Method of producing aluminum composite material

a composite material and aluminum alloy technology, applied in the direction of manufacturing tools, foundry patterns, foundry moulding apparatus, etc., can solve the problems of oxidation-loss of activated charcoal and graphite, the application of aluminum alloy is limited to a sliding portion of the structure, and the inability to prevent the oxidation of charcoal and graphi

Inactive Publication Date: 2006-08-03
CENTRAL MOTOR WHEEL CO LTD
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Problems solved by technology

Nevertheless the application of the aluminum alloy is limited to a sliding portion of structure because of low resistance to abrasion.
Further, especially in an automobile, comfortable ride and driving performance are not well achieved due to noise and vibration because an aluminum alloy has lower vibration damping property than a cast iron.
Even though heating over 600° C. by hot solution or sintering of aluminum alloy are used in the methods above, no means to prevent the oxidation of activated charcoal or graphite was disclosed and accordingly the oxidation-loss of activated charcoal and graphite could not be prevented.
Thus it was difficult to obtain an aluminum alloy composite material having excellent abrasion resistant and vibration damping properties.

Method used

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  • Method of producing aluminum composite material
  • Method of producing aluminum composite material
  • Method of producing aluminum composite material

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Experimental program
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embodiment 1

[0026] Referring to FIG. 1(a), alumina fiber 5 and powder of graphite 6 were mixed by stirring with stirring rod 31 in water in designated vessel 21. Alumina sol as an inorganic binder was added to water in which alumina fiber 5 and graphite 6 were being mixed. Alumina fiber 5 used had approximately 3 μm of average diameter, 50 cc / 5 gf of an average length, chemical composition composed of approximately 95% of Al2O3 and approximately 5% of SiO2, and graphite 6 used had approximately 20 μm of average diameter and chemical composition composed of 97% of C and approximately 3% of Al2O3 and SiO2. Alumina sol 7 used was approximately 11% of Al2O3.

[0027] Aqueous solution 8 in which alumina fiber 5, powder of graphite 6 and alumina sol 7 being mixed was transferred to suction-forming device 22 from vessel 21. Suction-forming device 22 was connected to vacuum pump 23 and referring to FIG. 1(b), suctions water of aqueous solution 8 by vacuum pump 23 through filter 24. Accordingly, dehydrate...

embodiment 2

[0031] According to embodiment 2, a manufacturing method relates to sintering in hydrogen gas as a reducing gas in the preform forming process. After dehydrated-formed base material 9 which was formed according to embodiment 1 was well dried, it was put into heating oven 25 in which the inside was at 1×10−3 Torr under vacuum. Then nitrogen gas was introduced to substitute and after substitution, heating the inside of the oven was started. When the temperature reached to 400° C., approximately 100 cc / min of hydrogen gas was introduced and the inside temperature of the oven was held for 2 hours at approximately 1000° C. Hydrogen gas over flown from leak valve 32 was burnt using a pilot burner to prevent filling and explosion in the inside. Then the oven was cooled down to room temperature to form preform 1. Further during cooling down flow of hydrogen gas was stopped at approximately 400° C. and instead, nitrogen gas was flown. According to aluminum impregnating process as described i...

embodiment 3

[0032] According to embodiment 3, a manufacturing method relates to sintering under vacuum in the preform forming process. Dehydrated-formed base material 9 which was formed according to embodiment 1 was put into heating oven 25 in which the inside was at 1×10−4 Torr under vacuum. Vacuum condition of the inside of the oven was held and the oven was heated up to approximately 1000° C., and the temperature of approximately 1000° C. was held for 2 hours and the oven was cooled down to room temperature to form preform 1. According to aluminum impregnating process as described in embodiment 1, hot solution 3 of aluminum alloy 2 was impregnated to preform 1 and aluminum composite material 4e composed of aluminum composite layer 12e and aluminum alloy layer 13 was obtained. Volumetric percentage (%) of graphite 6 was 15% of aluminum composite layer 12d of aluminum composite material 4d, volumetric percentage (%) of alumina fiber 5 was 6.5% and the rest was for aluminum alloy 2. According t...

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Abstract

A manufacturing method of an aluminum composite material having excellent abrasion resistant and vibration damping properties is disclosed. The aluminum composite material is manufactured by impregnating a perform with an aluminum alloy the perform is formed by mixing an alumina fiber and graphite or activated charcoal and an inorganic binder in water and sintering the resultant mixed product at a predetermined sintering temperature under vacuum, in an inert gas, or in a reducing gas.

Description

BACKGROUND OF THE INVENTION [0001] (1) Field of the Invention [0002] The present invention relates to a method of producing aluminum composite material produced by mixing an aluminum fiber and graphite or activated charcoal to an aluminum alloy. [0003] (2) Description of the Background Art [0004] An aluminum alloy has been optimally used in devices including such as automobiles, electric appliances, electronic parts, and precious measurement equipment because of its lightness and malleability. Nevertheless the application of the aluminum alloy is limited to a sliding portion of structure because of low resistance to abrasion. Further, especially in an automobile, comfortable ride and driving performance are not well achieved due to noise and vibration because an aluminum alloy has lower vibration damping property than a cast iron. Accordingly, various composite materials such as graphite and activated charcoal with superior lubricating property and damping property have been added t...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B22D19/02
CPCB22D18/02B22D19/14C22C47/06C22C47/12
Inventor FUJITA, MAKOTO
Owner CENTRAL MOTOR WHEEL CO LTD
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