Briquette manufacturing method

Abstract

This disclosure provides a method for producing briquettes that can improve the dissolution yield of metal powders used for component adjustment. [Solution] The method for manufacturing a briquette according to the present disclosure is a method for manufacturing a briquette 10 used for casting an alloy, comprising: a step of mixing scrap material 1 generated when manufacturing a metal member with metal powder 2 for adjusting the composition; a pressing step of compressing the mixed scrap material 1 and metal powder 2 to form a briquette 10; and a heating step of heating the briquette 10 to alloy the contact surface between the scrap material 1 and the metal powder 2.

Description

Technical Field

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[0001] The present disclosure relates to a method for manufacturing briquettes.

Background Art

[0002] Edge materials generated during the production of metal members, such as swarf (also called chips) generated by cutting the metal member and abrasive dust generated by polishing, are strongly desired to be reused from the perspective of resource conservation. For example, Patent Document 1 discloses a method for reusing swarf of an aluminum alloy by melting a briquette formed by compressing the swarf of the aluminum alloy and using it in casting.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Regarding the briquettes used for casting an alloy, the inventors have found the following problems. In order to obtain a molten metal of a target alloy composition, the inventors have considered putting into the molten metal not only the briquettes formed by compression molding the above-mentioned edge materials but also the briquettes formed by compression molding metal powders for component adjustment.

[0005] However, the briquettes of the metal powders for component adjustment may be powdered due to, for example, vibrations during transportation or contact with other briquettes. The powdered metal for component adjustment floats on the molten metal and is difficult to melt, which may deteriorate the melting yield into the molten metal.

[0006] The present disclosure has been made to solve such problems, and provides a method for manufacturing a briquette capable of improving the melting yield of metal powders for component adjustment. [Means for solving the problem]

[0007] The method for manufacturing briquettes according to this disclosure is a method for manufacturing briquettes used for casting alloys, comprising: a step of mixing scrap material generated during the manufacture of a metal member with metal powder for component adjustment; a pressing step of compressing the mixed scrap material and metal powder to form a briquette; and a heating step of heating the briquette to alloy the contact surface between the scrap material and the metal powder. This improves the dissolution yield of the metal powder for component adjustment.

[0008] The metal powder may have a higher melting point than the scrap material.

[0009] The heating step may be carried out by irradiating the briquette with microwaves to heat the briquette.

[0010] The alloy cast using the briquet is an Al-Si alloy, the scrap material is composed of the Al-Si alloy, and the metal powder may be Si powder.

[0011] The aforementioned scrap material may also be metal shavings. [Effects of the Invention]

[0012] This disclosure provides a method for producing briquettes that can improve the dissolution yield of metal powders used for component adjustment. [Brief explanation of the drawing]

[0013] [Figure 1] Figure 1 shows the configuration of the briquette according to this disclosure. [Figure 2] Figure 2 is a flowchart of the method for manufacturing briquettes according to this disclosure. [Figure 3] Figure 3 shows the briquettes before the heating step in the method for manufacturing briquettes according to the present disclosure. [Figure 4]Figure 4 shows the briquette after the heating step in the method for manufacturing briquettes according to the present disclosure. [Modes for carrying out the invention]

[0014] Embodiment 1 The method for manufacturing briquettes according to this disclosure will be described below with reference to the figures.

[0015] <Composition of a briquette> First, the structure of the briquette according to this disclosure will be described with reference to Figure 1. Figure 1 is a diagram showing the structure of the briquette according to this disclosure. The briquette 10 is used to cast an alloy. More specifically, first, the briquette 10 is placed into the molten metal. The molten metal in which the briquette 10 has melted is then used to cast a new alloy. The briquette 10 is formed by mixing scrap material 1 generated during the manufacture of a metal component with metal powder 2 for adjusting the composition, and then compression molding it. Note that the composition of the alloy cast using the briquette 10 as a raw material does not necessarily have to be the same as the composition of the scrap material 1. In this embodiment, both the alloy cast using the briquette 10 and the alloy constituting the scrap material 1 are Al-Si alloys.

[0016] The scrap material 1 is, for example, chips or grinding debris generated by machining or polishing an alloy. The alloy constituting the scrap material 1 is not particularly limited. For example, the scrap material 1 may be made of an Al alloy, a Ti alloy, a Mg alloy, etc. In this embodiment, the scrap material 1 is made of an Al-Si alloy, which is an aluminum alloy.

[0017] The metal powder 2 is included in the briquette 10 to adjust the composition of the alloy made from the briquette 10. The metals constituting the metal powder 2 are not particularly limited. For example, the metal powder 2 may be composed of Si, Mn, Mg, etc. In this embodiment, the metal powder 2 is Si powder.

[0018] In this embodiment, the alloy and end material 1 cast using the briquette 10 are Al-Si based alloys. When it is desired to adjust the concentration of Si in the Al-Si based alloy cast using the briquette 10, for example, the metal powder 2 of the Fe-Si based alloy can also be used. However, if the proportion of the metal powder 2 of the Fe-Si based alloy in the briquette 10 is increased to increase the concentration of Si, the concentration of Fe will also increase along with Si. On the other hand, if the metal powder 2 is made into Si powder, only the concentration of Si can be adjusted in the composition adjustment of the alloy using the briquette 10 as a raw material.

[0019] <Method for manufacturing briquette> Next, referring to FIGS. 2 to 4, the method for manufacturing a briquette according to the present disclosure will be described. FIG. 2 is a flowchart of the method for manufacturing a briquette according to the present disclosure. FIG. 3 is a diagram showing the briquette before the heating step in the method for manufacturing a briquette according to the present disclosure. FIG. 4 is a diagram showing the briquette after the heating step in the method for manufacturing a briquette according to the present disclosure. The method for manufacturing the briquette 10 according to the present disclosure includes a mixing step (step S101), a pressing step (step S102), and a heating step (step S103).

[0020] First, in the mixing step, the end material 1 and the metal powder 2 are mixed (step S101). The end material 1 and the metal powder 2 are, for example, put into a mixer and stirred in the mixer, and the end material 1 and the metal powder are mixed. Then, the mixed end material 1 and metal powder 2 are transported to the next pressing step (step S102).

[0021] Next, in the pressing step, the mixed end material 1 and metal powder 2 are compressed to form the briquette 10 (step S102). The end material 1 and the metal powder 2 are compressed by a press at a predetermined pressure and time to form the briquette 10. For example, in this embodiment, the end material 1 made of an Al-Si based alloy and the metal powder 2 which is Si powder are compressed at 150 MPa for 300 seconds. Note that the appropriate pressure and time vary greatly depending on the type, shape, size, etc. of the metal material. Therefore, the pressure and time are not limited to the above example.

[0022] As shown in FIG. 3, the end material 1 and the metal powder 2 come into contact with each other within the briquette 10 by being compressed. The end material 1 within the briquette 10 has a smaller area in contact with air compared to the state of the end material 1 alone, so the contact with oxygen is reduced and oxidation is suppressed. Then, the formed briquette 10 is conveyed to the next heating process (step S103).

[0023] Next, in the heating process, the briquette 10 is irradiated with microwaves and heated (step S103). The briquette 10 is put into a heating furnace and heated at a predetermined time and temperature. For example, in this embodiment, the briquette 10 composed of the end material 1 of an Al - Si - based alloy and the metal powder 2 of Si powder is irradiated with microwaves of about 1 kW, and the heating is terminated when the temperature reaches the predetermined temperature from room temperature. As specific examples, for the first example, the heating is terminated when the temperature reaches 400°C from room temperature, and the total heating time is 900 seconds; for the second example, the heating is terminated when the temperature reaches 600°C from room temperature, and the total heating time is 1500 seconds (the heating time from 400°C to 600°C is 900 seconds); for the third example, the heating is terminated when the temperature reaches 800°C from room temperature, and the total heating time is 3000 seconds (the heating time from 400°C to 600°C is 600 seconds, and the heating time from 600°C to 800°C is 1800 seconds), etc. Note that the heating time and heating temperature are appropriately set according to the appropriate output of microwaves depending on the type, shape, size, etc. of the metal material. By using microwaves, it is possible to heat the inside of the briquette with high energy efficiency or time efficiency. However, depending on the target quality, device limitations, etc., heating methods other than microwaves, such as electric heating, gas heating, infrared heating, etc., can be appropriately adopted.

[0024] By heating the briquette 10, the moisture and oil remaining in the end material 1 and the metal powder 2 volatilize. Further, as shown in FIG. 4, by heating the briquette 10, the contact surfaces of the end material 1 and the metal powder 2 are alloyed, and the alloy layer 3 is formed.

[0025] By alloying the contact surfaces of the scrap material 1 and the metal powder 2, the mechanical bond between the scrap material 1 and the metal powder 2 becomes stronger. This suppresses the pulverization of the scrap material 1 and the metal powder 2 within the briquette 10 caused by vibrations during transportation of the briquette 10 and contact with other briquettes 10. Therefore, the melting yield of the scrap material 1 and the metal powder 2 within the briquette 10 into the molten metal can be improved.

[0026] Here, if the melting point of the metal powder 2 in the briquette 10 is higher than the melting point of the scrap material 1, the metal powder 2 will not dissolve easily in the molten metal. Therefore, if the contact surface between the scrap material 1 and the metal powder 2 in the briquette 10 is not alloyed, the temperature of the molten metal required to melt the briquette 10 will be higher than when melting the scrap material 1 alone. As a result, energy consumption such as electricity and fuel will increase in order to maintain the temperature of the molten metal at a high temperature.

[0027] In contrast, in briquettes 10, the contact surface between the scrap material 1 and the metal powder 2 is pre-alloyed, making it easier for the metal powder 2 to dissolve in the molten metal. Therefore, the temperature of the molten metal required to melt the briquettes 10 can be kept low, thereby suppressing an increase in energy consumption. The melting point of the alloy layer 3, which is composed of an Al-Si alloy, is lower than the melting point of the metal powder 2, which is Si powder.

[0028] As described above, the briquette manufacturing method according to this disclosure makes it possible to improve the dissolution yield of the metal powder 2 contained in the briquette 10 by alloying the contact surface between the scrap material 1 and the metal powder 2 contained in the briquette 10. Furthermore, it is possible to suppress the energy consumption required to dissolve the briquette 10.

[0029] It should be noted that the present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the spirit of the invention. [Explanation of Symbols]

[0030] 1. Scrap wood 2 Metal powder 3 alloy layer 10 briquettes

Claims

1. A method for manufacturing briquettes used for casting alloys, A process of mixing scraps generated during the manufacture of metal components with metal powder for adjusting the composition, A pressing step in which the mixed scrap material and the metal powder are compressed to form a briquette, The process includes a heating step of heating the briquette to alloy the contact surface between the scrap material and the metal powder. A method for manufacturing briquettes.

2. The aforementioned metal powder has a higher melting point than the aforementioned scrap material. A method for producing briquettes according to claim 1.

3. The heating step involves heating the briquette by irradiating it with microwaves. A method for producing briquettes according to claim 1 or 2.

4. The alloy cast using the aforementioned briquettes is an Al-Si alloy. The aforementioned scrap material is composed of the Al-Si alloy, The aforementioned metal powder is Si powder. A method for producing briquettes according to claim 1 or 2.

5. The aforementioned scrap material is metal shavings. A method for producing briquettes according to claim 1 or 2.

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