Copper-iron alloy

Abstract

[Problem] This invention relates to: a copper-iron alloy which has high performance as a shielding material against electromagnetic waves and for which metal is obtained by adding, to metal obtained by melting copper and iron in a furnace, chaff ash as a catalyst and thereby removing gas from within the melt and uniformly distributing the mixture of copper and iron; and a method for manufacturing said copper-iron alloy.　[Solution] Provided is a copper-iron alloy characterized by comprising a compound obtained by adding, to metal obtained by melting copper and iron in a furnace, chaff ash as a catalyst and thereby distributing the mixture of copper and iron.

Description

Copper-iron alloy

[0001] This invention relates to a copper-iron alloy that has high performance as a shielding material against electromagnetic waves, which is obtained by adding rice husk ash as a catalyst to a metal made by melting copper and iron in a furnace, and then forming a metal in which the mixture of copper and iron is uniformly distributed.

[0002] A conventional method for producing copper-iron alloys is disclosed in Japanese Patent No. 5608704, which includes a copper molten metal degassing step in which electrolytic copper is melted in a first melting furnace and gas is removed from the molten copper; a molten iron degassing step in which pure iron is melted in a second melting furnace and gas is removed from the molten iron; a reaction step in which the temperature of the molten copper in the first melting furnace is increased to approximately the same as that of the molten iron in the second melting furnace and then mixed to cause a crystallization reaction between the copper and iron; and a pouring step in which the crystallized molten metal is poured into a mold. Also known in the copper molten metal degassing step is a method in which a deoxidizer containing at least one of silicon, phosphorus, or lithium is added to the molten copper. Another known method in the iron molten metal degassing step is a method in which a deoxidizer containing at least one of aluminum, manganese, titanium, or silicon is added to the molten iron.

[0003] JP 2013-237887 (Patent No. 5608704)

[0004] The conventional manufacturing process involves melting electrolytic copper in a first melting furnace and degassing the molten copper. Then, pure iron is melted in a second melting furnace and degassed. The temperature of the molten copper in the first melting furnace is increased to approximately the same temperature as the molten iron in the second melting furnace, and the two are mixed together to cause a crystallization reaction between the copper and iron. The resulting molten metal is then poured into a mold. Examples of adding a deoxidizer such as silicon to the molten copper or molten iron degassing process have also been disclosed. However, copper and iron are metals with completely different properties. Even if they are melted in a furnace to form an alloy, the copper and iron will separate when exposed to air. Therefore, a cooling technique that prevents contact with air is required to create a uniformly distributed copper and iron compound. In this invention, copper and iron are melted in a furnace and then reacted using rice husk ash, a pyrolyzed plant silica, as a catalyst. This not only removes gas from the molten copper and iron, but also uniformly disperses the copper and iron compounds. Furthermore, the inventors discovered that even if the molten copper is cooled in an ingot case in the air, the uniform dispersion of the copper and iron compounds is not lost, leading to the completion of this invention. Furthermore, adding a metal that improves magnetic properties to the catalyst enhances the magnetic shielding effect beyond that of copper and iron alone. Furthermore, the electromagnetic wave shielding effect of the copper-iron compound is not lost even when it is reheated and processed by extrusion, rolling, drawing, etc.

[0005] The problem that this invention aims to solve is an invention that adds rice husk ash as a catalyst to a metal made by melting copper and iron in a furnace, resulting in a metal in which the mixture of copper and iron is uniformly distributed, making it possible to create a copper-iron alloy that has high performance as a shielding material against electromagnetic waves.

[0006] In order to solve the above problems, the present invention provides, in claim 1, a copper-iron alloy characterized by being composed of a compound in which a mixture of copper and iron is uniformly dispersed by adding rice husk ash as a catalyst to a metal obtained by melting copper and iron in a furnace.

[0007] Copper and iron are metals with completely different properties. Even if they are melted in a furnace to form an alloy, the copper and iron separate when exposed to air. Therefore, a cooling technique without air contact is required to create a uniformly distributed copper-iron compound. In this patent, copper and iron are melted in a furnace and then reacted with fine powder of pyrolyzed rice husk ash (white silica) as a catalyst. This degassing of the molten copper and iron occurs, and the copper-iron compounds are uniformly dispersed. Furthermore, even when the molten copper is cooled in an ingot case in the air, the uniform dispersion of the copper-iron compounds is not lost. Furthermore, adding a metal that improves magnetic properties to the catalyst enhances the magnetic shielding effect beyond that of copper and iron alone. Furthermore, the copper-iron compound maintains its electromagnetic wave shielding effect even when reheated and processed through processes such as extrusion, rolling, and drawing. Furthermore, by melting copper and iron in separate furnaces or in the same furnace and then adding pyrolyzed rice husk ash as a catalyst, the copper and iron become a uniformly dispersed compound, which has a high electromagnetic wave shielding effect. By melting copper and iron in a furnace and then adding pyrolyzed rice husk ash as a catalyst, the copper and iron do not lose their uniformly dispersed characteristic even when cooled in air. Furthermore, rice husk powder can also simultaneously degas copper and iron bathwater. Furthermore, this copper-iron compound does not lose its electromagnetic wave shielding effect even when reheated and processed into products.

[0008] 1 is a flowchart for producing a copper-iron alloy.

[0009] A preferred embodiment of the present invention will be described below with reference to the drawings. Fine copper powder 2, fine iron powder 3, and only vegetable silica as an additive 4 are placed in an electric melting furnace 1 (see FIG. 1). Next, these are melted in the melting furnace 1, and the gas in the molten metal is degassed. Here, the fine copper powder 2 and the fine iron powder 3 may be melted and degassed separately in separate melting furnaces (A) and (B), or they may be melted and degassed in the same melting furnace.

[0010] At the same time, or after this, white silica fine powder using rice husks as a catalyst is added.The temperature of the molten metal is then raised to cause a crystallization reaction, and the molten metal is then poured into a mold.

[0011] Since white silica fine powder also functions as a deoxidizer, it can be added to the molten alloy during the degassing process. It can also function as a catalyst for the copper-iron alloy. The copper-iron alloy is then crystallized in the furnace, and the resulting molten alloy is poured into an ingot case for processing.

[0012] The ingot obtained by pouring has a uniform distribution of crystals of Cu / Fe compounds, and can be made into various industrial materials by processing such as extrusion, rolling, drawing, etc. Such industrial materials have excellent properties as shielding materials against electromagnetic waves because they contain dispersed crystal pieces of Cu / Fe, which are highly permeable.

[0013] 1 Melting furnace 2 Fine copper powder 3 Fine iron powder 4 White silica fine powder

Claims

1. A copper-iron alloy characterized in that by adding rice husk ash as a catalyst to a metal obtained by melting copper and iron in a furnace, a compound in which the copper and iron mixture is uniformly dispersed is formed.

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