. NI. and about 1 hour by volume 154 colloidal graphite from Athesan. Colloids, Port Horon MN, At least three coatings of the graphite mixture are applied with a paintbrush on the inside of the container. Each coating of the graphite mixture is dried before the next coating is applied. The coated container is placed in a resistance furnace in heated atmospheric air, set at about 380 ° C for about 2 hours. About 1/2 inch (13 mm) of alumina filling material including 90 grit El Alundum from Norton Co is placed on the bottom of the container and well leveled. The leveled surface of the alumina filler material is then substantially completely coated with a graphite tape having a thickness of about 0.01 inches (0.25 mm) (VG-25-N throat graphite tape from TT America 1 ps, Portland, OR sold under the trade name Ferma- foll: About 1/2 inch (13 mm) of the molten matrix metal, including about 6% silicon, about 0.5% Fe, about 0.5% AI, and about 0.5% AI and the rest of copper by weight, is poured into a container at room temperature on a graphite tape and filling material aluminum oxide About 20 g of BrO3 powder are poured onto the melt a bronze matrix metal, a package of sheets, including a carbon steel container and its contents, is placed in a chamber of a resistance furnace with heated atmospheric air at a temperature of about 1100 ° C. After about 2.25 hours at about 1100 ° C and during which B2O3 it melts substantially completely, degasses and forms a sealant, a carbon steel container and its contents are transferred from the furnace and placed on a water-cooled copper cooling plate for directional curing of the matrix metal. Although the molten matrix metal dissolves a portion of the plane of the carbon steel container, the metal matrix composite body is removed from the sheet stack.
Sample N.
The procedures described above for sample F are followed, except that container 32 (shown in phi. 1A) includes porous clay crucible DFC container No. 28-1000, from I.H. Berge Co., South Plainfield. N1, and a packet of sheets is placed directly in the oven at 1100 ° C, rather than 1025 ° C, followed by heating. As soon as the room temperature is established, each of the stacks of sheets corresponding to samples F, CuN is cut in the transverse direction. to determine if the matrix metal has infiltrated the filling material to form a metal matrix composite body. It was observed that sheet packs corresponding to samples F and C create favorable conditions for the formation of a metal matrix composite body, while a sheet pack corresponding to sample H with a gas-tight clay crucible does not create favorable conditions for the formation of a metal matrix composite body.
This example illustrates the need for a gas-tight container to connect with a gas-tight sealant to create conditions conducive to the formation of a self-generated vacuum, which is the cause of the metal matrix composite.
Example 5. This example demonstrates that a number of matrix metals 33 can be used in combination with a gas-tight container 32 and a gas-tight sealant 34 to create conditions favorable for the formation of metal matrix composite bodies. Table 2 contains a summary of the experimental conditions used to obtain a variety of metal matrix composite bodies, including various matrix metals 33, filling materials 31, containing means 32, processing temperatures and processing times.
Samples 1-M.
For samples of 1-M package of sheets shown in figure 1 A. and the stages set forth in example 1, e basically repeat. The amount of filler used for each of these sheet packs is about 150 g, while the amount of alloy is about 525 g. Metal matrix composite bodies are successfully obtained from each experimental sheet pack.
Samples 1-0.
For samples N and O, the method of example 1 is basically repeated, except that the temperature of the furnace is about 1100 ° C.
Sample R.
The experimental sheet package used for sample P is slightly different from all previous experimental sheet packages discussed above. The entire package of sheets is constructed at room temperature and placed at room temperature in an electric resistance furnace. In particular, as shown in FIG. 5, a dense sintered alumina crucible 32 of about 4 inches (102 mm) in height and having an inner diameter of about 2.6 inches (66 mm) from Bolt Ceramie of Conrol TX is used as impermeable container. Ninety Grit 38 Alundum AI2O3 Filler 31 from Norton Co. placed on the bottom of the crucible 32. A solid cylindrical matrix metal ingot 33. comprising gray cast iron (A TM A-48, grade 30.35) is placed on top of the filling material 33 so that a gap is formed between the matrix metal 33 to the side walls of the container 32. The patch Paris 39 (Bondex from International Inc .. Brunswick. OH) is placed in part of the gap 38 near the top of the cast iron ingot 33 inside the container 32. In addition, the Parisian patch 39 acts to isolate the powdered 82O3 34, which is placed on the upper surface of the matrix metal 33. from the filling material 31. thereby promoting the formation of a sealing agent under the conditions of the method. The packet of sheets shown in Figure 5 is placed in a resistance heating furnace with atmospheric air and a heating temperature of up to about 1400 ° C for about 7 hours at which time B2O3 34 mainly melts, degasses, and forms a gas-tight sealant over molten cast iron 33. When melting level of molten iron
33. As observed, drops after about 4 hours at temperature. A stack of sheets 30 is removed from the oven and cooled.
Samples of OT.
For O-T samples, the sheet stack shown in FIG. 1A and the steps set forth in Example 1 are basically repeated. The specific parameters of the matrix metal, filling material, container, temperature and time are set forth in Table 2.
Sample.
The experimental sheet package used for the sample is slightly different from all previous experimental sheet packages. Like sample P., the entire package of sheets is constructed at room temperature and placed in an electric resistance heating furnace at room temperature. In particular, as shown in FIG. 6, a thick, sintered alumina crucible 32 of about 1.5 inches (38 mm) high and having an inner diameter of about 1 inch (25 mm) from Bolt Ceramics of Conrol TX is used as an impermeable container . Silicon carbide filler material 31, known as Crystalon 39, having a grain size of 54. is mixed with about 25 wt.% 325 mesh of copper powder (from Consolidated Astranautles and the mixture is poured into container 32 to a depth of about 1/2 inch (13 mm). The ground copper 33 from alloy C 811 (i.e. basically pure copper wire that is ground into many pieces) is placed on top of the filling material31 to a depth of about 1/2 inch, GRAFOIIl · graphite tape is then placed on top of the ground copper 33 so. to basically coat crushed copper. and 34 of about 50 wt.% B2O3 powder from Aesar Company and about 50 wt.% 220 grit AI2O3 known as 38 Alumdum from Notron Co. are placed on top of graphite tape 50 so as to completely cover the graphite tape 50. Sheet pack 37 shown in Fig.6, placed in a resistance heating furnace with atmospheric air and heated from room temperature to about 1250 ° C for 6 1/2 hours, and during this time the mixture of sealing means 34 is melted, degassed and forms a sealant on a molten copper matrix metal 33, and incubated at about 1250 ° C for 3 hours A stack of sheets 30 is removed from the oven and allowed to cool.
Each of the 1-U samples forms a suitable metal matrix composite body. Some physical properties of these samples are reported in Table 2.
In addition, micrographs obtained at about 400X are presented for some samples in Fig.7. In particular, figa shows a micrograph corresponding to sample 1; Fig. 7B shows a micrograph corresponding to sample R. Fig. 7C shows a micrograph corresponding to sample L; figo shows a micrograph corresponding to sample M; Fig. 7E shows a micrograph corresponding to sample N. Position 51 represents the filling material and position 53 represents the matrix metal.
Example 6. This example demonstrates that the self-generated vacuum technique can be used to seal aluminum matrix metal composite materials in a temperature range. The method described in example 1 is generally repeated, except that the matrix metal is an aluminum alloy having a composition of 7.5-9.5% Si. 3.0-4.0 Cu, <2.9% Zn. 2.22.3% Mg, <1.5% Fe, <0.5 Μη. <0.35 Sn and Al residue. As in example 1, 90 grit 38 Alundum.
'1831413
AI2O3 material from Co is used as filling material 31. Aluminum matrix metal 33 is poured into containers 52 at room temperature at three different temperatures. In particular, the matrix, metal l 33. is at three temperatures of 800.900 and 1000 ° C. As in the example, 1.15 minutes is given in order to melt the BrO3 powder, degass and form a gas-tight sealant. Each of the three containers 32 is placed in an electric resistance furnace with heated air, which operates at a temperature that mainly corresponds to the temperatures of the molten matrix metal, which is poured into the container 32 (i.e., 800.900 and 1000 ° C, respectively). After an additional 2 hours, each of the sheet packs is removed from the furnace and placed on a water-cooled copper cooling plate for directionally curing the matrix metal.
Once room temperature is reached, three packs of sheets are cut in the transverse direction to show that the matrix metal has saturated the filling material to form metal matrix composite bodies. In particular, FIGS. 3A, 8B and 8C are micrographs. made at 400X, which correspond to aluminum metal matrix composite bodies, which form at 800, 900 and 1000 ° C, respectively: 51 - filling material, 53 - matrix metal.
Example 7. This example demonstrates that the self-generated vacuum technique can be used to form bronze metal matrix composite materials in the temperature range. The package of sheets of the example is basically the same as that shown in FIG. 1 A. In addition, the method described in example 1 basically repeats, except that the matrix metal is a copper alloy (i.e., a bronze alloy ) having a composition of about 93 wt.% Cu. about 6 wt.% SI and about 1 wt.% Her. As in Example 1, 90 grit 38 Alundum AI2O3 material from Norton Co is used as filling material 31. The bronze matrix metal 33 is poured into two containers 32 at room temperature at two different temperatures. In particular, the matrix metal 33 was at temperatures of 1050 ° C and 1100 ° C. As in the example, 1.15 min for B2O3 so that it melts, degasses and forms a gas-tight sealant. Each of the two containers 32 is placed in a heated air resistance electric furnace, which operates at a temperature that mainly corresponds to the temperatures of the molten matrix metal 5 metal 33, which is poured into the container 32. After an additional 2 hours, each sheet packet is removed from the furnace and placed on a water-cooled copper plate for directional curing of the matrix metal 10.
Immediately upon reaching room temperature, the sheet packs are cut in the transverse direction to show that the matrix metal is impregnated with the filling material 15 to form metal matrix composite bodies. In particular, FIGS. EA and 9B are micrographs taken at 50X. which correspond to bronze metal 20 matrix composite bodies that are formed at 1050 and 1100 ° C, respectively. Pos. 51 - filling material, pos. 53 - matrix metal.
Example 8. This example demonstrates 25 that a variety of filling materials can be impregnated with an aluminum matrix metal using a self-generated vacuum technique. In particular, a sheet package similar to the package 30 shown in FIG. 1A is used in Example 8. In addition, the procedures described in Example 1 are followed up with the exception that the aluminum matrix metal has a composition of 35 7.5–9.5 % Si, 3.0-4.0% Cu. <2.9% Zn, 2.2. 2.3% Mg. <1.5% Her. <0.5 MP, <0.35% Sn and the rest of AI, The composition and size of the grit of the filler material 33 used in this example, as well as the other relevant experimental parameters, are listed in Table 3.
Immediately, each of the packs of sheets 30 was cooled to room temperature, they were torn open45 in the transverse direction to determine whether a metal matrix composite was formed. All V-AB samples of this example were observed to form aluminum metal 50 matrix composite materials. In particular. FigLOA is a micrograph obtained at 400X, which corresponds to sample V. Fig. SE-SE are micrographs 55 obtained at 400X, which correspond to sample X-AA, respectively; fig.! 0F is a photomicrograph obtained at 50X, which corresponds to sample AB. Pos. 51 - filling material. Pos. 53 - matrix metal.
Example 9. This example demonstrates that a number of filling materials can be impregnated with a bronze matrix metal using the self-generated vacuum technique. In particular, a sheet package similar to the sheet package shown in Fig. 1 A was used. In addition, the experimental the methods described in example 1, except that the bronze matrix metal includes about 93 wt.% Cu, 6 wt.% SI and 1 wt.% Fe. The temperature of the molten metal and furnace is about 1100 ° C. The composition and size of the grit of the filling material 33. used in this example, as well as other relevant experimental parameters, are listed in Table 4.
Immediately each of the packages of sheets is cooled to room temperature, they are cut. they are shear in the transverse direction in order to determine whether the matrix metal has saturated the filling materials 33 to form the corresponding metal matrix composite bodies. All AC-A1 examples in this example form metallic matrix composite bodies. In particular, figa-11D are micrographs obtained at 400X, which correspond to samples of AC-AG, respectively; while FIG. IE is a photomicrograph obtained at 50X, which corresponds to an AC sample. Pos. 51 - filling material, pos. 53 - matrix material.
Example 10. This example discloses a method and apparatus for measuring the magnitude of the vacuum generated by the self-generated vacuum technique of the present invention. In addition, the same equipment can be used to create a specific controlled atmosphere inside an impermeable container. Thus, a self-generated vacuum can be observed as a function of the atmosphere.
This example quantifies the importance of using an external physical sealant under the conditions of the method discussed in the example.
Vacuum measuring equipment is manufactured by first constructing an impenetrable container of 16 gauge (1.6 mm thickness) AiSi type 304 stainless steel. In particular, the stainless steel container is similar to the container discussed in Example 1. However, the container is provided with 1/8 (3 cm) CD and 1/16 (1.6 mm) 1D stainless steel tube, which has an L shape and about 21 (533 mm) total length. In particular, FIG. 12A shows a vacuum gauge 60 that includes a stainless steel container 32 having a stainless steel tube 61 extending through and welded to the side wall 64 of the container 32. The portion of the tube 61. that extends into the container 32 has the size is about 3 1/2 inches (89 mm), while the height of the tube is about 17 1/2 inches (445 mm). It should be understood that the dimensions of the tube 61 are not significant, one tube must be of appropriate size and shape in order to allow one end of the tube 61 to be located inside the container 32 and the other end of the tube 61 to be located outside the furnace. The vacuum sensor 63 is a commercially available vacuum sensor that is not able to withstand the temperature of formation of the metal matrix composite material. Therefore, the tube 61 protruding from the furnace and is attached by a removable connection to the vacuum sensor using a threaded connection 62, which is welded to the end of the tube 61. FIG. 12A also shows that the sheet package used is similar to the sheet package discussed in Example 1, except that the bottom of the container 32 contains a layer of freely packed 500 grit AI2O3 (38 Alundum) 65, which is used to cover the stainless steel pipe 61. This powder 65 allows the pipe 61 to bind to the inner chamber of the container 32 during the impregnation process, since under the specific conditions of this technique, the matrix metal cannot impregnate the powder 65. 90 grit alumina material 51 (38 Alundum Norton Co ..) is placed on top of the powder 65 about 1 1/2 (38 mm) high. The molten aluminum matrix metal 33 at a temperature of about 900 ° C is then poured into a container 32. located at room temperature. Aluminum metal is a commercially available 170.1 alloy, which is mainly pure aluminum. A layer of powdered B2O3 is then placed on the surface of molten metal 33 and the entire ensemble 60 is placed in a heated electric resistance furnace, which is at a temperature of about 900 ° C (note, however, that the vacuum sensor is located outside the furnace).
An experimental sheet package similar to the sheet package shown in Figure 12A is then placed in the same furnace as the sheet package discussed above.
The second packet of sheets is exactly the same as the first packet of sheets except that the sealing layer 34 (e.g., BrO3) is not used in the comparative packet of sheets. Therefore, this example allows a quantitative comparison between the two. sheet lacquers, with only one difference between sheet packages, which is to use a sealing agent in one sheet package.
In particular, the vacuum generated in each container 32. is controlled as a function of time. FIG. 13 shows a graph in inches of mercury as a function of time for each of two batch sheets. In particular, the graph AK corresponds to a packet of sheets in which a sealing layer 34 (sample AK) is used and graph A1 corresponds to a comparative packet of sheets (sample A1) in which the sealing layer 34 is not used. From FIG. 13 it is clear that no vacuum is generated in the comparative sheet package, while a vacuum of about 26 inches (660 mm) of mercury is generated from the sheet package that uses a sealing layer
34.
After about 2 hours at about 900 ° C., each of the containers 32, which corresponds to samples of AK and AL, is removed from the furnace and solidified by the use of a water-cooled copper cooling plate. Then the samples are cut in the transverse direction and photographed. FIG. 14A, which corresponds to sample AK, shows that a metal matrix composite body 40 is formed. Only the place where the metal matrix composite body does not form corresponds to the place where 900 grit powder 65 is located. In addition, the end of the tube 61. which is located inside the 50 grit powder 65 can be clearly seen. FIG. 14B, which corresponds to sample AL, shows that no impregnation takes place. In particular, only the cavity 43, the matrix metal 33 of the nozzle 61 remain after the sample AL is cut in the transverse direction (i.e., all of the filling material 31 falls out of the container 32 while cutting it in the transverse direction),
Example 11. This example demonstrates that the atmosphere is different than air can be used in conjunction with an aluminum matrix metal. The apparatus 66 shown in FIG. 12B is similar to the apparatus 60 shown in FIG. 12A. However, the tube 61 communicates with the nitrogen gas source 67. and not with the vacuum sensor 63. The nitrogen atmosphere is introduced into the filling material 31 due to the flow of nitrogen through the tube 61 at a speed of about 180 cm / min. In particular, molten 170.1 alloy discussed in Example 5-10 is poured onto the filler material 31 discussed in Example 10. Nitrogen is introduced to the bottom of the container 32, and during this time, the molten aluminum matrix metal 33 solidifies and nitrogen 10 continues to flow for a predetermined time thereafter (i.e., nitrogen flows for a total of 1 hour after molten aluminum 33 is poured onto the filler material 31). After 1 hour 15 of the flow of nitrogen, the nitrogen source 67 is disconnected from the tube 61 and replaced immediately by the vacuum sensor 63. Immediately after this, the molten BrO3 layer is poured onto the surface of the cured parent metal 33. Thus, the sheet package 66 is modified, which is substantially the same. as a packet of sheets 60, shown in Figure 12A. Then the packet of sheets is placed in the chamber of the resistance furnace with heated air of the atmosphere, which is preheated to 900 ° C. The packet of sheets is kept in the oven for 2 hours, at which time the vacuum sensor is monitored.
The maximum vacuum achieved over 2 hours is about 12 inches (305 mm) of mercury.
A packet of sheets is removed from the oven after 2 hours and placed on a water-cooled copper 35 cooling plate for directing from. curing residual matrix metal. Immediately upon cooling to room temperature, the packet of sheets was cut in the transverse direction to show that the 40 matrix metal impregnated the filling material to form a metal matrix composite material.
Example 12. The methods of example 11 are repeated, except that the composition of the matrix metal 45 is changed from 170.1, alloy to alloy, which has the following composition: 7.5-9.5% St, 3.0-4.0% Cu. <2.9% Zn. 2.2-2.3% Mg, <1.5% Fe, <0.5% N1 and <0.35% Sn, and residue Ai. A metal matrix 50 composite body is successfully formed.
Example 13. The procedure of example 11 is repeated, except that the oxygen is replaced by nitrogen. The maximum vacuum that can be reached within two hours 55 at 900 ° C is about 10 inches (254 mm) of mercury. After isothermal exposure for 2 hours, a packet of sheets is removed from the furnace and placed on a water-cooled copper cooled plate for directional curing of the matrix metal.
Upon reaching room temperature, the packet of sheets is cut in the transverse direction to show that the matrix metal has impregnated the filling material to form a metal matrix composite body.
Example 14. The methods described in example 11 are repeated except that the matrix metal is a bronze matrix metal and the temperature of the furnace is about 1100 ° C. The matrix metal has a specific composition of about 6 wt.% SI, 1 wt.% Fe and the remainder of Cu. FIG. 15 shows an AM graph that corresponds to an AM sample made according to this example; which shows that a maximum vacuum of about 29 inches (737 mm) of mercury is achieved. After about 2 hours at a temperature of 1100 ° С, a packet of sheets is removed from the furnace and placed on a water-cooled copper cooling plate for directional curing of the matrix metal.
Upon reaching room temperature, the packet of sheets is cut in the transverse direction to show that the matrix metal has impregnated the filling material to form a metal matrix composite body.
PRI me R 15. This example demonstrates that a number of materials can be used as the material forming the external sealant of the present invention. The experimental sheet package was the same as the sheet package used in Figure 1 A, and the experimental procedure was the same as that described in Example 1. The only difference was that the matrix metal was a bronze alloy containing 93 wt. .% Cu, 6 wt.% SI and 1 wt.% Fe, the temperature of the furnace and alloy are about 1100 ° C and use various materials that form the sealant. Specifically, the three separate seal forming materials included B ₂ 0z from Aesar Co of Seabrook, NH (same as the forming sealant material 34 in Example 1) Class V 212 V 514 from Vltrlfunctlons Gunburg. RA. After 2 hours at 1100 ° C, the samples are removed from the furnace and placed on a water-cooled copper cooling plate for directional curing of the matrix metal. Each of these examples successfully forms a metal matrix composite body.
Present another example material. forming a sealant. In particular, the impermeable container of Example 1 is filled with about 1 inch (25 mm) of a mixture of filling material 31. comprising grit (37 Crystolon) SIC with about 20 wt.% 90 grit A1 ₂₀ 0z (38 Alundum) added thereto. About 1 inch (25 mm) of molten matrix metal, including 6 wt.% SI. 1 wt.% Fe and the remainder of Cu are poured into a container 32. Pieces of ordinary broken bottle glass are scattered on the surface of the matrix metal 33. A packet of sheets, including a stainless steel container and its contents, is placed in a chamber of a resistance furnace with heated atmospheric air installed at 1100 ° C. After 3 to 4 hours at 1100 ° C, the device is removed from the oven and cooled.
At room temperature, the installation is taken apart to show that a metallic matrix composite body is being formed.
Example 16. The package of sheets shown in Figure 1 B. and the steps described in Example 2 are basically repeated for two additional samples. In particular B ₂ 0z not added to any of the packets of sheets. The only difference in the experimental procedure is that one sample is kept in the oven for about 2 hours (also As in Example 2); while the other sample is kept in the furnace for about 3 hours. After 2 and 3 hours have passed, respectively, each packet of sheets is removed from the furnace and placed on a water-cooled copper cooling plate for directional curing of the matrix metal. Upon reaching room temperature, the packet of sheets is cut in the transverse direction to determine if a metal matrix composite has formed. It was observed that the container, kept at a temperature for 3 hours, forms a metal matrix material, while the container, kept at a temperature for 2 hours, does not form a metal matrix composite material. It was also found that the slag-like material is formed in a container kept at a temperature for 3 hours. The slag-like material includes Cu ₂ O and is located along the perimeter of the interface between the matrix metal and the container 32. It is possible that the matrix metal component interacts with the surrounding atmosphere. taking part in the formation of a gas tight sealant.
Example 17. This example demonstrates a sealant facilitator involved in the formation of an internal physical and / or chemical sealant. In particular. two identical sheet packs similar to the sheet pack shown in FIG. 1 B. produce one container 32 provide an alloy that contains a sealant facilitator, while the other alloy does not. Both alloys 33 did not cover BrO3 or any material forming an external sealant. The composition of the filler, the amount of filling material, and stainless steel containers were identical to those used in Example 1. One container was filled with approximately 10 575 g of molten matrix metal 33, including the commercially available named aluminum alloy. 170.1. A second container 32 is filled with approximately 5751 molten matrix metal 15, comprising 7.5-9.5% SI; 3.0-4.0% Cu: 2.9 Zn; 2.2-2.3% Mg: <1.5% Fe: <0.5% Ni; 0.35% Sn and Al residue. Two packages of sheets, including 32 stainless steel containers and their contents, are placed in the 20 chamber of the furnace with atmospheric air, which is preheated to a temperature of about 900 ° C. About 15 minutes are given to packs of sheets in order to reach temperature. The packs of sheets are held for 25 at a temperature for about an additional 2 hours. Then both packs of sheets are removed from the furnace and placed on a water-cooled copper cooling plate for targeted curing of the matrix metal.
Upon reaching room temperature _: two packs of sheets are cut in the transverse direction to determine if the matrix metal (s) 33 has infiltrated the filler material 31 with the formation of the metal matrix composite bodies. It was observed that the container having 170.1 alloy does not form a metal matrix composite body, while the container is -40 s (7.5-9.5% SI, 3.0-4.0 Cu, <2.9% Zn, 2, 22.3% Mg, <1.5% Fe. <0.5% Ni. <0.35% Sn and the remainder Al) forms a metal matrix composite material. It was also observed that this second alloy forms a 45 surface layer at the place where the matrix metal 33 contacts the stainless steel container 32. This surface layer is analyzed by x-ray diffraction, as shown. 50 is preferably spinel of magnesium and alumina. Thus, this example illustrates that the sealant facilitator itself (for example, without using any external sealant 55) can create conditions favorable for the matrix metal to impregnate the filling material to form a metal matrix composite body.
Example 18. This example demonstrates the use of a wetting amplifier that promotes the formation of metal matrix composite bodies using a self-generated vacuum technique. Table 5 summarizes the matrix metals, filling materials, temperatures, processing time, and amounts of the wetting enhancer used for the various 10 experiments presented according to this example.
Sample A
A stack of sheets, similar to that shown in FIG. 1 A, is made by forming an impermeable container 32 constructed of about 16 gauge (1.6 mm thickness) A1 1 type 304 stainless steel and having an internal diameter of about 1.6 inches (41 mm) and a height of about 2.5 inches (64 to 20 mm). The container 32 is filled with filling. material 21, including 220 grit SIC (39 Crystolon from Norton Co). About 1 inch (25 mm) of molten matrix metal 33, including about 6% silicon by weight, 25 about 0.5% Fe, about 0.5 AI. and the rest copper, poured into a container 32 at room temperature. About 2 g of BrO3 powder from Aesar Co. of Johnson Matthey. Seabrook, NH poured onto the surface of molten 30 metal matrix 33 to create a gas-tight sealant. A package of sheets, including a stainless steel container, its contents, is placed in a chamber of a resistance furnace with a heated air atmosphere of 35 preheated to a temperature of about 1100 ° C. After • about 2.25 hours at a temperature, the 32 stainless steel container and its contents are removed from the oven and placed on a sand • 40 pillow to allow the matrix metal to solidify. Upon reaching room temperature, the packet of sheets was separated, and it was observed that the matrix metal did not impregnate the filling material and therefore 45 did not form a metal matrix composite body.
Samples AO-AT
The experimental procedures described above in reference and to sample AN are repeated for each of these samples, except that a variable amount of (selenium) is added to the filling material 31 by a standard mixing operation. 55 The exact amount of filling material. wetting amplifier, processing temperature and processing time are presented in table.5. Each of the examples of AO-AT successfully forms metal matrix composite bodies.
Samples A
The sheet package used in this example is slightly different from all other sheet packages used in this example. In particular, an alumina crucible 70, as shown in FIG. 16 obtained from Bolt Technical Ceramics, Inc Conrol TX, having about 1 inch (25 mm) inner diameter and about 1, inch (36 mm) height cut to about 1/2 inch (13 mm) height, placed inside the filling material 31 The bottom of the crucible is filled with 325 mesh powder 71 treated by Atlantic Egulprnent Engineers. Bergenfield, NS. The remaining unfilled, part of the crucible of alumina 70 is filled with a filler material 31, including ΑΙ2Ο3, known as 38 Alundum (from Norton Co) Sn 71 in the crucible 70 is about 10% by weight of the total content in the crucible. An additional filling material 31 having the same characteristics of the filling material inside the crucible 70 is then placed around and on top of the crucible 10. About 1 inch (25 mm) of molten matrix metal 33, comprising about 5% Si, about 2% Fe by weight. about 3% Zn and the remaining copper are poured into a container 32. The molten matrix metal 33 is then coated with about 20 g of B2O3 powder 34. A packet of sheets, including a stainless steel container 32 and its contents, is placed in a chamber of a resistance furnace with heated atmospheric air installed at about 1100 ° C. After about 5 hours at a temperature of about 1100 ° C, a packet of sheets is removed from the oven and cooled.
Upon reaching room temperature, a packet of sheets was opened and it was observed that the matrix metal had impregnated 220 grit 38 Alundum inside the alumina crucible 70. However, 220 grit 38 Alundum, which occupied the space between the alumina crucible and the stainless steel container (and which did not were in contact with the powder Sn) do not impregnate the matrix metal. Thus, a powder similar to Sn powder acts as a wetting enhancer for a bronze matrix metal.
Example 19. This example demonstrates that a number of fill material sizes and compositions can be incorporated into aluminum metal matrix composite bodies made by a self-generated vacuum technique.
The experimental procedures are basically the same as those described in Example 1 and the sheet package similar to the sheet package shown in FIG. 1A, use. Table 6 summarizes which matrix metals, filling materials, temperatures and processing times are used for various samples obtained according to this example. Each of the AU-A samples successfully form metal matrix composite bodies.
Example 20. This example demonstrates that a number of fill material sizes and compositions can be incorporated into bronze metal matrix composite bodies made by a self-generated vacuum technique.
Samples VA-BE,
The experimental procedures are basically the same as described in Example 1, and the use of a sheet package similar to the sheet package shown in FIG. 1A is used.
Table 7 summarizes which matrix metals filling materials, temperatures and processing times are used for various samples obtained according to this example.
VG sample
This sample is obtained using the same methods used to obtain the sample AP in example 18.

权利要求:
Claims (32)
[1]
Claim
1. A method of producing a composite material with a metal matrix, comprising forming a reaction system consisting of a container, a permeable filler placed therein, impregnating a matrix material, a reaction atmosphere, sealing the system from an external atmosphere, heating the matrix material to melt, impregnating the permeable filler with molten matrix material , subsequent solidification, characterized in that, in order to increase the efficiency and simplify the method, when forming a reaction The first systems use a container made of impermeable material, a filler - in a freely sprinkled state or in a preformed form, sealing is created using a surface protective layer impermeable to the external atmosphere.
[2]
2. The method according to claim 1, about tl available in that they completely seal the reaction atmosphere from the external atmosphere.
[3]
3. The method according to claim 1, characterized in that as the matrix material using a material selected from the group consisting of aluminum, magnesium, bronze, copper, an alloy based on iron.
[4]
4. The method according to π. 1, excellent in that a wetting agent is additionally introduced into the reaction system,
[5]
5. The method according to claim 1, characterized in that a substance is additionally introduced into the reaction system, which promotes the formation of a protective layer that is not permeable to the external atmosphere.
[6]
6. The method according to claim 1, characterized in that at least one glassy material is introduced into the surface protective layer.
[7]
7. The method according to claim 1, characterized in that the reaction product of the matrix material with the external atmosphere is used as the surface protective layer.
[8]
8. The method according to claim 1, with the fact that the protective layer is formed by wetting the impermeable container with a matrix material.
[9]
9. The method according to claim 1, wherein the surface reaction layer is a reaction product of a matrix material with a non-permeable container.
[10]
10. The method of pop. 1, different. that the reaction atmosphere at least partially interacts with the matrix material or filler material or container material to create a pressure drop.
[11]
11. The method according to PP. 1 and 4, characterized in that the wetting agent is introduced into the matrix material.
[12]
12. The method according to claims 1..4, characterized in that aluminum is used as a matrix material, and a metal selected from the group consisting of magnesium, bismuth, lead, tin is used as a wetting agent.
[13]
13. The method according to claims 1, 4, with the fact that bronze or copper is used as the matrix material, and a substance selected from the group consisting of selenium is used as a wetting agent tellurium, sulfur.
[14]
14. The method according to claim 1, with the fact that as a filler, powders, flakes, tablets, microspheres, bubbles, fibers, small particles, fiber mats, cut, are used in a loose state fibers, spheres, granules, tubes, refractory fabrics.
[15]
15. The method according to claim 1, characterized in that as a filler, substances selected from the group consisting of oxides, carbides, borides, nitrides are used in a freely poured state.
[16]
16. The method according to claim 1, characterized in that. that as a material, an impermeable container using a material selected from the group comprising ceramics, metal, glass, polymer.
[17]
17. The method according to claim 1, characterized in that as the matrix material using a material selected from the group consisting of aluminum, copper, bronze, and as the material of an impermeable container using non-stainless steel.
[18]
18. A method according to claim 1.15, characterized in that alumina or silicon carbide is used as the material of the impermeable container.
[19]
19. The method according to claim 1. Characterized in that an oxygen-containing or nitrogen-containing atmosphere is used as a reaction atmosphere.
.
[20]
20. The method according to claim 1, characterized in that aluminum is used as the matrix material, and air, oxygen or nitrogen is used as the reaction atmosphere.
[21]
21. The method according to claim 1, with the fact that as the matrix material using a material selected from the group consisting of bronze, copper, an alloy based on iron, and as a reaction atmosphere use air, oxygen or nitrogen.
[22]
22. The method according to claim 1, characterized in that the heating is carried out to a temperature above the melting temperature of the matrix material, but below the evaporation temperature of the matrix material and the melting temperature of the filler material.
[23]
23. The method according to claim 1, characterized in that aluminum is used as a matrix material, and a material selected from the group consisting of oxides, borides, carbides, nitrides is used as a filler material.
[24]
24. The method according to PP. 1 and 23, which is characterized in that the heating is carried out to 700-1000 ° C.
[25]
25. The method according to claim 1, characterized in that bronze or copper is used as the matrix material, and a material selected from the group consisting of oxides, carbides, borides, nitrides is used as the filler material.
[26]
26. The method according to PP. 1 and 25, which is characterized in that the heating is carried out to 1050-1125 ° C.
[27]
27. The method according to claim 1, characterized in that an iron-based alloy is used as a matrix material, and a material selected from the group consisting of oxides, carbides, borides, nitrides is used as a filler material.
[28]
28. The method according to claims 1 and 27, characterized in that the heating is carried out to 1250-1400 ° C. 5
[29]
29. The method according to claim 1, characterized in that preformed powders, flakes, tablets, microspheres, mustaches, and bubbles are used as filler. fibers, small particles, fiber mats, fiber trimmings, spheres, granules, tubes, refractory fabrics.
[30]
30. The method according to claim 1 and 3. about t and ch and yuy with it. that the filler material is a material selected from the group consisting of alumina, silicon carbide, zirconia, titanium nitride, boron carbide, and mixtures thereof.
[31]
31. The method according to claim 1, characterized in that boron glasses or silicon glasses are used as the surface protective layer, which at least partially melt upon impregnation.
[32]
32. The method according to claim 1. Characterized in that the solidification is carried out on a cooled substrate.
Table 1
- Sample Matrix metal Filler Temperature, * C Processing time, h Container The formation of a metal matrix component A Aluminium alloy! 90 # Al’Oj 900 2.25 Type 30k La IN Aluminum Alloy ¹90 ♦ A1 _Z O 900 2.25 Glazed coffee cup Yes FROM 1100 5k # SiC ** 1000 1,5 In ^ Oz coated type 304 Yes D Al - 10J, 10Mg 90 * SiC ** 950 if Glazed icing cast Al _t Oj shell Yes Ε Aluminium alloy 90 # Aljoy 900 2.25 Clay crucible Not F 93 * Si - 6 * Si - P Fe 90 * A1, O _E1100 2.25 Type 30k Yes G 93 * Si - 6 "Si - o, 5 * Fe -0.5 * Al 90 # Al _{/ oj}1100 2.25 Colloidal graphite deposited on flat carbon steel Yes H 93 * Si - 6 * Si + 1 * Fe 90> Al _t o _s1100 2.25 Clay crucible Not
+38 Alundum, Norton Co, Worcester, N.A.
+39 Crystolon, Norton Co, Worcester,! 1.A.
+ ♦ + El Alundum, Nortpn Co, Worcester, H.A.
# means grish
SS means stainless steel) ^f (7.5-9.5 * si; 3.0-4.0% Cu: <2.9Z Zn; 2.2-2.3 * Mg; <l, 5 * Fe; Ζ 0.51 lln; Z 0.5 Ni; K0.35X Sn and Al residue
Table 2
Sample Base metal Filler Container material Processing temperature, • s Processing time, h Density, g / cm ³The coefficient of thermal expansion, ί 10 * / * C Figure D 1 * 5052 90 grit ΛΙ, Ο * Type 304 SS 900 2.25 3.30 - 7A I Π 00 90 grit ΛΙ, Οί Type 30 * " SS 900 2.25 - - - G 6061 90 grit A1.0 ‘ Tin 304 SS 900 2.25 3.44 12.7 7B L 170.1 90 grit Al, o; Type 304 SK 900 2.25 3.39 12.3 7C H Aluminium alloy 90 shingle whether about; Type 304 S3 900 2.25 5, se ’2.7 7 N 93 * cu b; Si -% Fe 90 grit αι, ο; Type 304 35 1100 2.25 5.92 11.2 7E 0 93 * C - 6 *Si - 0.5 * Fe 0.5 * * 1. 90 grit l □; Type 30 * " SS 1100 2 P ASTM A-48 Grade30.35 gray cast iron 90 grit m _: o; Sintered 1U00 4 5.68Q fifty! -Al-50% C 54 grit SiC ° Type 304 SS 900 1.5 - - R 75 * C - 25 * Al 54 grit Si with ‘* Type 304 SS 1100 1.5 - - - S 90 * Si - 5 * Si - 2 *Ge2 *,Zn 1 * Al 54 grit Sic ** Type 304 SS 1125 2 I 90 * Si - 5 * Si - 2 *Fe - 3 * Zn 90 grit SiC ** Type 30 * " SS 1100 2 V C 811 (ground copper) 54 grit SiC ** sinteredA |, O. <+ 1250 3 -
♦ 38 Alundum, Norton Co, Worcester, I.A.
♦♦ 39 Crystalon, Norton Co., Worcester, Μ.A.
φ Bobt Ceramics, Conroe, TX * Kelly Foundry, Elkine WV i (7.5-9.5Z Si; 3, Ο-ή, ΟΖ Cu, <2.9Z Zn, 2.2-2.3Z Mg, <1.5 Z Fe, 4 0.5Z Mn, <0.51 Ni _t z O, 35X Sn and residue Μ)
Table)
g —---—-- 1 1-------- —--- U —-_____ Matrix Filler Material Tempe Time Raft- CoEffI- Picture metalcontainer Rathura back KNOB cient 1G FROM bot ni g / cm ’ term- hhuman xY extension ‘* / 'C
V Aluminium alloy 90 grit Aio; A type 304 ss 900 2.25 3,58 12.7 10A W Aluminum 90 grit alloy SiC ** A type 304 SS 900 2.25 3.38 8.5 - X Aluminum 90 grit alloy Al ₂ From ' A type 304 S3 900 2.25 2.91 9.2 108 ¥ Aluminum 90 grit alloy ΖηΟ -Α1 _ζ 0, A type 304 SS 900 2.25 3.48 12.6 Jus Z Aluminum 100 grit alloy TiN ♦ A type 304 SS 900 2.25 3.56 10.9 10 ΑΛ Aluminum 100 grit alloy b ^ s ^£A type 304 S3 900 2.25 2.67 I.4 UE AB Aluminum T — 6 ^ 4 cylinders alloy cheskaya• AljQj A type 304 SS 900 2.25 3.47 10.0 SOUTH(-24, + 48 grit) ____________ _ - “T ----4+ ISA 1360, Norton Co, Worcester, And, .A. + ♦ + EL Alundum, Norton Co, Worcester, Mea.
4 + 39
CrystoLon, Norton Co, Worcester, 11.A,
Alunsum, Norton Co, Worcester, M, A.
/ - Atlantic Eguipment Engineers, Bergenfield, N1 * * Alcoa, Pittesburg, PA
CE SK Engineered Ceramics, Wocker Chemical, New Conaan, CT,
Table ¹ !
and· Matrix metal Filler Container material time of processing,h Density, g / cm ’ Elastic modulusGPa Coefficient of thermal expansion If Slicer AC 93% C - 6%- 1% Fe 90 grit 38 ALjOj Type 304 SS 2.25 5.92 "1.1. 154 11A AD 93% Si - 6% Si -- 1% Fe 90 grit SiC * Type 304 SS 2.25 5.01 9.0 124 Willow Ae 93% Si - 6% Si- 1% Fe 90 grit ZrCj-Alj6j Type 304 SS A1.0 2.25 - *11C AF 93% Si - 6% Si-1% Fe 90 grit AljOj Type 304 SS 2.25 5.66 10.5 146 eleven AG 93% Si -6% Si-1% Fe T-64 cylindrical A1 _g 0, (- 24, + 48 grit) Type 304 SS 2.25 5.52 11.8 128 118 Ah 93% Si - 6% Si- 1% Fe -80, +100 grit ZnO * Type 304 SS 2.25•- Al 90% Si - 5% Si - 2%Fe - 3% 0.14 inch diameter At _t Oi hollow spheres Type 304 SS 2 3.9
4 + ISA 1360 t J.1 Alundum, Norton Co, Worcester, M.A.
t + jf Crystolon, Norton Co, Weraster, M.A., + + "EL Alundum, Norton Co, Worcester, M, A.
+ Norton Co, Worcester, M.A, # Misele Shoals Minerals, Tuscombia, Al »Alcoa, Pittesburg, PA
CESK Engintrtied Ceramics, Wacker, Chemicals Nev-Conaan CI
K # Ceramic Fillers Inc ,, Aflantq, GA.
Table5
Obra-  Matrix Filler Amplifier Tempera- Time Obraao, - zets . metalwetting tour, * C back bath If boots metal h humanmatrixgo com , ___________ - posit 1 2 ........ J ....... A6^μ t ~
AN 93% Cu - 6% Si - 0.5% Fe - 0.5% Al 220 grit SiC ‘* not 1100 * 2 not AO 93% Cu - 6% Si - 0.5% Fe - 0.5% Al 220 grit SiC * ‘ 2% by weight325 mesh 1100 * 2.25 Yes AR 93% Cu - 6% Si - 0.5% Fe - 0.5% Al 220 grit SiC 3 * by weight -325 mesh 1100 * 2.25 Yes Aq 93% Cu - 6% Si - 0.5% Fe - 0.5% Al 18O Grit Al ^ Cl * 1% by weight -325 mesh 1100 ' 2 Yes AR 93% Cu - 6% Si - 0.5% Fe - 0.5% Al 220 grit Al ^ 0 *, '* 1 "by weight -325 me 1100 ' 2 Yes As 93% Si - 6% Si - 0.5% 180 grit Al ^ Oj ’* 1 by weight -325 mesh 1100 ’ 2 Yes
Fe - 0.5% Al
Continuation of the table. 5
_______________________ ___________ i ............... 5 ........... i ....... 1 ^{Z /} 1 Τ Ί Γ ⁷ 7 j 2 .1 2 J -........1. ---------------------------- -J --...... - - —— · -J— AT 93Z Cu - 67.Si - 0.57.Fe - 0.57 Al ISO grit Al, 0 / IS 1325 weightmesh 1125 ' 2.25 Yes AV 90X Cu - 57. Si - 27.Fe - 37. Zn 220 grit Aj ₍ o; ' ⁴ 10 * 325 no mesh weight 1100 ' 5 Yes
+ 3g Alundum, Norton Co., Worcester, M.A. Crystolcn, Norton Co., Worcester, M.A +++ El Alundum, Norton Co ,: Worcester, M.A.
1 Atlantic Equipment Engineers, Bergenfield, N1
2 Aesar of Johnson Matthey, Seabrook, NH.
Table 6
•••• - “- ••“ ► • I Processing time, h The formation of a metal matrix composite Sample Matrix metal- Filler__________________ Temperature ⁱⁿ C AV 170, 1 220 grit Α1 _ζ 0 950 2.25 Yes ΑΧ 170.1 90 grit A1 ₂ 0z 950 2.25 Yes Ay Aluminum (T-64 cylinder alloy ^ kaya A1.0J(-24, +48 mesh) 900 2.25 Yes AZ Aluminum 180 grit Sic ' 800 3,5 Αθ
+ 3S Alundum, Norton Co., Worcester, M „A.
7 + jf 'Cry stolon, Norton Co., Worcester, M.A
Alcoa, Pittesburg, P.A.
1 (7.5-9.5 / i, 3.0-4.0 / 'Cu, / 2.9 / ”Zn, 2.2-2.3% Mg, <7.5% Fe, <0 , 5% Mn, <0.35% Sn and Al residue)
Table/
————— atObra- Matrix metal Filler Tempera- Time zets tour, * C processingh
VA 90% Ci -57. Si-37. Zn - 27. Fe 14 grit and 90 SiC * ⁺ (50¾14 grit, 50¾90 grit) 1100 * 2 BB 90% Ci -57. Si-3% Zn-2% Fe T-64 cylindrical A1 ₂ Oj (-24, +48 mesh) 1100 ' 3 Sun 90% Cu - 5% Si - 3% Zn -2% Fe 54 grit 39 SiC ^# * 1125 ' 2 Bd 90% Cu -5% Si - 2% Zn - 2% Fe 90 grit 1125 * 3 BE 90% Cu - 6% Si -0.57. 180 grit SiC ** and 1100 * 4 Fe - 0.5% Al 10¾ 325 mesh / p 'Bf 90% Si-6% Si-0.5% 220 * 51С * and 3% - 1100 * 2.25 Fe - 0.5% Al 325 mesh Se ²
(used as a wetting amplifier)
Alundum, N <. ; .ton co. , Worcester, M.A.
♦ + 39 Crystolon, Norton Co., Worcester, M _O A.
τ Atlantic Equipment Engineers, Bergenfield, N1
2 Aesar of Johnson jjatthey, Seatrook, Nil
ΙΑ 3o ^
Fi C 2 figs! A figM
5 zo7
Fig 7C (rSh
Fig! 8
5 / Fig. 70q
FIG. Ju
53 51
Fig. Yu
FIG. / 05
53 51 fig 10b
Fig / A Fig. NB
Figs i 5f fig fie
53 5f FIG
Fiss | 2 A
Jj
FigSh / p _ig u (rig. 15

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FI91496B|1994-03-31|A method of forming macrocomposite bodies and macrocomposite bodies formed thereon

---

FI91723B|1994-04-29|Method of manufacturing a metal matrix composite by directed solidification

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FI91613B|1994-04-15|Process for producing a shaped metal matrix composite body

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JP2859329B2|1999-02-17|Modification method of metal matrix composite

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FI91492B|1994-03-31|Method of forming a metal matrix composite

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JP2905517B2|1999-06-14|Method of forming metal matrix composite

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JP2905515B2|1999-06-14|Method of forming metal matrix composite by spontaneous infiltration method

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US5188164A|1993-02-23|Method of forming macrocomposite bodies by self-generated vacuum techniques using a glassy seal

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FI91491B|1994-03-31|A method of making a metal matrix composite body using an injection molding method

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KR0121462B1|1997-12-03|Method for forming a metal matrix composite body by an outside-in spontaneous infiltration process

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FI91493B|1994-03-31|Method of forming a metal matrix composite

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KR0183973B1|1999-04-01|Methods for forming macrocomposite bodies and macrocomposite bodies produced thereby

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KR100216334B1|1999-08-16|Production methods for metal matrix composite

同族专利:

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公开号 | 公开日

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KR0183974B1|1999-04-01|

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FI903607A0|1990-07-17|

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CN1048893A|1991-01-30|

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ZA905590B|1992-03-25|

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DD301879A9|1994-06-09|

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IL94957A|1994-12-29|

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DE69017544D1|1995-04-13|

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HUT64932A|1994-03-28|

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YU139890A|1992-07-20|

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IL94957D0|1991-06-10|

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CN1032224C|1996-07-03|

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PT94738B|1997-03-31|

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EP0409763A3|1991-10-23|

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PT94738A|1991-03-20|

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FI91611B|1994-04-15|

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CA2020673A1|1991-01-19|

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JP3256217B2|2002-02-12|

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AU636627B2|1993-05-06|

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IE902462A1|1991-02-13|

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EP0409763B1|1995-03-08|

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FI91611C|1994-07-25|

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BG60649B1|1995-11-30|

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NZ234365A|1993-02-25|

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TR27109A|1994-11-08|

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CS354790A3|1992-06-17|

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JPH03138328A|1991-06-12|

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EP0409763A2|1991-01-23|

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YU47109B|1994-12-28|

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BR9003429A|1991-08-27|

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NO902978D0|1990-07-04|

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PL286092A1|1991-04-08|

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DE69017544T2|1995-07-27|

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AT119582T|1995-03-15|

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PL166638B1|1995-06-30|

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MX174653B|1994-05-31|

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AU5877490A|1991-01-24|

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HU904202D0|1990-12-28|

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NO902978L|1991-01-21|

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KR910002738A|1991-02-26|

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法律状态:

优先权:

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申请号 | 申请日 | 专利标题

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US38152389A| true| 1989-07-18|1989-07-18|

---