An in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method

Abstract

This invention discloses an in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method, relating to the field of metal material preparation technology. The in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method consist of the following components by mass fraction: 90%-98% aluminum alloy matrix; 0.1%-40% inert ceramic particles; and 0.5%-3% composite salt. This invention introduces inert ceramic particles and composite salt, and through solid-state diffusion infiltration and high-temperature in-situ reaction, ions in the composite salt form a transition layer at the interface between the ceramic particles and the aluminum alloy, and react to generate nano-compounds, achieving a metallurgical bond between the ceramic particles and the matrix. This bonding method enhances the interfacial bonding strength, improves the strength and hardness of the aluminum alloy, and simultaneously, the inert ceramic particles are uniformly distributed in the matrix, playing a dispersion strengthening role, further improving the mechanical properties of the material. This results in the aluminum alloy ingot having higher wear resistance, fatigue resistance, and corrosion resistance, meeting the stringent requirements for material performance in high-end fields.

Description

Technical Field

[0001] This invention relates to the field of metal material preparation technology, specifically to an in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method. Background Technology

[0002] With the rapid development of modern industry, especially in high-end fields such as aerospace, automobile manufacturing, and electronic information, the requirements for material performance are becoming increasingly stringent. As a lightweight and high-strength metallic material, aluminum alloys have been widely used in these fields due to their excellent physical and chemical properties. However, with the continuous expansion of application scenarios and the continuous improvement of performance requirements, traditional aluminum alloy materials have gradually shown limitations in terms of strength, hardness, wear resistance, fatigue resistance, and corrosion resistance. Therefore, the development of new aluminum alloy materials with higher comprehensive performance has become a research hotspot in the field of materials science. As a result, in-situ self-generated ceramic particle reinforced aluminum alloy technology has emerged.

[0003] Traditional aluminum alloy reinforcement technologies mainly include external particle reinforcement and fiber reinforcement. However, these methods have many shortcomings in practical applications. First, the interfacial bonding strength between external particles and the aluminum alloy matrix is ​​often low, resulting in limited reinforcement effects and making it difficult to meet the high performance requirements of high-end fields. Second, although fiber reinforcement technology can improve the strength and toughness of aluminum alloys to a certain extent, the addition of fibers often complicates the material preparation process, significantly increases costs, and the compatibility problem between fibers and the matrix is ​​also difficult to solve. In addition, the wear resistance, fatigue resistance, and corrosion resistance of aluminum alloy materials prepared by traditional methods still need to be improved. Therefore, it is particularly urgent to develop a new technology that can effectively enhance the performance of aluminum alloys while simplifying the preparation process and reducing costs. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide an in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method. By introducing inert ceramic particles and composite salts, a transition layer is formed at the interface between the ceramic particles and the aluminum alloy through solid-state diffusion infiltration and high-temperature in-situ reaction, and nano-compounds are generated, achieving metallurgical bonding between the ceramic particles and the matrix. This bonding method greatly enhances the interfacial bonding strength and effectively improves the strength and hardness of the aluminum alloy. At the same time, the inert ceramic particles are uniformly distributed in the matrix, playing a dispersion strengthening role and further improving the mechanical properties of the material. In addition, the process parameters of this preparation method are precisely controllable, making it easy to achieve large-scale industrial production. This not only reduces production costs but also improves production efficiency, and has broad application prospects and market potential.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: In one aspect, an in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method, wherein the aluminum alloy ingot comprises, by mass fraction, the following components:

[0006] Aluminum alloy matrix 90%-98%;

[0007] Inert ceramic particles: 0.1%-40%;

[0008] Compound salt 0.5%-3%.

[0009] Furthermore, the composite salt is composed of Na2B4O7, AlPO4 and purification aids, wherein Na2B4O7 accounts for 50%-65% of the total mass of the composite salt, AlPO4 accounts for 30%-45%, and the purification aids account for 3%-8%.

[0010] Furthermore, the purification aid is lithium carbonate or sodium bicarbonate.

[0011] Furthermore, the inert ceramic particles can be single particles or mixed particles; single particles can be ZrO2, BN or TiB2; mixed particles can be a combination of ZrO2 and TiB2, or BN and TiB2, wherein the mass percentage of TiB2 in the mixed particles is 30%-70%; the particle size of the inert ceramic particles is 1-10 μm.

[0012] On the other hand, an in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method are disclosed, the method comprising:

[0013] Preparation of composite salt and raw materials: Weigh Na2B4O7, AlPO4 and purification aid according to the proportion. Dry Na2B4O7 and AlPO4 and then crush and sieve them. Dissolve the purification aid in deionized water to make a solution, mix and stir it with the sieved powder, dry it and crush it to obtain composite salt. Weigh aluminum alloy matrix, inert ceramic particles and the above composite salt according to the mass fraction.

[0014] Melt self-cleaning treatment: The aluminum alloy matrix is ​​placed in a melting furnace to obtain aluminum alloy melt. Some composite salt is added to the melt, stirred and allowed to stand, and the slag is skimmed off.

[0015] Solid-state diffusion infiltration: The remaining composite salt is mixed evenly with inert ceramic particles and spread on the surface of a pre-made aluminum alloy blank. The blank is then placed in a sealed reaction furnace and kept at a constant temperature under an inert atmosphere. This allows ions in the composite salt to diffuse infiltrate to the interface between the ceramic particles and the aluminum alloy through solid-state diffusion, forming a transition layer.

[0016] High-temperature in-situ reaction: The billet is heated to near the semi-solid temperature of aluminum alloy and then held at that temperature to allow the elements in the transition layer to react and generate nano-compounds, thus achieving metallurgical bonding between ceramic particles and the matrix.

[0017] Forging: The reacted billet is heated and then hot-forged, and then air-cooled to room temperature to obtain an in-situ self-generated ceramic particle reinforced aluminum alloy ingot.

[0018] Furthermore, in the steps of preparing the composite salt and raw materials, Na2B4O7, AlPO4 and purification aid are weighed according to the proportion. Na2B4O7 and AlPO4 are dried at 80-100℃ for 2-4 hours, pulverized and passed through a 200-mesh sieve. The purification aid is dissolved in deionized water to prepare a solution with a mass fraction of 10%-15%, mixed with the above powder, stirred at 300-400 r / min for 30-60 min, and then dried at 120-150℃ for 5-8 hours. After pulverization, the composite salt is obtained. 90%-98% aluminum alloy matrix, 0.1%-40% inert ceramic particles and 0.5%-3% of the above-prepared composite salt are weighed according to the mass fraction.

[0019] Furthermore, in the melt self-cleaning treatment step, the aluminum alloy matrix is ​​placed in a melting furnace and heated to 700-800℃ to melt it, thereby obtaining an aluminum alloy melt; 30%-50% of the total amount of composite salt is added to the melt, and it is stirred at 200-250r / min for 10-15min, so that the composite salt reacts with the impurities in the melt to generate a slag phase that is easy to float, and the slag is skimmed off after standing for 5-10min.

[0020] Furthermore, in the solid-state diffusion infiltration step, the remaining composite salt is uniformly mixed with inert ceramic particles, spread on the surface of a pre-fabricated aluminum alloy blank, placed in a sealed reaction furnace, heated to 500-600℃, maintaining an inert atmosphere inside the furnace, and held at this temperature for 4-6 hours, allowing the B in the composite salt to... 3+ P 5+ Ions diffuse through solid-state diffusion to the interface between ceramic particles and aluminum alloy, forming a B- and P-rich transition layer.

[0021] Furthermore, in the high-temperature in-situ reaction step, the billet is heated to 600-700℃ and held for 2-3 hours, so that the B and P elements in the B- and P-rich transition layer react with Al to generate AlB2 and AlP nanocompounds.

[0022] Furthermore, in the forging step, the reacted billet is heated to 400-500℃ for hot forging treatment, with a forging ratio of 2-3:1, and finally air-cooled to room temperature to obtain an in-situ self-generated ceramic particle reinforced aluminum alloy ingot.

[0023] Compared with existing technologies, this in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method have the following advantages:

[0024] I. This invention introduces inert ceramic particles and composite salts, which, through solid-state diffusion and high-temperature in-situ reaction, allow ions in the composite salts to form a transition layer at the interface between the ceramic particles and the aluminum alloy, and react to generate nano-compounds, achieving a metallurgical bond between the ceramic particles and the matrix. This bonding method enhances the interfacial bonding strength, improves the strength and hardness of the aluminum alloy, and at the same time, the inert ceramic particles are uniformly distributed in the matrix, playing a dispersion strengthening role, further improving the mechanical properties of the material. This results in aluminum alloy ingots having higher wear resistance, fatigue resistance, and corrosion resistance, meeting the stringent requirements for material performance in high-end fields.

[0025] Second, this invention ensures the quality stability of the composite salt by precisely controlling the proportion of each component and the process parameters of drying, crushing, and stirring. By controlling the amount of composite salt added and the stirring parameters, impurities in the melt are effectively removed, improving the purity of the aluminum alloy melt. By achieving good bonding between ceramic particles and the matrix at a relatively low temperature, the adverse effects of high temperature on material properties are avoided, while energy consumption is reduced. The forging step further optimizes the internal structure of the material, improving its density and uniformity. The process parameters of the entire preparation process are precise and controllable, making it easy to achieve large-scale industrial production, which not only reduces production costs but also improves production efficiency.

[0026] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0028] Figure 1 This is a flowchart of an in-situ self-generated ceramic particle reinforced aluminum alloy ingot and its preparation method. Detailed Implementation

[0029] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0030] Example 1:

[0031] Composition and proportions of aluminum alloy ingots:

[0032] In this embodiment, the composition and proportion of the in-situ self-generated ceramic particle reinforced aluminum alloy ingot are as follows by mass fraction:

[0033] Aluminum alloy matrix (6061 aluminum alloy selected): 95%;

[0034] Inert ceramic particles (TiB2, 5μm particle size, single particle type): 3.5%;

[0035] Composite salt: 1.5%, of which the composite salt components are: Na2B4O7 accounting for 55%, AlPO4 accounting for 40%, and purification aid (lithium carbonate) accounting for 5%.

[0036] The preparation steps of aluminum alloy ingot blanks are as follows: Figure 1 As shown

[0037] Preparation of composite salt and raw materials: Weigh 55g of Na2B4O7, 40g of AlPO4, and 5g of lithium carbonate; dry Na2B4O7 and AlPO4 at 90℃ for 3h, pulverize and pass through a 200-mesh sieve; dissolve lithium carbonate in deionized water to make a 12% mass fraction solution, mix with the above powder, stir at 350r / min for 45min, dry at 130℃ for 6h and pulverize to obtain composite salt; weigh 950g of 6061 aluminum alloy matrix, 35g of TiB2 particles and 15g of composite salt according to the proportion.

[0038] Melt self-cleaning treatment: Place the 6061 aluminum alloy matrix in a melting furnace and heat it to 750℃ to melt it to obtain aluminum alloy melt; add 50% composite salt (7.5g) to the melt, stir at 220r / min for 12min, let it stand for 8min and then skim off the slag to remove oxides and impurities from the melt.

[0039] Solid-state diffusion infiltration: The remaining composite salt (7.5g) was mixed evenly with TiB2 particles and spread on the surface of a pre-fabricated aluminum alloy billet. The billet was then placed in a sealed reactor. Argon gas (inert atmosphere) was introduced, and the temperature was raised to 550℃ and held for 5 hours to allow the B in the composite salt to diffuse in. 3+ P 5+ Ions diffuse to the TiB2-aluminum alloy interface, forming a B- and P-rich transition layer.

[0040] High-temperature in-situ reaction: The billet is heated to 650℃ (close to the semi-solid temperature of 6061 aluminum alloy 615-650℃) and held for 2.5h; B and P in the transition layer react with Al to generate AlB2 and AlP nano compounds, realizing the metallurgical bonding between TiB2 particles and the matrix.

[0041] Forging: The reacted billet is heated to 450°C and hot-forged at a forging ratio of 2.5:1, then air-cooled to room temperature to obtain an aluminum alloy ingot.

[0042] The aluminum alloy ingot prepared in this embodiment, through the metallurgical bonding and dispersion strengthening effect of TiB2 particles with the matrix, has increased tensile strength and hardness by 37.1% and 42.1% respectively, significantly improved wear resistance and salt spray corrosion resistance, reduced wear by 45.6%, and reduced weight loss by 57.3% after 500 hours of salt spray corrosion. Moreover, the process is controllable and energy consumption is low, making it suitable for industrial production.

[0043] Example 2:

[0044] Composition and proportions of aluminum alloy ingots:

[0045] In this embodiment, the composition and proportion of the in-situ self-generated ceramic particle reinforced aluminum alloy ingot are as follows by mass fraction:

[0046] Aluminum alloy matrix (6061 aluminum alloy): 95%;

[0047] Inert ceramic particles (a mixture of ZrO2 and TiB2 particles, with ZrO2 particle size of 5μm and TiB2 particle size of 5μm, and TiB2 accounting for 50% of the mass of the mixture): 3.5%;

[0048] Composite salt: 1.5%, of which the composite salt components are: Na2B4O7 accounting for 65%, AlPO4 accounting for 30%, and purification aid (lithium carbonate) accounting for 5%.

[0049] Preparation steps of aluminum alloy ingot blanks:

[0050] Preparation of composite salt and raw materials: Weigh 65g of Na2B4O7, 30g of AlPO4, and 5g of lithium carbonate; dry Na2B4O7 and AlPO4 at 90℃ for 3h, pulverize and pass through a 200-mesh sieve; dissolve lithium carbonate in deionized water to make a 12% mass fraction solution, mix with the above powder, stir at 350r / min for 45min, dry at 130℃ for 6h and pulverize to obtain composite salt; weigh 950g of 6061 aluminum alloy matrix, 35g of mixed particles (including 17.5g of ZrO2 and 17.5g of TiB2, with TiB2 accounting for 50%) and 15g of composite salt according to the proportion.

[0051] Melt self-cleaning treatment: Place the 6061 aluminum alloy matrix in a melting furnace and heat it to 750℃ to melt it to obtain aluminum alloy melt; add 50% composite salt (7.5g) to the melt, stir at 220r / min for 12min, let it stand for 8min and then skim off the slag to remove oxides and impurities from the melt.

[0052] Solid-state diffusion infiltration: The remaining composite salt (7.5g) was mixed evenly with ZrO2-TiB2 mixed particles (TiB2 content 50%), and spread on the surface of the pre-made aluminum alloy billet. The mixture was then placed in a sealed reaction furnace; argon gas (inert atmosphere) was introduced, and the temperature was raised to 550℃ and held for 5 hours to allow the B in the composite salt to diffuse in.3+ P 5+ Ions diffuse to the interface between the ZrO2-TiB2 mixed particles and the aluminum alloy, forming a B- and P-rich transition layer.

[0053] High-temperature in-situ reaction: The billet is heated to 650℃ (close to the semi-solid temperature of 6061 aluminum alloy 615-650℃) and held for 2.5h; B and P in the transition layer react with Al to generate AlB2 and AlP nano compounds, realizing the metallurgical bonding between ZrO2-TiB2 mixed particles and the matrix.

[0054] Forging: The reacted billet is heated to 450°C and hot-forged at a forging ratio of 2.5:1, then air-cooled to room temperature to obtain an aluminum alloy ingot.

[0055] The aluminum alloy ingot prepared in this embodiment, through the metallurgical bonding and dispersion strengthening effect of ZrO2-TiB2 mixed particles (TiB2 accounting for 50%) with the matrix, has increased tensile strength and hardness by 41.2% and 48.3% respectively, improved wear resistance by 53.5% (reduced wear amount), and reduced weight loss by 60.1% after 500h salt spray corrosion. The process remains controllable, has low energy consumption, and is suitable for industrial production.

[0056] Example 3:

[0057] Composition and proportions of aluminum alloy ingots:

[0058] In this embodiment, the composition and proportion of the in-situ self-generated ceramic particle reinforced aluminum alloy ingot are as follows by mass fraction:

[0059] Aluminum alloy matrix (6061 aluminum alloy): 95%

[0060] Inert ceramic particles (a mixture of BN and TiB2 particles, with BN particle size of 5 μm and TiB2 particle size of 5 μm, and TiB2 accounting for 30% of the mass of the mixture): 3.5%

[0061] Composite salt: 1.5%, of which the composite salt components are: Na2B4O7 accounting for 50%, AlPO4 accounting for 45%, and purification aid (lithium carbonate) accounting for 5%.

[0062] Preparation steps of aluminum alloy ingot blanks:

[0063] Preparation of composite salt and raw materials: Weigh 50g of Na2B4O7, 45g of AlPO4, and 5g of lithium carbonate; dry Na2B4O7 and AlPO4 at 90℃ for 3h, pulverize and pass through a 200-mesh sieve; dissolve lithium carbonate in deionized water to make a 12% mass fraction solution, mix with the above powder, stir at 350r / min for 45min, dry at 130℃ for 6h and pulverize to obtain composite salt; weigh 950g of 6061 aluminum alloy matrix, 35g of mixed particles (of which BN2 4.5g, TiB2 10.5g, TiB2 accounts for 30%), and 15g of composite salt according to the proportion.

[0064] Melt self-cleaning treatment: Place the 6061 aluminum alloy matrix in a melting furnace and heat it to 750℃ to melt it to obtain aluminum alloy melt; add 50% composite salt (7.5g) to the melt, stir at 220r / min for 12min, let it stand for 8min and then skim off the slag to remove oxides and impurities from the melt.

[0065] Solid-state diffusion infiltration: The remaining composite salt (7.5g) was mixed evenly with BN-TiB2 mixed particles (TiB2 content 30%), and spread on the surface of the pre-made aluminum alloy billet. The mixture was then placed in a sealed reaction furnace; argon gas (inert atmosphere) was introduced, and the temperature was raised to 550℃ and held for 5 hours to allow the B in the composite salt to diffuse in. 3+ P 5+ Ions diffuse to the interface between the BN-TiB2 mixed particles and the aluminum alloy, forming a B- and P-rich transition layer.

[0066] High-temperature in-situ reaction: The billet is heated to 650℃ (close to the semi-solid temperature of 6061 aluminum alloy 615-650℃) and held for 2.5h; B and P in the transition layer react with Al to generate AlB2 and AlP nano compounds, realizing the metallurgical bonding between BN-TiB2 mixed particles and the matrix.

[0067] Forging: The reacted billet is heated to 450°C and hot-forged at a forging ratio of 2.5:1, then air-cooled to room temperature to obtain an aluminum alloy ingot.

[0068] The aluminum alloy ingot prepared in this embodiment, through the metallurgical bonding and dispersion strengthening effect of BN-TiB2 mixed particles (TiB2 accounting for 30%) with the matrix, has a 38.5% increase in tensile strength, a 43.7% increase in hardness, a 49.2% improvement in wear resistance (reduction in wear amount), and a 61.0% reduction in weight loss after 500 hours of salt spray corrosion. The process parameters are stable and controllable, with low energy consumption, and are easy to mass-produce industrially.

[0069]

[0070] This invention focuses on in-situ self-generated ceramic particles to reinforce aluminum alloy ingots. Inert ceramic particles and composite salts are added to the aluminum alloy matrix. The invention details the processes of composite salt preparation, melt treatment, diffusion infiltration, in-situ reaction, and forging. As shown in the table above, the effect is verified by changing the proportion of composite salt components. Different ratios all achieve metallurgical bonding between ceramic particles and the matrix, thereby improving performance through dispersion strengthening. Moreover, the process is controllable, suitable for industrial production, and can meet the needs of different fields for high-performance aluminum alloys.

[0071] Example 4:

[0072] Composition and proportions of aluminum alloy ingots:

[0073] In this embodiment, the composition and proportion of the in-situ self-generated ceramic particle reinforced aluminum alloy ingot are as follows by mass fraction:

[0074] Aluminum alloy matrix (6061 aluminum alloy selected): 95%;

[0075] Inert ceramic particles (a mixture of ZrO2 and TiB2 particles, with ZrO2 particle size of 5μm and TiB2 particle size of 5μm, and TiB2 accounting for 70% of the mass of the mixture): 3.5%;

[0076] Compound salt: 2.0% (increased percentage, but the percentages of each component remain unchanged), of which the compound salt components are: Na2B4O7 55%, AlPO4 40%, and purification aid (lithium carbonate) 5%.

[0077] Preparation steps of aluminum alloy ingot blanks:

[0078] Preparation of composite salt and raw materials: The total mass of the ingot is 1000g (950g aluminum alloy matrix corresponds to 95% proportion), the composite salt accounts for 2.0%, so the mass of the composite salt is 20g; Weigh out 11g of Na2B4O7 20×55%=, 8g of AlPO4 20×40%=, and 1g of lithium carbonate 20×5%=: Dry Na2B4O7 and AlPO4 at 90℃ for 3h, pulverize and pass through a 200-mesh sieve; Dissolve lithium carbonate in deionized water to make a 12% mass fraction solution, mix with the above powder, stir at 350r / min for 45min, dry at 130℃ for 6h and pulverize to obtain composite salt; Weigh out 950g of 6061 aluminum alloy matrix, 35g of ZrO2 particles (of which ZrO2 10.5g, TiB2 24.5g, TiB2 accounts for 70%) and 20g of composite salt according to the proportion.

[0079] Melt self-cleaning treatment: Place the 6061 aluminum alloy matrix in a melting furnace and heat it to 750℃ to melt it to obtain aluminum alloy melt; add 50% composite salt (10g) to the melt, stir at 220r / min for 12min, let it stand for 8min and then skim off the scum to remove oxides and impurities from the melt.

[0080] Solid-state diffusion infiltration: The remaining composite salt (10g) was mixed evenly with ZrO2-TiB2 mixed particles (TiB2 content 70%), and spread on the surface of the pre-made aluminum alloy billet. The mixture was then placed in a sealed reaction furnace; argon gas (inert atmosphere) was introduced, and the temperature was raised to 550℃ and held for 5 hours to allow the B in the composite salt to diffuse in. 3+ P 5+ Ions diffuse to the interface between the ZrO2-TiB2 mixed particles and the aluminum alloy, forming a B- and P-rich transition layer.

[0081] High-temperature in-situ reaction: The billet is heated to 650℃ (close to the semi-solid temperature of 6061 aluminum alloy 615-650℃) and held for 2.5h; B and P in the transition layer react with Al to generate AlB2 and AlP nano compounds, realizing the metallurgical bonding between ZrO2-TiB2 mixed particles (TiB2 accounting for 70%) and the matrix.

[0082] Forging: The reacted billet is heated to 450°C and hot-forged at a forging ratio of 2.5:1, then air-cooled to room temperature to obtain an aluminum alloy ingot.

[0083] In this embodiment, the total mass of the composite salt is increased to 2.0%. Due to the increased B and P elements participating in the reaction, the generated AlB2 and AlP nanocompounds are more abundant. The ZrO2-TiB2 mixed particles (TiB2 accounts for 70%) are more fully integrated with the matrix metallurgy. Tests show that the tensile strength is increased by 42.5% (to 445MPa), the hardness is increased by 47.3% (to 138HV), the wear is reduced by 50.2%, and the weight loss due to 500h salt spray corrosion is reduced by 62.2%. Although the energy consumption increases by about 8%, the process is controllable and suitable for high-end aerospace components and other scenarios with stringent performance requirements.

[0084] Example 5:

[0085] Composition and proportions of aluminum alloy ingots:

[0086] In this embodiment, the composition and proportion of the in-situ self-generated ceramic particle reinforced aluminum alloy ingot are as follows by mass fraction:

[0087] Aluminum alloy matrix (6061 aluminum alloy selected): 95%;

[0088] Inert ceramic particles (a mixture of BN and TiB2 particles, with BN particle size of 5 μm and TiB2 particle size of 5 μm, and TiB2 accounting for 60% of the mass of the mixture): 3.5%;

[0089] Composite salt: 1.0% (the proportion is reduced, but the proportion of each component remains unchanged), of which the composite salt components are: Na2B4O7 accounting for 55%, AlPO4 accounting for 40%, and purification aid (lithium carbonate) accounting for 5%.

[0090] Preparation steps of aluminum alloy ingot blanks:

[0091] Preparation of composite salt and raw materials: The total mass of the ingot is 1000g (same logic as in Example 1). The composite salt accounts for 1.0%, so the mass of the composite salt is 10g. Weigh out 5.5g of Na2B4O7 (10×55%), 4g of AlPO4 (10×40%), and 1g of lithium carbonate (10×5%). Dry Na2B4O7 and AlPO4 at 90℃ for 3h, pulverize and pass through a 200-mesh sieve. Dissolve lithium carbonate in deionized water to make a 12% mass fraction solution, mix with the above powder, stir at 350r / min for 45min, dry at 130℃ for 6h and pulverize to obtain the composite salt. Weigh out 950g of 6061 aluminum alloy matrix, 35g of mixed particles (including 14g of BN and 21g of TiB2, with TiB2 accounting for 60%) and 10g of composite salt according to the proportion.

[0092] Melt self-cleaning treatment: Place the 6061 aluminum alloy matrix in a melting furnace and heat it to 750℃ to melt it to obtain an aluminum alloy melt; add 50% composite salt (5g) to the melt, stir at 220r / min for 12min, let it stand for 8min and then skim off the scum to remove oxides and impurities from the melt.

[0093] Solid-state diffusion infiltration: The remaining composite salt (5g) was mixed evenly with BN-TiB2 mixed particles (TiB2 content 60%), and spread on the surface of the pre-made aluminum alloy billet. The mixture was then placed in a sealed reaction furnace; argon gas (inert atmosphere) was introduced, and the temperature was raised to 550℃ and held for 5 hours to allow the B in the composite salt to diffuse in. 3+ P 5+ Ions diffuse to the interface between the BN-TiB2 mixed particles and the aluminum alloy, forming a B- and P-rich transition layer.

[0094] High-temperature in-situ reaction: The billet is heated to 650℃ (close to the semi-solid temperature of 6061 aluminum alloy, 615-650℃) and held for 2.5h; B and P in the transition layer react with Al to generate AlB2 and AlP nano compounds, and BN-TiB2 mixed particles (TiB2 accounts for 60%) are metallurgically bonded to the matrix.

[0095] Forging: The reacted billet is heated to 450°C and hot-forged at a forging ratio of 2.5:1, then air-cooled to room temperature to obtain an aluminum alloy ingot.

[0096] In this embodiment, the total mass of the composite salt is reduced to 1.0%, the amount of B and P elements participating in the reaction is reduced, the amount of nano-compounds generated is insufficient, and the bonding strength between the BN-TiB2 mixed particles (TiB2 accounts for 60%) and the matrix is ​​slightly reduced. Tests show that the tensile strength is increased by 32.6%, the hardness is increased by 36.8%, the wear is reduced by 40.8%, the weight loss after 500 hours of salt spray corrosion is reduced by 52.4%, and the energy consumption is reduced by about 12%. It is suitable for the production of ordinary industrial structural parts with mild performance requirements and a focus on cost control.

[0097]

[0098] As shown in the table above, Examples 1, 4, and 5 all used 6061 aluminum alloy as the matrix. The inert ceramic particles all met the requirements of "single particles can be TiB2, and mixed particles can be a combination of ZrO2 and TiB2, or BN and TiB2, with TiB2 accounting for 30%-70%". Furthermore, the aluminum alloy ingots were prepared using the same steps, with the only difference being the total amount of composite salt added. The different total amounts of composite salt resulted in varying amounts of B participating in solid-state diffusion infiltration. 3+ P 5+ The amount of ions and the quantity of AlB2 and AlP nanocompounds generated by the high-temperature in-situ reaction differ, resulting in variations in the bonding effect between ceramic particles and the matrix and the degree of material performance improvement. Higher composite salt content leads to a more abundant ion supply, a denser transition layer, and a greater amount of nanocompounds generated, resulting in more significant improvements in tensile strength, hardness, wear resistance, and corrosion resistance. Conversely, lower content results in a more moderate performance improvement but lower energy consumption. However, all three achieve performance enhancements through the metallurgical bonding and dispersion strengthening effect of TiB2 with the matrix, and the entire process is controllable, making them suitable for industrial production. They can respectively meet the needs of high-end demanding applications, balanced performance applications, and cost-sensitive general industrial applications for high-performance aluminum alloys.

[0099] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. An in-situ self-generated ceramic particulate reinforced aluminum alloy ingot characterized in that, The aluminum alloy ingot, by mass fraction, comprises the following components: Aluminum alloy matrix 95%-98%; Inert ceramic particles 0.1%-3.5%; the inert ceramic particles are single particles or mixed particles; the single particles can be ZrO2, BN or TiB2; the mixed particles can be a combination of ZrO2 and TiB2, BN and TiB2; Composite salt 0.5%-3%; the composite salt is composed of Na2B4O7, AlPO4 and a purification aid, wherein Na2B4O7 accounts for 50%-65% of the total mass of the composite salt, AlPO4 accounts for 30%-45%, and the purification aid accounts for 3%-8%; the purification aid is lithium carbonate or sodium bicarbonate; The preparation method of the aluminum alloy ingot comprises the following steps: Preparation of the composite salt and preparation of raw materials: weigh Na2B4O7, AlPO4 and the purification aid according to the proportion, dry and crush Na2B4O7 and AlPO4 after drying, and sieve; dissolve the purification aid in deionized water to form a solution, mix and stir the sieved powder, dry and crush to obtain the composite salt; weigh the aluminum alloy matrix, inert ceramic particles and the above-mentioned composite salt according to the mass fraction; Self-cleaning treatment of the melt: melt the aluminum alloy matrix in a melting furnace to obtain an aluminum alloy melt, add part of the composite salt to the melt, stir and stand, and remove the dross; Solid-state diffusion penetration: the remaining composite salt is mixed with inert ceramic particles uniformly, laid on the surface of the pre-prepared aluminum alloy blank, put into a sealed reaction furnace, heated to 500-600°C, kept in an inert atmosphere in the furnace, and kept for 4-6h, so that B 3+ , P 5+ ions in the composite salt diffuse and penetrate to the interface between the ceramic particles and the aluminum alloy to form a B, P-rich transition layer; High-temperature in-situ reaction: heat the blank to a temperature close to the semi-solid temperature of the aluminum alloy and keep it for 2-3 hours, so that the elements in the transition layer react to form nanometer compounds, and the ceramic particles and the matrix are metallurgically combined; Forging forming: heat the reacted blank and perform hot forging treatment, and air cool to room temperature to obtain the in-situ self-grown ceramic particle reinforced aluminum alloy ingot; In the high-temperature in-situ reaction step, the blank is heated to 600-700℃ and kept for 2-3 hours, so that the B and P elements in the B and P-rich transition layer react with Al to form AlB2 and AlP nanometer compounds; In the forging forming step, the reacted blank is heated to 400-500℃, hot forging treatment is performed, the forging ratio is 2-3:1, and finally air cooling to room temperature is performed to obtain the in-situ self-grown ceramic particle reinforced aluminum alloy ingot.

2. The in-situ formed ceramic particle reinforced aluminum alloy ingot of claim 1, wherein, The mass ratio of TiB2 in the mixed particles is 30%-70%; the particle size of the inert ceramic particles is 1-10μm.

3. The in-situ formed ceramic particle reinforced aluminum alloy ingot of claim 1, wherein, In the composite salt preparation and raw material preparation step, weigh Na2B4O7, AlPO4 and the purification aid according to the proportion, dry Na2B4O7 and AlPO4 at 80-100℃ for 2-4 hours, crush and sieve through a 200-mesh sieve; dissolve the purification aid in deionized water to form a solution with a mass fraction of 10%-15%, mix with the above-mentioned powder, stir at a speed of 300-400r / min for 30-60 minutes, then dry at 120-150℃ for 5-8 hours, and crush to obtain the composite salt; weigh the aluminum alloy matrix 95%-98%, inert ceramic particles 0.1%-3.5% and the above-mentioned composite salt 0.5%-3% according to the mass fraction.

4. The in-situ formed ceramic particle reinforced aluminum alloy ingot of claim 1, wherein, In the melt self-cleaning treatment step, the aluminum alloy base is placed in a smelting furnace, heated to 700-800 DEG C to melt, and an aluminum alloy melt is obtained; 30%-50% of the total amount of the composite salt is added to the melt, stirred at 200-250 r / min for 10-15 min, and the composite salt reacts with impurities in the melt to generate a easily floating slag phase, and the floating slag is removed after standing for 5-10 min.

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