Silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material and preparation method thereof

Abstract

The invention discloses a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material and a preparation method thereof.The performance of the silicon carbide reinforced aluminum-based composite material is improved through low-density and low-expansion-coefficient silicon dioxide, and the wettability of silicon carbide and an aluminum alloy matrix can be improved by adding the silicon dioxide; and the thermal expansion coefficient of the aluminum-based composite material can be further reduced. According to the method, the aluminum alloy powder is obtained by adopting an aerosol method, and the high-energy ball milling method and the hot isostatic pressing sintering process are combined, so that the composite powder is formed under uniform pressure and lower temperature, an AlC3 brittle phase generated by harmful interface reaction is avoided, the compactness of the aluminum-based composite material can be greatly improved, and the service life of the aluminum-based composite material is prolonged. The problems that an aluminum alloy matrix containing silicon carbide reinforced particles is poor in wettability and poor in size stability under the condition that the temperature changes drastically are solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of aluminum alloy composite materials, and more specifically, relates to a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material and a preparation method thereof. Background Art

[0002] In recent years, with the development of national defense and military industries, aerospace, and the rapid growth of the communications and information industries, high-end manufacturing and precision equipment have placed higher demands on the dimensional stability of materials. Aluminum alloys are already widely used in industries such as aviation, aerospace, automotive, and shipbuilding. However, as performance requirements in various industries increase, so too do the demands on the performance of aluminum alloys. Aluminum has the advantages of low density and, when combined with other materials, excellent physical and mechanical properties such as specific strength, specific stiffness, and elastic modulus, as well as good machinability, leading to its increasingly widespread application.

[0003] For example, aluminum-based composites reinforced with silicon carbide particles can improve specific strength and specific stiffness, reduce the thermal expansion coefficient, are lightweight, and have good thermal conductivity and wear resistance. Due to the poor wettability of silicon carbide reinforcements with aluminum or aluminum alloy matrices, defects such as holes are easily generated. The actual aluminum-carbon composites produced have a high thermal expansion coefficient and poor mechanical properties, especially in environments with drastic temperature changes. The dimensional stability of the composites produced is extremely poor. The performance deteriorates easily during actual application, and it is difficult to be used as a material for aviation structural parts. For example, CN103074507A discloses a method for preparing a silicon-aluminum alloy-based composite material reinforced with silicon carbide particles for brake discs, which discloses reinforcing the silicon-aluminum alloy by impregnation with silicon carbide particles, wherein the silicon carbide particles need to be electrolessly copper-plated before impregnation, so that the silicon carbide particles are evenly distributed in the silicon-aluminum alloy matrix, achieving good impregnation and bonding. However, this method increases the modification cost of the silicon carbide material. The high raw material and preparation costs and processing difficulties make it difficult to be applied on a large scale, and it is difficult to maintain its dimensional stability under service conditions with drastic temperature changes. Summary of the Invention

[0004] The present invention provides a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material, a preparation method and an application thereof to overcome the problems of poor wettability of the aluminum alloy matrix of existing silicon carbide reinforced particles and poor dimensional stability under drastic temperature changes.

[0005] The present invention is achieved through the following technical solutions:

[0006] A silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material. The raw materials, calculated by volume fraction, include 5-20% silicon carbide, 10-25% silicon dioxide, and the remainder is aluminum or aluminum alloy.

[0007] Preferably, the raw materials include 10-15% silicon carbide, 10-20% silicon dioxide, and the remainder is aluminum or aluminum alloy.

[0008] Furthermore, the particle size of the silicon carbide is 10 μm-50 μm; the particle size of the silicon dioxide is 20 μm-50 μm.

[0009] Furthermore, the silicon carbide is one or more of flaky silicon carbide, granular silicon carbide, whisker-shaped silicon carbide, and short fiber silicon carbide.

[0010] Furthermore, the aluminum alloy is one of Al-Si alloy, Al-Cu alloy, Al-Mg alloy, Al-Si-Cu alloy, Al-Mg-Cu alloy, Al-Si-Mg alloy and Al-Si-Mg-Cu alloy.

[0011] Furthermore, the preparation steps of the silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material include:

[0012] S1. Aluminum or aluminum alloy, silicon carbide and silicon dioxide are mixed uniformly in proportion to obtain a mixed powder;

[0013] S2. The mixed powder is subjected to aerosol powdering to obtain a metal-based composite powder material;

[0014] S3. Hot isostatic pressing and sintering the metal matrix composite powder material to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0015] Furthermore, the spray pressure of the aerosol powder preparation is 1.2 to 1.6 MPa, the spray temperature is -25 to -15°C, and the spray rate is 0.12 to 0.24 m 3 ×S -1 .

[0016] Furthermore, the hot isostatic pressing sintering has a sintering pressure of 150-250 MPa, a sintering temperature of 460-580° C., and a sintering time of 2-10 h.

[0017] Furthermore, in order to precisely control the added content of silicon carbide and silicon dioxide and further mix the composite powders evenly, the preparation step further includes high-energy ball milling the metal-based composite powder material with silicon carbide and / or silicon dioxide.

[0018] Furthermore, the rotation speed of the high-energy ball mill is 200-300 r / min, and the ball milling time is 5-25 h.

[0019] Compared with the prior art, the beneficial effects are:

[0020] The present invention utilizes low-density, low-thermal expansion coefficient silicon dioxide to improve the aluminum alloy reinforced with silicon carbide. The addition of silicon dioxide not only improves the wettability of the silicon carbide with the aluminum alloy matrix, but also, due to its inherent low thermal expansion coefficient, further reduces the thermal expansion coefficient of the aluminum-based composite material. While providing strength to the aluminum alloy, silicon dioxide improves the wettability of the aluminum alloy with silicon carbide, further reduces the thermal expansion coefficient, and improves the density of the composite material.

[0021] In addition, the present invention adopts an aerosol method to prepare aluminum or aluminum alloy powder, and by combining the high-energy ball milling method with the hot isostatic pressing sintering process, the composite powder is formed under uniform pressure and a relatively low temperature, thereby avoiding the AlC3 brittle phase produced by harmful interfacial reactions and greatly improving the density of the aluminum-based composite material. The obtained composite material has a dense structure and excellent mechanical properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a metallographic photograph of a silicon carbide / silicon dioxide hybrid reinforced low expansion aluminum matrix composite material;

[0023] Figure 2 This is a scanning electron microscope image of a silicon carbide / silicon dioxide hybrid reinforced low expansion aluminum matrix composite material;

[0024] Figure 3 This is a scanning electron microscope image of silicon carbide / silicon dioxide hybrid reinforced low expansion aluminum matrix composite material. DETAILED DESCRIPTION

[0025] The present invention will be further explained and illustrated below with reference to the examples, but the specific examples do not limit the present invention in any form. Unless otherwise specified, the methods and equipment used in the examples are conventional methods and equipment in the art, and the raw materials used are all conventional commercially available raw materials.

[0026] Example 1

[0027] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0028] S1. Melt the aluminum ingot into a molten state, and respectively load silicon carbide particles with a particle size of 10μm-50μm and silicon dioxide particles with a particle size of 20μm-50μm into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 5%, the silicon dioxide particles with a volume fraction of 10% and the aluminum powder are mixed by controlling the flow rate of the valves of each tank. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m 3 ×S -1Under the mixing and stirring of high-pressure vaporized liquid nitrogen, the various powder materials are fully mixed and evenly mixed in the gas mixing device according to the principles of fluid dynamics, forming a gaseous suspension. The aluminum metal liquid is atomized and crushed through the gas delivery pipe and quenched. In this process, the powder material acts as a particle for heterogeneous nucleation, promoting the nucleation of metal droplets, and even forming amorphous powder material under the quenching effect of high-pressure vaporized liquid nitrogen. It is then cooled and deposited on a water cooling table to form a composite powder.

[0029] S2. The composite powder mixed by the aerosol method was pre-pressed and then subjected to a hot isostatic pressing sintering process at a sintering pressure of 200 MPa, a sintering temperature of 570°C, and a sintering time of 3 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0030] Example 2

[0031] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0032] S1. Melt the aluminum ingot into a molten state, and respectively load silicon carbide particles with a particle size of 10μm-50μm, silicon dioxide particles with a particle size of 20μm-50μm, and aluminum powder into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 10%, the silicon dioxide particles with a volume fraction of 25%, and the aluminum powder are mixed by controlling the flow rate of the valves of each tank. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m 3 ×S -1 Under the mixing and stirring of high-pressure vaporized liquid nitrogen, the various powder materials are fully mixed and evenly mixed in the gas mixing device using the principles of liquid dynamics to form a gaseous suspension. The metal liquid is atomized and broken through the gas delivery pipe and quenched. In this process, the powder material acts as a particle point for heterogeneous nucleation, promoting the nucleation of metal droplets, and even forming amorphous powder material under the quenching effect of high-pressure vaporized liquid nitrogen. It is then cooled and deposited on a water cooling table to form a composite powder.

[0033] S2. Before high-energy ball milling, silicon carbide and silicon dioxide powders were added to the composite powder, with precise control of the content. Alcohol was also added to promote uniform dispersion of the reinforcement particles within the composite powder. High-energy ball milling was then performed at a speed of 300 rpm for 10 hours to obtain a metal-based composite powder material.

[0034] S3. The obtained metal matrix composite powder material is vacuum dried, and after pre-pressing, a hot isostatic pressing sintering process is performed at a sintering pressure of 200 MPa, a sintering temperature of 560° C., and a sintering time of 4 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0035] Example 3

[0036] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0037] S1. Melt the aluminum ingot into a molten state, and respectively load silicon carbide particles with a particle size of 10μm-50μm, silicon dioxide particles with a particle size of 20μm-50μm, and aluminum powder into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 20% and the silicon dioxide particles with a volume fraction of 15% are mixed with the aluminum powder by controlling the flow rate of the valves of each tank. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m 3 ×S -1 Under the mixing and stirring of high-pressure vaporized liquid nitrogen, the various powder materials are fully mixed and evenly mixed in the gas mixing device using the principles of liquid dynamics to form a gaseous suspension. The metal liquid is atomized and broken through the gas delivery pipe and quenched. In this process, the powder material acts as a particle point for heterogeneous nucleation, promoting the nucleation of metal droplets, and even forming amorphous powder material under the quenching effect of high-pressure vaporized liquid nitrogen. It is then cooled and deposited on a water cooling table to form a composite powder.

[0038] S2. The composite powder is mixed with silicon carbide powder and silicon dioxide powder, precisely controlling the content. Alcohol is added to promote uniform dispersion of the reinforcement particles within the composite powder. High-energy ball milling is then performed at a speed of 300 rpm for 10 hours to obtain a metal-based composite powder material.

[0039] S3. The obtained metal matrix composite powder material is vacuum dried, and after pre-pressing, a hot isostatic pressing sintering process is performed at a sintering pressure of 200 MPa, a sintering temperature of 560° C., and a sintering time of 4 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0040] Example 4

[0041] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0042] S1. Melt each metal ingot into a molten state according to the proportion of 6061Al alloy, and respectively load silicon carbide particles with a particle size of 10μm-50μm, silicon dioxide particles with a particle size of 20μm-50μm, and 6061 aluminum alloy powder into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 9%, the silicon dioxide particles with a volume fraction of 12% and the aluminum powder are mixed by controlling and adjusting the flow rate of the valves of each tank to perform aerosol powder making. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m3 ×S -1 After cooling and deposition, a composite powder is formed.

[0043] S2. Based on the deviations in the silicon carbide and silicon dioxide content of the composite powder, the metal-based composite powder material is mixed with a predetermined amount of silicon carbide and silicon dioxide particles. The content of the reinforcing powder is precisely controlled, and an alcohol additive is added to promote uniform dispersion of the reinforcing particles within the composite powder. This is then subjected to high-energy ball milling at a speed of 300 rpm for 10 hours to obtain the metal-based composite powder material.

[0044] S3. The obtained metal matrix composite powder material is vacuum dried, and after pre-pressing, a hot isostatic pressing sintering process is performed at a sintering pressure of 200 MPa, a sintering temperature of 560° C., and a sintering time of 4 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0045] Example 5

[0046] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0047] S1. Melt each metal ingot into a molten state according to the proportion of 6061Al alloy, and respectively load silicon carbide particles with a particle size of 10μm-50μm, silicon dioxide particles with a particle size of 20μm-50μm, and 6061 aluminum alloy powder into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 9%, the silicon dioxide particles with a volume fraction of 12% and the aluminum powder are mixed by controlling and adjusting the flow rate of the valves of each tank to perform aerosol powder making. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m 3 ×S -1 After cooling and deposition, a composite powder is formed.

[0048] S2. Based on the deviations in the silicon carbide and silicon dioxide content of the composite powder, the metal-based composite powder material is mixed with a predetermined amount of silicon carbide and silicon dioxide particles. The content of the reinforcing powder is precisely controlled, and an alcohol additive is added to promote uniform dispersion of the reinforcing particles within the composite powder. This is then subjected to high-energy ball milling at a speed of 300 rpm for 10 hours to obtain the metal-based composite powder material.

[0049] S3. The obtained metal matrix composite powder material is vacuum dried, and after pre-pressing, a hot isostatic pressing sintering process is performed at a sintering pressure of 200 MPa, a sintering temperature of 580° C., and a sintering time of 3 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0050] Example 6

[0051] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0052] S1. Melt each metal ingot into a molten state according to the proportion of 6061Al alloy, and respectively load silicon carbide particles with a particle size of 10μm-50μm, silicon dioxide particles with a particle size of 20μm-50μm, and 6061 aluminum alloy powder into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 12%, the silicon dioxide particles with a volume fraction of 15% and the aluminum powder are mixed by controlling the flow rate of the valves of each tank. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m 3 ×S -1 After cooling and deposition, a composite powder is formed.

[0053] S2. Based on the deviations in the silicon carbide and silicon dioxide content of the composite powder, the metal-based composite powder material is mixed with a predetermined amount of silicon carbide and silicon dioxide particles. The content of the reinforcing powder is precisely controlled, and an alcohol additive is added to promote uniform dispersion of the reinforcing particles within the composite powder. This is then subjected to high-energy ball milling at a speed of 300 rpm for 10 hours to obtain the metal-based composite powder material.

[0054] S3. The obtained metal matrix composite powder material is vacuum dried, and after pre-pressing, a hot isostatic pressing sintering process is performed at a sintering pressure of 200 MPa, a sintering temperature of 580° C., and a sintering time of 3 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0055] Example 7

[0056] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0057] S1. Melt each metal ingot into a molten state according to the proportion of 7075Al alloy, and respectively load silicon carbide particles with a particle size of 10μm-50μm and silicon dioxide particles with a particle size of 20μm-50μm into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 9%, the silicon dioxide particles with a volume fraction of 12% and the aluminum powder are mixed by controlling and adjusting the flow rate of the valves of each tank to perform aerosol powder making. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m 3 ×S -1 After cooling and deposition, a composite powder is formed.

[0058] S2. Based on the deviations in the silicon carbide and silicon dioxide content of the composite powder, the metal-based composite powder material is mixed with a predetermined amount of silicon carbide and silicon dioxide particles. The content of the reinforcing powder is precisely controlled, and an alcohol additive is added to promote uniform dispersion of the reinforcing particles within the composite powder. This is then subjected to high-energy ball milling at a speed of 300 rpm for 10 hours to obtain the metal-based composite powder material.

[0059] S3. The obtained metal matrix composite powder material is vacuum dried, and after pre-pressing, a hot isostatic pressing sintering process is performed at a sintering pressure of 200 MPa, a sintering temperature of 560° C., and a sintering time of 3 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0060] Example 8

[0061] This embodiment provides a method for preparing a silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material, the preparation steps comprising:

[0062] S1. Melt each metal ingot into a molten state according to the proportion of 7075Al alloy, and respectively load silicon carbide particles with a particle size of 10μm-50μm and silicon dioxide particles with a particle size of 20μm-50μm into the storage tanks of the aerosol powder making device. During the aerosol powder making process, the silicon carbide particles with a volume fraction of 9%, the silicon dioxide particles with a volume fraction of 12% and the aluminum powder are mixed by controlling and adjusting the flow rate of the valves of each tank to perform aerosol powder making. The spray pressure of the aerosol powder making process is 1.2-1.6Mpa, the spray temperature is -25--15℃, and the spray rate is 0.12-0.24m 3 ×S -1 After cooling and deposition, a composite powder is formed.

[0063] S2. Based on the deviations in the silicon carbide and silicon dioxide content of the composite powder, the metal-based composite powder material is mixed with a predetermined amount of silicon carbide and silicon dioxide particles. The content of the reinforcing powder is precisely controlled, and an alcohol additive is added to promote uniform dispersion of the reinforcing particles within the composite powder. This is then subjected to high-energy ball milling at a speed of 300 rpm for 10 hours to obtain the metal-based composite powder material.

[0064] S3. The obtained metal matrix composite powder material is vacuum dried, and after pre-pressing, a hot isostatic pressing sintering process is performed at a sintering pressure of 200 MPa, a sintering temperature of 580° C., and a sintering time of 3 h to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

[0065] The performance of the silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite materials prepared in Examples 1-8 was tested, and the test results are shown in the following table:

[0066]

[0067]

[0068] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Those skilled in the art will appreciate that other variations or modifications can be made based on the above description. It is not necessary and impossible to enumerate all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the claims of the present invention.

Claims

1. A silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material, characterized in that: The raw materials, calculated by volume fraction, include 5-20% silicon carbide, 10-25% silicon dioxide, and the rest is aluminum or aluminum alloy.

2. The silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material according to claim 1, characterized in that: The raw materials include 10-15% silicon carbide, 10-20% silicon dioxide, and the rest is aluminum or aluminum alloy.

3. The silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material according to claim 1 or 2, characterized in that: The particle size of the silicon carbide is 10 μm-50 μm; the particle size of the silicon dioxide is 20 μm-50 μm.

4. The silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material according to claim 1 or 2, characterized in that: The silicon carbide is one or more of flaky silicon carbide, granular silicon carbide, whisker-shaped silicon carbide, and short fiber silicon carbide.

5. The silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material according to claim 1 or 2, characterized in that: The aluminum alloy is one of Al-Si alloy, Al-Cu alloy, Al-Mg alloy, Al-Si-Cu alloy, Al-Mg-Cu alloy, Al-Si-Mg alloy, and Al-Si-Mg-Cu alloy.

6. The method for preparing the silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material according to claim 1, characterized in that: The preparation steps include: S1. Aluminum or aluminum alloy, silicon carbide and silicon dioxide are mixed uniformly in proportion to obtain a mixed powder; S2. The mixed powder is subjected to aerosol powdering to obtain a metal-based composite powder material; S3. Hot isostatic pressing and sintering the metal matrix composite powder material to obtain a silicon carbide / silicon dioxide hybrid reinforced aluminum matrix composite material.

7. The method for preparing the silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material according to claim 6, characterized in that: The spray pressure of the aerosol powder preparation method is 1.2 to 1.6 MPa, the spray temperature is -25 to -15°C, and the spray rate is 0.12 to 0.24 m 3 ×S -1 .

8. The method for preparing the silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material according to claim 6, characterized in that: The hot isostatic pressing sintering has a sintering pressure of 150-250 MPa, a sintering temperature of 460-580° C., and a sintering time of 2-10 hours.

9. The method for preparing the silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material according to claim 6, characterized in that: The preparation step further comprises high-energy ball milling the metal-based composite powder material and silicon carbide and / or silicon dioxide.

10. The method for preparing the silicon carbide / silicon dioxide hybrid reinforced aluminum-based composite material according to claim 6, characterized in that: The rotation speed of the high-energy ball mill is 200-300 r / min, and the ball milling time is 5-25 h.

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