Porous aluminum floating material with high compressive strength and manufacturing method thereof

Abstract

The invention relates to a porous aluminum floating material with high compressive strength and a manufacturing method thereof. The manufacturing method comprises the following steps: melting an aluminum material to form molten metal; a mixed gas is injected into the molten metal, so that the molten metal is filled with a plurality of bubbles generated by the mixed gas to form a foamed molten metal, and the mixed gas comprises inert gas accounting for 1-5% of the total volume, carbon dioxide accounting for 15-40% of the total volume and air accounting for the balance amount; controlling the foamed metal melt to be maintained at a working temperature, so that the foamed metal melt is maintained in a semi-solid state until the plurality of bubbles are filled and dispersed in the foamed metal melt to form a target melt; and solidifying the target molten soup to form a foamed metal, wherein a plurality of holes which are not completely communicated are filled in the foamed metal. Therefore, the porous aluminum floating material has the advantages of being low in density, large in size, relatively low in price, high in compressive strength, capable of being used in the deep sea environment with the depth of 100-1000 meters below the sea level and the like.

Description

Technical Field

[0001] The present invention mainly relates to a method for manufacturing a floating material, and in particular to a method for manufacturing a porous aluminum floating material with high compressive strength, and the porous aluminum floating material manufactured by the manufacturing method. Background Art

[0002] With the rise of marine science, countries have an increasingly urgent need for deep-sea exploration, investigation and development. However, the average depth of the ocean is about 3,700 meters, but there is almost no light below 100 meters, and the water pressure increases by 1 atmosphere for every 10 meters of descent. Such a dark and high-pressure environment is the biggest obstacle for humans to explore the deep sea. Therefore, appropriate instruments and equipment are needed to support observation and measurement in the deep sea.

[0003] Buoyancy material is a composite material with high strength, low density, resistance to hydrostatic external pressure, resistance to seawater corrosion and low water absorption, which can provide buoyancy for underwater detection vehicles. Buoyancy material is one of the indispensable basic materials for the development of modern ocean deep-sea diving technology. The advancement of its technical performance indicators directly affects the reliability and safety of the underwater detection vehicle.

[0004] Known buoyancy materials, such as glass ball composite polymer substrates, ceramic composite metal substrates, and ceramic ball composite polymer substrates, require more than five processing passes in their manufacturing process, and are limited by factors such as mixing uniformity and raw material costs. The products manufactured using the known buoyancy materials are relatively small in size, and a balance cannot be achieved in terms of density, compressive strength, and price.

[0005] In view of this, it is necessary to provide a method for manufacturing a porous aluminum float material with high compressive strength to solve the above problems. Summary of the invention

[0006] The object of the present invention is to provide a method for manufacturing a porous aluminum float material with high compressive strength, which can inject inert gas, carbon dioxide and air into a molten metal according to a specific ratio.

[0007] Another object of the present invention is to provide a porous aluminum floating material with high compressive strength, which is manufactured by the above manufacturing method.

[0008] To achieve the above-mentioned object, the present invention provides a method for manufacturing a porous aluminum float material with high compressive strength, comprising: melting an aluminum material to form a metal melt; injecting a mixed gas into the metal melt so that the metal melt is filled with a plurality of bubbles generated by the mixed gas to form a foamed metal melt, wherein the mixed gas comprises an inert gas, carbon dioxide and air, the volume ratio of the inert gas to the total content of the mixed gas is X, 1%≦X≦5%, and the volume ratio of the carbon dioxide to the total content of the mixed gas is The invention relates to a method for preparing a foamed metal material having a volume ratio of Y, 15% ≤ Y ≤ 40%, a volume ratio of air to the total content of the mixed gas being Z, and Z = 100% - XY; controlling the foamed metal melt to be maintained at a working temperature so that the foamed metal melt is maintained in a semi-solid state until the plurality of bubbles are filled and dispersed in the foamed metal melt to form a target melt; and solidifying the target melt to form a foamed metal, wherein the foamed metal is filled with a plurality of incompletely connected pores and serves as a porous aluminum float, wherein the density of the foamed metal is between 0.3 and 0.8 g / cm 3 The compressive strength is between 4.5 and 8.5Mpa.

[0009] In some embodiments, the aluminum material is recycled aluminum or primary aluminum mixed with ceramic powder, and the inert gas is argon.

[0010] In some embodiments, the operating temperature is between 650°C and 700°C.

[0011] In some embodiments, when the mixed gas is injected into the molten metal, the molten metal is continuously stirred by a stirring blade, and the rotation speed of the stirring blade is between 600 and 1000 rpm.

[0012] In some embodiments, the operating temperature is 680°C, the injection flow rate of the mixed gas injected into the molten metal is 10sccm, the volume ratio of the inert gas to the total content of the mixed gas is 5%, the volume ratio of the carbon dioxide to the total content of the mixed gas is 15%, and the volume ratio of the air to the total content of the mixed gas is 80%.

[0013] In some embodiments, the operating temperature is 680°C, the injection flow rate of the mixed gas injected into the molten metal is 10sccm, the volume ratio of the inert gas to the total content of the mixed gas is 5%, the volume ratio of the carbon dioxide to the total content of the mixed gas is 25%, and the volume ratio of the air to the total content of the mixed gas is 70%.

[0014] In some embodiments, the operating temperature is 680°C, the injection flow rate of the mixed gas injected into the molten metal is 10sccm, the volume ratio of the inert gas in the total content of the mixed gas is 5%, the volume ratio of the carbon dioxide in the total content of the mixed gas is 40%, and the volume ratio of the air in the total content of the mixed gas is 55%.

[0015] The present invention also provides a porous aluminum floating material with high compressive strength, comprising: a foamed metal, the interior of which is filled with a plurality of incompletely connected holes, and the density of the foamed metal is between 0.3 and 0.8 g / cm 3 The compressive strength is between 4.5 and 8.5Mpa.

[0016] In some embodiments, the density of the foamed metal is 0.3-0.5 g / cm 3 , and the compressive strength is 4.5~6.2Mpa.

[0017] In some embodiments, the density of the foamed metal is 0.5 to 0.8 g / cm 3 , and the compressive strength is 6.2~8.5Mpa.

[0018] The porous aluminum float material with high compressive strength and the manufacturing method thereof of the present invention have the following characteristics: the manufacturing process requires only 1 to 2 processing passes, and the inert gas, the carbon dioxide and the air are injected into the molten metal according to a specific ratio, so that the finally solidified porous aluminum float material has low density, large volume, relatively low price and high compressive strength, and can be used in deep sea environments 100 to 1000 meters below sea level. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A flowchart of the steps of the method for manufacturing a porous aluminum float material with high compressive strength according to the present invention;

[0020] Figure 2 An enlarged cross-sectional view of a first embodiment of a porous aluminum floating material having high compressive strength according to the present invention;

[0021] Figure 3 An enlarged cross-sectional view of a second embodiment of a porous aluminum floating material having high compressive strength according to the present invention;

[0022] Figure 4 It is an enlarged cross-sectional view of a third embodiment of the porous aluminum floating material with high compressive strength according to the present invention.

[0023] Explanation of symbols in the accompanying drawings:

[0024] S1: smelting step;

[0025] S2: gas injection step;

[0026] S3: foaming step;

[0027] S4: Casting step. DETAILED DESCRIPTION

[0028] The embodiments of the present invention are described in detail with reference to the drawings as follows. The drawings are mainly simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner. Therefore, only components related to the present invention are marked in the drawings, and the components shown are not drawn in terms of the number, shape, size ratio, etc. during implementation. The specifications and dimensions during actual implementation are actually a selective design, and the component layout may be more complicated.

[0029] The following descriptions of the embodiments are with reference to the attached drawings to illustrate specific embodiments in which the present invention may be implemented. The directional terms mentioned in the present invention, such as "upper", "lower", "front", "back", etc., are only with reference to the directions of the attached drawings. Therefore, the directional terms used are used to illustrate and understand the present invention, rather than to limit the present invention. In addition, in the specification, unless explicitly described to the contrary, the word "comprising" will be understood to mean including the components described, but not excluding any other components.

[0030] Please refer to Figure 1 , is a flow chart of the steps of the method for manufacturing a porous aluminum float material with high compressive strength according to the present invention, which comprises the following steps:

[0031] Melting step S1: Melting an aluminum material in a melting furnace to form a molten metal. For example but not limited to, the melting furnace may be an induction furnace, which utilizes electromagnetic induction to heat the aluminum material to melt and form the molten metal.

[0032] For example, the aluminum material can be recycled aluminum or primary aluminum, and mixed with a ceramic powder, wherein the recycled aluminum is composed of primary aluminum accounting for more than 75% by weight and an aluminum alloy waste; the ceramic powder can be a composite ceramic such as metal oxide, metal carbide, metal sulfide, metal nitride or metal boride, preferably, the ceramic powder can also be SiC, SiO 2 、Al 0.47 Si 0.53 、Si 3 N 4 , Si and other silicon compounds.

[0033] Gas injection step S2: Inject a mixed gas into the molten metal through a gas injection foaming furnace, so that the molten metal is filled with several bubbles generated by the mixed gas to form a foamed molten metal. Among them, the mixed gas includes an inert gas, carbon dioxide, and air. The volume ratio of the inert gas in the total content of the mixed gas is X, 1% ≤ X ≤ 5%. The volume ratio of the carbon dioxide in the total content of the mixed gas is Y, 15% ≤ Y ≤ 40%. The volume ratio of the air in the total content of the mixed gas is Z, and Z = 100% - X - Y. In this embodiment, the inert gas is argon, and the gas injection flow rate of the gas injection foaming furnace injecting the mixed gas into the molten metal can be 5 - 15 sccm, preferably 10 sccm.

[0034] Specifically, the gas injection foaming furnace is connected to the melting furnace and injects the mixed gas into the molten metal located in the melting furnace to form the foamed molten metal. In this embodiment, the gas injection foaming furnace can refer to the device disclosed in the Chinese Taiwan Patent Publication No. I756955B. Furthermore, when injecting the mixed gas (including an inert gas with a volume ratio of 1 - 5% of the total content, 15 - 40% of carbon dioxide, and the balance of air) into the molten metal, the manufacturing method of the porous aluminum floating material further includes the following steps: continuously stir the molten metal with a stirring blade, and the rotation speed of the stirring blade can be between 600 rpm and 1000 rpm. When the rotation speed of the stirring blade is greater, the density and compressive strength of the foamed metal in the subsequent process are greater. In particular, the compressive strength of the foamed metal manufactured at a rotation speed of 1000 rpm is greater than that of the foamed metal manufactured at a rotation speed of 600 rpm.

[0035] Foaming step S3: Use an intermediate foaming chamber to control the foamed molten metal to maintain at a working temperature, so that the foamed molten metal remains in a semi-solid state until the several bubbles are filled and dispersed in the foamed molten metal (that is, the sizes of the pore diameters formed by the several bubbles do not differ too much, for example, the difference in pore diameter sizes does not exceed 6 mm) to form a target molten metal.

[0036] Specifically, the intermediate foaming chamber is connected to the gas injection foaming furnace and is used to control the working temperature of the foamed molten metal between 650 and 700 °C, and while maintaining the working temperature, control the pressure borne by the foamed molten metal between normal pressure and 500 mbar. In this embodiment, the working temperature is preferably controlled at 680 °C, and the intermediate foaming chamber can also refer to the device disclosed in the Chinese Taiwan Patent Publication No. I756955B.

[0037] Casting step S4: using a casting device to solidify the target molten metal to form a foamed metal, the foamed metal is filled with a plurality of incompletely connected pores and serves as a porous aluminum float, wherein the density of the foamed metal is between 0.3 and 0.8 g / cm 3 and the compressive strength is between 4.5 and 8.5 Mpa. Figures 2 to 4 , are enlarged cross-sectional views of the first to third embodiments of the porous aluminum float material with high compressive strength of the present invention, and the data of the porous aluminum float material in different embodiments can be shown in the following table 1:

[0038] Table 1

[0039]

[0040] In addition, according to the above embodiments, the present invention can further design porous aluminum floats with various densities and compressive strength specifications. For example, the density of the foamed metal of the porous aluminum float is between 0.3 and 0.5 g / cm 3 , and the compressive strength is 4.5-6.2Mpa; and the density of the foamed metal of the porous aluminum float is between 0.5-0.8g / cm 3 , and the compressive strength is 6.2~8.5Mpa, which can be used for detection at different depths.

[0041] Specifically, the casting device is connected to the intermediate foaming chamber and is used to solidify the target molten metal to form the foamed metal. For example but not limited to, the casting device can be a water-cooled mold.

[0042] As mentioned above, the porous aluminum float material with high compressive strength and the manufacturing method thereof of the present invention require only 1 to 2 processing passes, and the inert gas, the carbon dioxide and the air are injected into the molten metal according to a specific ratio, so that the finally solidified porous aluminum float material has low density, large volume, relatively low price and high compressive strength, and can be used in deep sea environments 100 to 1000 meters below sea level.

[0043] The above disclosed embodiments are only illustrative of the principles, features and effects of the present invention, and are not intended to limit the scope of the present invention. Anyone familiar with the art may modify and alter the above embodiments without violating the spirit and scope of the present invention. Any equivalent changes and modifications made using the contents disclosed in the present invention shall still be covered by the scope of the attached patent application.

Claims

1. A method for manufacturing a porous aluminum float material with high compressive strength, It is characterized in that Include: Melting an aluminum material to form a molten metal; Injecting a mixed gas into the molten metal so that the molten metal is filled with a plurality of bubbles generated by the mixed gas to form a foamed molten metal, wherein the mixed gas comprises an inert gas, carbon dioxide and air, the volume ratio of the inert gas to the total content of the mixed gas is X, 1%≦X≦5%, the volume ratio of the carbon dioxide to the total content of the mixed gas is Y, 15%≦Y≦40%, and the volume ratio of the air to the total content of the mixed gas is Z, Z=100%-XY; Controlling the foaming molten metal to maintain a working temperature so that the foaming molten metal is maintained in a semi-solid state until the plurality of bubbles are filled with and dispersed in the foaming molten metal to form a target molten metal; and The target melt is solidified to form a foamed metal, the foamed metal is filled with a plurality of incompletely connected pores and serves as a porous aluminum float, wherein the density of the foamed metal is between 0.3 and 0.8 g / cm 3 The compressive strength is between 4.5 and 8.5Mpa.

2. The method for manufacturing a porous aluminum floating material having high compressive strength according to claim 1, It is characterized in that The aluminum material uses recycled aluminum or primary aluminum and is mixed with ceramic powder, and the inert gas is argon.

3. The method for manufacturing a porous aluminum floating material having high compressive strength according to claim 1, It is characterized in that The operating temperature is between 650 and 700°C.

4. The method for manufacturing a porous aluminum floating material having high compressive strength according to claim 1, It is characterized in that When the mixed gas is injected into the molten metal, the molten metal is continuously stirred by a stirring blade, and the rotation speed of the stirring blade is between 600 and 1000 rpm.

5. The method for manufacturing a porous aluminum floating material having high compressive strength according to claim 1, It is characterized in that The working temperature is 680°C, the injection flow rate of the mixed gas injected into the molten metal is 10sccm, the volume ratio of the inert gas to the total content of the mixed gas is 5%, the volume ratio of the carbon dioxide to the total content of the mixed gas is 15%, and the volume ratio of the air to the total content of the mixed gas is 80%.

6. The method for manufacturing a porous aluminum floating material having high compressive strength according to claim 1, It is characterized in that The working temperature is 680°C, the injection flow rate of the mixed gas injected into the molten metal is 10sccm, the volume ratio of the inert gas to the total content of the mixed gas is 5%, the volume ratio of the carbon dioxide to the total content of the mixed gas is 25%, and the volume ratio of the air to the total content of the mixed gas is 70%.

7. The method for manufacturing a porous aluminum floating material having high compressive strength according to claim 1, It is characterized in that The working temperature is 680°C, the injection flow rate of the mixed gas injected into the molten metal is 10sccm, the volume ratio of the inert gas to the total content of the mixed gas is 5%, the volume ratio of the carbon dioxide to the total content of the mixed gas is 40%, and the volume ratio of the air to the total content of the mixed gas is 55%.

8. A porous aluminum floating material with high compressive strength, It is characterized in that It comprises: a foamed metal, the interior of which is filled with a plurality of incompletely connected holes, and the density of the foamed metal is between 0.3 and 0.8 g / cm 3 The compressive strength is between 4.5 and 8.5Mpa.

9. The porous aluminum floating material having high compressive strength according to claim 8, It is characterized in that The density of the foamed metal is 0.3-0.5 g / cm 3 , and the compressive strength is 4.5~6.2Mpa.

10. The porous aluminum floating material having high compressive strength according to claim 8, It is characterized in that The density of the foamed metal is 0.5-0.8 g / cm 3 , and the compressive strength is 6.2~8.5Mpa.

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