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WO1992003582A1 - Metal leger a pores separes et procede de production - Google Patents

Metal leger a pores separes et procede de production Download PDF

Info

Publication number
WO1992003582A1
WO1992003582A1 PCT/CA1991/000300 CA9100300W WO9203582A1 WO 1992003582 A1 WO1992003582 A1 WO 1992003582A1 CA 9100300 W CA9100300 W CA 9100300W WO 9203582 A1 WO9203582 A1 WO 9203582A1
Authority
WO
WIPO (PCT)
Prior art keywords
metal
composite
pores
process according
stabilizer particles
Prior art date
Application number
PCT/CA1991/000300
Other languages
English (en)
Inventor
Harry Sang
Iljoon Jin
Martin Thomas
Lorne Douglas Kenny
Original Assignee
Alcan International Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US07/573,716 external-priority patent/US5112697A/en
Priority claimed from CA002046814A external-priority patent/CA2046814C/fr
Application filed by Alcan International Limited filed Critical Alcan International Limited
Priority to EP91914312A priority Critical patent/EP0545957B1/fr
Priority to DE69121242T priority patent/DE69121242T2/de
Publication of WO1992003582A1 publication Critical patent/WO1992003582A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C22C1/083—Foaming process in molten metal other than by powder metallurgy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt

Definitions

  • This invention relates to a lightweight gas-metal composite with isolated particle-stabilized pores, particularly a lightweight aluminum composite, and its production.
  • Lightweight foamed metals have high strength-to- weight ratios and are extremely useful as load-bearing materials and as thermal insulators.
  • Metallic foams are characterized by high impact energy absorption capacity, low thermal conductivity, good electrical conductivity and high absorptive acoustic properties.
  • Foamed metals have been described previously, e.g. in U.S. Patent Nos. 2,895,819, 3,300,296 and 3,297,431.
  • foams are produced by adding a gas-evolving compound to a molten metal.
  • the gas evolves to expand and foam the molten metal.
  • the resulting body is cooled to solidify the foamed mass thereby forming a foamed metal solid.
  • the gas-forming compound can be metal hydride, such as titanium hydride, zirconium hydride, lithium hydride, etc. as described in U.S. Patent No. 2,983,597.
  • a composite of a metal matrix and finely divided solid stabilizer particles is heated above the liquidus temperature of the metal matrix.
  • the molten metal composite is then vigorously mixed such that a vortex is formed.
  • Gas on the surface of the molten metal composite is by way of the action of the vortex drawn into the molten composite.
  • the gas is drawn in as mixing continues such that the hot molten metal composite eventually forms into an expanded material having a pasty or viscous consistency. The gas is distributed throughout this expanded, viscous material in the form of small isolated pores.
  • the expanded metal product of this invention can be allowed to solidify and can be remelted for forming into a shaped product without breakdown of the expanded structure.
  • the pores are generally spherical and are widely dispersed within the matrix. These pores typically have diameters in the range of 10-500 microns and these are relatively uniformly spaced through the matrix with substantial amounts of matrix material between the pores. In a typical structure, there are widely spaced pores of large diameter with pores of small diameter in the matrix material between the large pores.
  • the spacing between pores is an average at least 50 microns and typically 100 microns or more. It is an important feature of the present invention that there be a substantial mass of metal composite between the pores.
  • the product preferably has a relative density (P*/P s ) of about 0.3 to ⁇ 1, where P* is the density of the porous material and P s is the density of the solid composite.
  • P* is the density of the porous material
  • P s is the density of the solid composite.
  • a wide variety of refractory materials may be used as the finely divided solid stabilizer particles. The main requirements of such particles are that they be capable of being incorporated in and distributed throughout the metal matrix and being capable of at least substantially maintaining their integrity as incorporated rather than losing their form or identity by dissolution in or by extensive chemical combination with the metal matrix.
  • suitable solid stabilizer materials include alumina, titanium diboride, zirconia, silicon carbide, silicon nitride, etc.
  • the volume fraction of particles in the foam is typically less than 25% and is preferably in the range of about 5 to 15%.
  • the particle sizes can range quite widely, e.g. from about 0.1 to 50 ⁇ m, but generally particle sizes will be in the range of about 0.5 to 25 ⁇ m with a particle size range of about 1 to 20 ⁇ m being preferred.
  • the metal matrix may consist of a wide variety of metals capable of being mixed in the molten state by vortex mixing. Examples of these include aluminum, magnesium, steel, zinc, lead, nickel, copper and alloys thereof. Of particular interest are standard wrought, cast or other aluminum alloys, for example alloys available under Aluminum Association (AA) designations 6061, 2024, 7075, 7079 and A 356.
  • AA Aluminum Association
  • the gas forming the pores may typically be selected from the group consisting of air, carbon dioxide, oxygen, inert gases, etc. Because of its ready availability, air is usually preferred.
  • the mixing may be done by any means capable of producing a vortex.
  • a mechanical impeller or an electromagnetic mixing system may be used.
  • the stabilizer particles adhere to the gas-liquid interface of the pores. This occurs because the total energy of this state is lower than the surface energy of the separate liquid-vapour and liquid-solid state. The presence of the particles around the periphery of the pores tends to stabilize the expanded lightweight material.
  • Figure 1 illustrates schematically an apparatus for carrying out the vortex mixing
  • Figure 2 shows at lOx magnification a cross-section through a cast lightweight aluminum composite of the invention
  • Figure 3 is a photomicrograph of the material of Figure 2 at lOOx magnification
  • Figure 4 shows at 4x magnification a cross-section through a further cast lightweight aluminum composite according to the invention.
  • Figure 5 shows at 25x magnification a cross-section throught part of the product of Figure 4.
  • a crucible 35 contains a rotatable shaft 36 with an impeller 37.
  • the crucible has a diameter of 32 cm and the blades of the impeller are rectangular, measuring about 76 mm x 127 mm.
  • a molten metal composite is filled to the level 38.
  • the impeller is then rotated at high speed to form a vortex 39.
  • a blanket of gas is provided on the surface of the melt vortex, and the gas is drawn into the melt to eventually form an expanded porous material.
  • the expansion is continued until the crucible is substantially filled. At that point, the mixing is stopped and the material is removed from the crucible for forming into desired shapes.
  • Example 1 illustrates certain preferred embodiments of the invention.
  • Example 2 Using the apparatus of Figure 1, a composite of 6061 aluminum alloy reinforced with 15 % by volume of alumina powder was melted. With the molten metal composite at a temperature of 710*C, the impeller was rotated at 800 rpm. After 15 minutes of mixing, the composite melt started to

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)
  • Catalysts (AREA)

Abstract

Nouveau matériau composite gaz-métal léger présentant des pores séparés à particules stabilisées. On chauffe un matériau composite comprenant une matrice métallique, par exemple l'aluminium, et des particules stabilisatrices solides finement divisées, par exemple de carbure de silicium, et cela au-delà de la température de liquidus de la matrice métallique, puis on le mélange de manière à former un tourbillon. Le matériau composite fondu est enrobé d'un gaz pendant le mélange par tourbillon. Ce gaz est aspiré dans le matériau en fusion de manière à produire un matériau composite fondu, visqueux et déployé contenant des pores très petits, sphériques et répartis de manière relativement égale. Ce matériau composite fondu et visqueux peut prendre directement la forme d'un produit profilé solide et peut également être refondu et remis en forme par des processus de formage sans que l'intégralité des pores ne soit détruite. On obtient ainsi un produit métallique déployé et léger auquel l'on peut donner des formes qui ont des tolérances dimensionnelles précises.
PCT/CA1991/000300 1990-08-27 1991-08-26 Metal leger a pores separes et procede de production WO1992003582A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP91914312A EP0545957B1 (fr) 1990-08-27 1991-08-26 Metal leger a pores separes et procede de production
DE69121242T DE69121242T2 (de) 1990-08-27 1991-08-26 Leichtgewichtmetall mit isolierten poren sowie seine herstellung

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US573,716 1990-08-27
US07/573,716 US5112697A (en) 1989-09-06 1990-08-27 Stabilized metal foam body
CA2,046,814 1991-07-11
CA002046814A CA2046814C (fr) 1991-07-11 1991-07-11 Metal leger avec pores isolants et production

Publications (1)

Publication Number Publication Date
WO1992003582A1 true WO1992003582A1 (fr) 1992-03-05

Family

ID=25674691

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA1991/000300 WO1992003582A1 (fr) 1990-08-27 1991-08-26 Metal leger a pores separes et procede de production

Country Status (7)

Country Link
EP (1) EP0545957B1 (fr)
JP (1) JPH06500359A (fr)
AT (1) ATE141108T1 (fr)
AU (1) AU8326791A (fr)
DE (1) DE69121242T2 (fr)
MX (1) MX9100828A (fr)
WO (1) WO1992003582A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4326982C1 (de) * 1993-08-11 1995-02-09 Alcan Gmbh Verfahren und Vorrichtung zur Herstellung von Formteilen aus Metallschaum
WO1998003686A1 (fr) * 1996-07-18 1998-01-29 The University Of Melbourne Formage de metaux semi-solides
WO1999011832A1 (fr) * 1997-08-30 1999-03-11 Honsel Ag Alliage destine a la production de corps metalliques en mousse a l'aide d'une poudre ayant des adjuvants formant des germes
WO1999064287A1 (fr) * 1998-06-09 1999-12-16 M.I.M. Hüttenwerke Duisburg Gmbh Procede pour renforcer la cavite d'un element d'automobile
EP0915007A3 (fr) * 1997-11-07 2000-09-13 DaimlerChrysler AG Structure de carosserie comportant au moins une cloison transversale
US6250362B1 (en) 1998-03-02 2001-06-26 Alcoa Inc. Method and apparatus for producing a porous metal via spray casting
US6555515B1 (en) 1995-12-06 2003-04-29 Henkel Kommanitgesellschaft Auf Aktien Formulations for cleaning hard surfaces based on at least partly branched-chain alkyl oligoglucosides
EP1338661A1 (fr) * 2002-02-15 2003-08-27 Honda Giken Kogyo Kabushiki Kaisha Une mousse métallique et procédé pour sa fabrication
DE102008000100A1 (de) 2008-01-18 2009-07-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Leichtgewichtiger Grün- und Formkörper aus einem keramischen und/oder pulvermetallurgischen Material und Verfahren zu seiner Herstellung

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7175689B2 (en) 2001-06-15 2007-02-13 Huette Klein-Reichenbach Gesellschaft Mbh Process for producing a lightweight molded part and molded part made of metal foam
CN110029256B (zh) * 2019-04-19 2020-10-23 青海民族大学 一种提高az91镁合金耐腐蚀性能的方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2282479A1 (fr) * 1974-08-19 1976-03-19 Pechiney Aluminium Pieces en alliage d'aluminium poreux et moyen de les preparer
EP0151434A1 (fr) * 1984-01-25 1985-08-14 Norsk Hydro A/S Procédé et dispositif pour traiter et fragmenter un liquide à l'acide d'une force centripète
EP0210803A1 (fr) * 1985-07-19 1987-02-04 Agency Of Industrial Science And Technology Mousse métallique et procédé pour sa fabrication
WO1991003578A1 (fr) * 1989-09-06 1991-03-21 Alcan International Limited Metal alveolaire leger et production d'un tel metal

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2282479A1 (fr) * 1974-08-19 1976-03-19 Pechiney Aluminium Pieces en alliage d'aluminium poreux et moyen de les preparer
EP0151434A1 (fr) * 1984-01-25 1985-08-14 Norsk Hydro A/S Procédé et dispositif pour traiter et fragmenter un liquide à l'acide d'une force centripète
EP0210803A1 (fr) * 1985-07-19 1987-02-04 Agency Of Industrial Science And Technology Mousse métallique et procédé pour sa fabrication
WO1991003578A1 (fr) * 1989-09-06 1991-03-21 Alcan International Limited Metal alveolaire leger et production d'un tel metal

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4326982C1 (de) * 1993-08-11 1995-02-09 Alcan Gmbh Verfahren und Vorrichtung zur Herstellung von Formteilen aus Metallschaum
US6555515B1 (en) 1995-12-06 2003-04-29 Henkel Kommanitgesellschaft Auf Aktien Formulations for cleaning hard surfaces based on at least partly branched-chain alkyl oligoglucosides
WO1998003686A1 (fr) * 1996-07-18 1998-01-29 The University Of Melbourne Formage de metaux semi-solides
US6311759B1 (en) 1996-07-18 2001-11-06 The University Of Melbourne Semi-solid metal processing
WO1999011832A1 (fr) * 1997-08-30 1999-03-11 Honsel Ag Alliage destine a la production de corps metalliques en mousse a l'aide d'une poudre ayant des adjuvants formant des germes
US6332907B1 (en) 1997-08-30 2001-12-25 Honsel Gmbh & Co. Kg Alloy for producing metal foamed bodies using a powder with nucleating additives
EP0915007A3 (fr) * 1997-11-07 2000-09-13 DaimlerChrysler AG Structure de carosserie comportant au moins une cloison transversale
US6286896B1 (en) 1997-11-07 2001-09-11 Daimlerchrysler Ag Body structure with at least one transverse connection and method of making same
US6250362B1 (en) 1998-03-02 2001-06-26 Alcoa Inc. Method and apparatus for producing a porous metal via spray casting
WO1999064287A1 (fr) * 1998-06-09 1999-12-16 M.I.M. Hüttenwerke Duisburg Gmbh Procede pour renforcer la cavite d'un element d'automobile
EP1338661A1 (fr) * 2002-02-15 2003-08-27 Honda Giken Kogyo Kabushiki Kaisha Une mousse métallique et procédé pour sa fabrication
DE102008000100A1 (de) 2008-01-18 2009-07-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Leichtgewichtiger Grün- und Formkörper aus einem keramischen und/oder pulvermetallurgischen Material und Verfahren zu seiner Herstellung

Also Published As

Publication number Publication date
ATE141108T1 (de) 1996-08-15
EP0545957A1 (fr) 1993-06-16
AU8326791A (en) 1992-03-17
MX9100828A (es) 1992-04-01
DE69121242T2 (de) 1997-01-23
EP0545957B1 (fr) 1996-08-07
JPH06500359A (ja) 1994-01-13
DE69121242D1 (de) 1996-09-12

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