EP1083013A2 - Preparation of foamable metal bodies and metal foams - Google Patents
Preparation of foamable metal bodies and metal foams Download PDFInfo
- Publication number
- EP1083013A2 EP1083013A2 EP00119602A EP00119602A EP1083013A2 EP 1083013 A2 EP1083013 A2 EP 1083013A2 EP 00119602 A EP00119602 A EP 00119602A EP 00119602 A EP00119602 A EP 00119602A EP 1083013 A2 EP1083013 A2 EP 1083013A2
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- EP
- European Patent Office
- Prior art keywords
- metal
- powder
- blowing agent
- gas
- powder mixture
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
- B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
- B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
- B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
- B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
Definitions
- the invention relates to a method for producing foamable metal bodies, being from a powder mixture which is at least one metal powder and at least a gas-releasing propellant powder, which when heated to a temperature splits off gas at or above the decomposition temperature of the blowing agent, a compact body is made.
- the invention also relates to those obtained from the foamable metal bodies Metal foams, also as a component of molded parts and composite bodies.
- the present invention has for its object a method and a Show device of the type mentioned by which the manufacture of foamable metal bodies simplified and / or the variability in Production of foamable metal bodies is enlarged.
- This object is achieved for the method in that the Production of the compact body by thermal spraying of the powder mixture using high-speed flame spraying or cold gas spraying.
- the object is achieved for the device in that the means for producing the compact body from the powder mixture a device for thermal spraying by means of high-speed flame spraying or cold-cold spraying.
- Thermal spray processes are essentially characterized in that they enable uniformly applied coatings of high quality and quality. Coatings applied by thermal spraying can be varied the spray materials and / or the process parameters to different requirements be adjusted.
- the spray materials can basically in Form of wires, rods or can be processed as a powder. There can also be one Aftertreatment should be provided.
- thermal spraying Details of thermal spraying are, for example, the European standard EN 657 refer to.
- a process variant of thermal spraying that has been known for some time provides high-speed flame spraying (sometimes also as an HVOF process [High Velocity Oxy-Fuel]).
- a high-speed flame spraying process can do the high-speed flame spraying first and second generation with medium spray particle speeds of 400 to 500 m / s (measured with a WC-Co spray powder with a grain size - 45 ⁇ m + 10 ⁇ m, i.e. a distribution with respect to the grain diameter of 10 to 45 ⁇ m) and prefers third generation high speed flame spraying Spray particle speeds of 500 to 700 m / s (measured with a spray powder WC-Co with a grain size - 45 ⁇ m + 10 ⁇ m) can be used.
- With cold gas spraying can accelerate the powder particles to a speed of 300 to 1600 m / s become. Speeds of the powder particles are particularly suitable between 500 and 1200 m / s to achieve particularly high application efficiency and layer densities.
- metal powder is used together with one containing the blowing agent Powder by high-speed flame spraying or cold gas spraying processed into a compact body.
- the compact body can be used as a layer or present as a shaped body. Because of the short residence time of the powder (usually this is in the range of a few milliseconds) with high-speed cold gas spraying in the heated carrier gas jet, the blowing agent remains at least in the essentially tied. If desired, it will only be heated up afterwards free to foam.
- the invention provides a simple and versatile method of manufacture of the foamable metal body.
- the so produced Metal bodies can be heated to a temperature equal to or preferred above the decomposition temperature of the blowing agent and then cooling can be used for the production of porous metal bodies or metal foams.
- the decomposition temperature of the blowing agent is not a sharp temperature value but a temperature range. In the context of the invention is therefore under a Temperature equal to or preferably above the decomposition temperature of the blowing agent in these cases a temperature in the decomposition temperature range or preferably understood above the decomposition temperature range of the blowing agent.
- the powder mixture can consist of metal plus blowing agent can be sprayed in almost any mixing ratio. This allows, that the mixing ratio of metal powder and blowing agent powder to each desired conditions is adjusted.
- the powder mixture is injected with a different proportion of propellant. Because through a change The mixing ratio of metal and blowing agent can layers and Structures are injected with a preferably changing propellant proportion (graded layers, structures).
- a proportion of blowing agent in the powder mixture between 0.01 and 1.0% by weight, preferably between 0.05 and 0.5% by weight, particularly preferably between 0.1 and 0.3% by weight.
- the gas-releasing blowing agent powder comprises, as blowing agent, metal hydrides, such as, for example, titanium hydrite (TiH 2 ), carbonates, such as, for example, calcium carbonate, potassium carbonate, sodium carbonate or sodium bicarbonate, hydrates, such as, for example, aluminum sulfate hydrate, alum, aluminum hydroxide or easily evaporating substances such as, for example, mercury compounds or powdered mercury compounds organic substances or mixtures of the aforementioned substances.
- metal hydrides such as, for example, titanium hydrite (TiH 2 )
- carbonates such as, for example, calcium carbonate, potassium carbonate, sodium carbonate or sodium bicarbonate
- hydrates such as, for example, aluminum sulfate hydrate, alum, aluminum hydroxide or easily evaporating substances such as, for example, mercury compounds or powdered mercury compounds organic substances or mixtures of the aforementioned substances.
- the powder mixture can advantageously be sprayed onto a substrate carrier, wherein at least temporarily a relative movement between the substrate carrier and the device for thermal spraying of the powder mixture using high-speed flame spraying or cold gas spraying.
- a substrate carrier for example, with the Powder mixture molded parts are injected, for example the spray gun Device for thermal spraying and / or the substrate carrier are moved.
- the powder mixture can be applied to any suitable substrate carrier in particular on a carrier material made of metal, plastic, ceramic and / or glass be injected.
- the compact body can advantageously be detached from the carrier material are, before a release of gas from the propellant by heating Foaming of the compact body takes place.
- the compact body can be released before the gas is released the blowing agent for foaming the compact body by changing the Pressure and / or temperature are deformed or reshaped.
- compressions For example, extrusion presses or rollers can be used.
- the powder mixture is on the inside injected into a mold that was wholly or partially foamed with metal foam shall be.
- the foaming agent's decomposition temperature is used to manufacture the metal foam.
- At least two layers are injected, wherein at least one layer with the metal powder and gas-releasing blowing agent powder comprehensive powder mixture and at least one further layer with metal powder can be thermally sprayed without gas-releasing blowing agent.
- the powder mixture of metal and blowing agent only in layers between two metal layers be injected.
- Metal foam By heating the compact body using the procedure described above is produced, to a temperature equal to or preferably above the decomposition temperature of the blowing agent and a subsequent cooling can Metal foam can be made.
- the compact is preferably heated Body to a temperature above the melting temperature of the metal or above the target alloy temperature of the metal alloy. In this case it foams as a gas escaping blowing agent on the molten metal. This foam forms after Cool a porous hollow body. So is preferred when decomposing the Blowing agent released gas the metal or the metal alloy as a melt lather up.
- Molded parts can be produced which comprise at least one metal foam.
- composite bodies can be produced which are at least one metal foam Include layer on or between a substrate support.
- For molded parts or composite bodies can in addition to the at least one foamed metal layer at least there is another thermally sprayed layer.
- Titanium hydride (TiH 2 ) is particularly suitable as a blowing agent.
- Titanium hydride can, for example, be sprayed using cold gas spraying together with other metal powders made of aluminum (Al), copper (Cu), nickel (Ni), iron (Fe), titanium (Ti) and alloys that contain one or more of these metals.
- a relatively small proportion of the blowing agent is sufficient to foam the compact body.
- a powder mixture with 0.2% by weight of TiH 2 and with essentially Al as the metal powder leads to a foam body with about five times the volume increase.
- a blowing agent content of 1.0% by weight of TiH 2 increases the volume of Al by more than ten times.
- the gas required for thermal spraying can be nitrogen, helium, argon, neon, Krypton, xenon, a gas containing hydrogen, a gas containing carbon, in particular carbon dioxide, oxygen, an oxygen-containing gas, air, Contain water vapor or mixtures of the aforementioned gases.
- a gas containing hydrogen in particular carbon dioxide, oxygen, an oxygen-containing gas, air, Contain water vapor or mixtures of the aforementioned gases.
- the powdered filler gas carrying a nitrogen, argon, neon, krypton, Xenon, oxygen, a gas containing hydrogen, a carbon-containing gas, in particular carbon dioxide, water vapor or mixtures of the aforementioned gases and mixtures of these gases with helium.
- the proportion of helium in the total gas can up to 90 vol .-%.
- a helium content of 10 to 50% by volume is preferred Gas mixture observed.
Abstract
Description
Die Erfindung betrifft ein Verfahren zur Herstellung von aufschäumbaren Metallkörpern, wobei aus einem Pulvergemisch, welches zumindest ein Metallpulver und zumindest ein gasabspaltendes Treibmittelpulver, welches bei Aufheizen auf eine Temperatur gleich oder oberhalb der Zersetzungstemperatur des Treibmittels Gas abspaltet, umfaßt, ein kompakter Körper hergestellt wird.The invention relates to a method for producing foamable metal bodies, being from a powder mixture which is at least one metal powder and at least a gas-releasing propellant powder, which when heated to a temperature splits off gas at or above the decomposition temperature of the blowing agent, a compact body is made.
Die Erfindung betrifft ferner eine Vorrichtung zum Herstellen von Metallschäumen, umfassend
- Mittel zur Zufuhr eines Pulvergemisches, welches zumindest ein Metallpulver und zumindest ein gasabspaltendes Treibmittelpulver beinhaltet,
- Mittel zur Herstellung eines kompakten Körpers aus dem Pulvergemisch und
- Mittel zum Aufheizen des kompakten Körpers auf eine Temperatur gleich oder oberhalb der Zersetzungstemperatur des Treibmittels unter Abspaltung von Gas.
- Means for supplying a powder mixture which contains at least one metal powder and at least one gas-releasing blowing agent powder,
- Means for producing a compact body from the powder mixture and
- Means for heating the compact body to a temperature equal to or above the decomposition temperature of the blowing agent with the elimination of gas.
Die Erfindung betrifft außerdem die aus den aufschäumbaren Metallkörpern gewonnene Metallschäume, auch als Bestandteil von Formteilen und Verbundkörpern.The invention also relates to those obtained from the foamable metal bodies Metal foams, also as a component of molded parts and composite bodies.
Die industrielle Fertigung von Metallschäumen oder porösen Metallkörpern ist seit langem bekannt. So ist beispielsweise in der Patentschrift US-3,087,807 A ein Herstellungsverfahren für Metallschäume beschrieben. Ein Metallpulver wird mit einem Treibmittel gemischt und unter einem Preßdruck von größer 80 MPa kalt kompaktiert und anschließend durch Strangpressen um mindesten 87,5 % umgeformt (extrudiert), damit die Pulverpartikel fest miteinander verbunden (verschweißt) sind. Die Temperatur beim Strangpressen muß unterhalb der Zersetzungstemperatur des Treibmittels liegen. Der stranggepreßte Stab wird anschließend in einer Form auf mindestens die Schmelztemperatur des Metalls erwärmt. Der Stab wird dabei zu einem porösen Metallkörper aufgeschäumt. Die Auf schäumung kann in verschiedenen Formen erfolgen, so daß der fertige poröse Metallkörper die gewünschte Form aufweist.The industrial production of metal foams or porous metal bodies has been around since known for a long time. For example, in US Pat. No. 3,087,807 A there is a manufacturing process described for metal foams. A metal powder is made with a blowing agent mixed and cold compacted under a pressure of greater than 80 MPa and then formed by extrusion by at least 87.5% (extruded) the powder particles are firmly connected (welded) together. The temperature at Extrusion must be below the decomposition temperature of the blowing agent. The extruded rod is then in a mold to at least the melting temperature of the metal warmed. The rod is foamed into a porous metal body. On the foaming can be done in different forms, so that finished porous metal body has the desired shape.
Aus der Patentschrift DE 40 18 360 C1 ist ein das oben beschriebene Verfahren verbesserndes Herstellungsverfahren für poröse Metallkörper bekannt, wobei mindestens ein Metallpulver und mindestens ein gasabspaltendes Treibmittelpulver gemischt werden und die Mischung durch Heißkompaktieren zu einem Halbzeug geformt wird. Das Halbzeug wird dann zum Aufschäumen auf Temperaturen oberhalb der Zersetzungstemperatur des Treibmittels, vorzugsweise im Temperaturbereich des Schmelzpunkes des verwendeten Metalles, aufgeheizt. Anschließend findet ein Abkühlen des so aufgeschäumten Körpers statt.From the patent DE 40 18 360 C1 is the method described above improving manufacturing process for porous metal bodies known, wherein at least one metal powder and at least one gas-releasing blowing agent powder be mixed and the mixture by hot compacting into a semi-finished product is formed. The semi-finished product is then foamed to temperatures above the decomposition temperature of the blowing agent, preferably in the temperature range of Melting point of the metal used, heated. Then finds one Cooling of the foamed body instead.
Aus der Patentschrift DE 41 01 630 C2 ist ein Herstellungsverfahren für aufschäumbare Metallkörper bekannt, bei dem beim Kompaktierungsvorgang die Temperatur so hoch gewählt wird, daß die Verbindung zwischen den einzelnen Metallpulverteilchen überwiegend durch Diffusion erfolgt und der Druck beim Heißkompaktieren so hoch gewählt wird, daß die Zersetzung des Treibmittels verhindert wird.From the patent DE 41 01 630 C2 is a manufacturing process for foamable Metal body known in which the temperature during the compacting process is chosen high that the connection between the individual metal powder particles mainly by diffusion and the pressure when hot compacting is so high is chosen that the decomposition of the blowing agent is prevented.
Die bekannten Verfahren sind noch nicht in jeder Hinsicht zufriedenstellend, insbesondere ist die damit zur Verfügung stehende Variationsbreite nicht befriedigend.The known methods are not yet satisfactory in all respects, in particular the range of variations available is not satisfactory.
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, ein Verfahren und eine Vorrichtung der eingangs genannten Art aufzuzeigen, durch welche die Herstellung von aufschäumbaren Metallkörpern vereinfacht und/oder die Variabilität bei der Herstellung von aufschäumbaren Metallkörpern vergrößert wird.The present invention has for its object a method and a Show device of the type mentioned by which the manufacture of foamable metal bodies simplified and / or the variability in Production of foamable metal bodies is enlarged.
Diese Aufgabe wird für das Verfahren erfindungsgemäß dadurch gelöst, daß die Herstellung des kompakten Körpers durch thermische Spritzen des Pulvergemisches mittels Hochgeschwindigkeits-Flammspritzen oder mittels Kaltgasspritzen erfolgt.This object is achieved for the method in that the Production of the compact body by thermal spraying of the powder mixture using high-speed flame spraying or cold gas spraying.
Die Aufgabe wird für die Vorrichtung dadurch gelöst, daß die Mittel zur Herstellung des kompakten Körpers aus dem Pulvergemisch eine Vorrichtung zum thermischen Spritzen mittels Hochgeschwindigkeits-Flammspritzens oder mittels Kaltkasspritzens umfassen.The object is achieved for the device in that the means for producing the compact body from the powder mixture a device for thermal spraying by means of high-speed flame spraying or cold-cold spraying.
Thermische Spritzverfahren zeichnen sich im wesentlichen dadurch aus, daß sie gleichmäßig aufgetragene Beschichtungen von hoher Qualität und Güte ermöglichen. Durch thermische Spritzverfahren aufgetragene Beschichtungen können durch Variation der Spritzmaterialien und/oder der Verfahrensparameter an unterschiedliche Anforderungen angepaßt werden. Die Spritzmaterialien können dabei grundsätzlich in Form von Drähten, Stäben oder als Pulver verarbeitet werden. Es kann zusätzlich eine Nachbehandlung vorgesehen sein.Thermal spray processes are essentially characterized in that they enable uniformly applied coatings of high quality and quality. Coatings applied by thermal spraying can be varied the spray materials and / or the process parameters to different requirements be adjusted. The spray materials can basically in Form of wires, rods or can be processed as a powder. There can also be one Aftertreatment should be provided.
Details zum thermischen Spritzen sind beispielsweise der europäischen Norm EN 657 zu entnehmen.Details of thermal spraying are, for example, the European standard EN 657 refer to.
Eine seit geraumer Zeit bekannte Verfahrensvariante des thermischen Spritzens stellt das Hochgeschwindigkeits-Flammspritzen (teilweise auch als HVOF-Verfahren [High Velocity Oxy-Fuel] bezeichnet) dar.A process variant of thermal spraying that has been known for some time provides high-speed flame spraying (sometimes also as an HVOF process [High Velocity Oxy-Fuel]).
In jüngerer Zeit wurde darüber hinaus ein weiteres thermisches Spritzverfahren entwickelt, welches auch als Kaltgasspritzen bezeichnet wird. Es handelt sich dabei um eine Art Weiterentwicklung des Hochgeschwindigkeits-Flammspritzens. Dieses Verfahren ist beispielsweise in der europäischen Patentschrift EP 0 484 533 B1 beschrieben. Beim Kaltgasspritzen kommt ein Zusatzwerkstoff in Pulverform zum Einsatz. Die Pulverpartikel werden beim Kaltgasspritzen jedoch nicht im Gasstrahl geschmolzen. Vielmehr liegt die Temperatur des Gasstrahles unterhalb des Schmelzpunktes der Zusatzwerkstoffpulverpartikel (EP 0 484 533 B1). Im Kaltgasspritzverfahren wird also ein im Vergleich zu den herkömmlichen Spritzverfahren "kaltes" bzw. ein vergleichsweise kälteres Gas verwendet. Gleichwohl wird das Gas aber ebenso wie in den herkömmlichen Verfahren erwärmt, aber in der Regel lediglich auf Temperaturen unterhalb des Schmelzpunktes der Pulverpartikel des Zusatzwerkstoffes.Recently, another thermal spraying process has also been developed which is also known as cold gas spraying. It is about a kind of further development of high-speed flame spraying. This method is described, for example, in European Patent EP 0 484 533 B1. A filler material in powder form is used for cold gas spraying. The However, powder particles are not melted in a gas jet during cold gas spraying. Rather, the temperature of the gas jet is below the melting point of the Filler powder particles (EP 0 484 533 B1). So in the cold gas spraying process a "cold" or a comparative compared to the conventional spraying process colder gas used. Nevertheless, the gas is just as in the conventional Process heated, but usually only to temperatures below the melting point of the powder particles of the filler material.
Je nach dem verwendeten thermischen Spritzverfahren ― mittels des Hochgeschwindigkeits-Flammspritzverfahrens oder mittels des Kaltgasspritzverfahrens ― ergibt sich eine kompakter Körper mit bestimmten Eigenschaften. Als Hochgeschwindigkeits-Flammspritzverfahren können dabei das Hochgeschwindigkeits-Flammspritzen der ersten und der zweiten Generation mit mittleren Spritzpartikelgeschwindigkeiten von 400 bis 500 m/s (gemessen mit einem Spritzpulver WC-Co mit einer Körnung ― 45µm + 10 µm, d.h. einer Verteilung bezüglich der Körnerdurchmesser von 10 bis 45 µm) und bevorzugt das Hochgeschwindigkeits-Flammspritzen der dritten Generation mit Spritzpartikelgeschwindigkeiten von 500 bis 700 m/s (gemessen mit einem Spritzpulver WC-Co mit einer Körnung ― 45 µm + 10 µm) zum Einsatz kommen. Beim Kaltgasspritzen können die Pulverpartikel auf eine Geschwindigkeit von 300 bis 1600 m/s beschleunigt werden. Es eignen sich dabei insbesondere Geschwindigkeiten der Pulverpartikel zwischen 500 und 1200 m/s zur Erzielung besonders hoher Auftragswirkungsgrade und Schichtdichten.Depending on the thermal spraying process used - using the high-speed flame spraying process or using the cold gas spraying process - results a compact body with certain properties. As a high-speed flame spraying process can do the high-speed flame spraying first and second generation with medium spray particle speeds of 400 to 500 m / s (measured with a WC-Co spray powder with a grain size - 45 µm + 10 µm, i.e. a distribution with respect to the grain diameter of 10 to 45 µm) and prefers third generation high speed flame spraying Spray particle speeds of 500 to 700 m / s (measured with a spray powder WC-Co with a grain size - 45 µm + 10 µm) can be used. With cold gas spraying can accelerate the powder particles to a speed of 300 to 1600 m / s become. Speeds of the powder particles are particularly suitable between 500 and 1200 m / s to achieve particularly high application efficiency and layer densities.
Als Materialien für das Metallpulver können im Rahmen der Erfindung alle geeigneten metallhaltigen Spritzpulver, insbesondere
- reine Metalle,
- Metallegierungen,
- Metalle und/oder Metallegierungen mit Zusätzen an Hartstoffen wie
Metalloxide (insbesondere Al2O3 und/oder TiO2), Carbide, Boride
und/oder mit Zusätzen an Kunststoffen
oder - Mischungen der vorgenannten Stoffe
- pure metals,
- Metal alloys,
- Metals and / or metal alloys with additives on hard materials such as metal oxides (in particular Al 2 O 3 and / or TiO 2 ), carbides, borides and / or with additives on plastics
or - Mixtures of the aforementioned substances
Gemäß der Erfindung wird Metallpulver zusammen mit einem das Treibmittel enthaltende Pulver durch Hochgeschwindigkeits-Flammspritzen oder Kaltgasspritzen zu einem kompakten Körper verarbeitet. Der kompakte Körper kann dabei als Schicht oder als Formkörper vorliegen. Wegen der kurzen Verweilzeit des Pulvers (üblicherweise liegt diese im Bereich einiger Millisekunden) beim Hochgeschwindigkeits-Kaltgasspritzen in dem aufgeheizten Trägergasstrahl bleibt das Treibmittel zumindest im wesentlichen gebunden. Es wird falls gewünscht erst beim anschließenden Aufheizen zum Aufschäumen frei. Entscheidend beim erfindungsgemäß eingesetzten technischen Spritzverfahren ist, daß das Treibmittelpulver beim Spritzvorgang im wesentlichen kein Gas abspaltet Beim Kaltgasspritzen wird dies außer durch die kurze Verweilzeit des Pulvers auch durch die niedrige Prozeßtemperatur des Kaltgasspritzens mit einem auf wenige 100°C aufgeheizten Trägergasstrahl gewährleistet. Das Kaltgasspritzen wird deshalb bevorzugt eingesetzt.According to the invention, metal powder is used together with one containing the blowing agent Powder by high-speed flame spraying or cold gas spraying processed into a compact body. The compact body can be used as a layer or present as a shaped body. Because of the short residence time of the powder (usually this is in the range of a few milliseconds) with high-speed cold gas spraying in the heated carrier gas jet, the blowing agent remains at least in the essentially tied. If desired, it will only be heated up afterwards free to foam. Crucial in the technical used according to the invention Spraying is that the blowing agent powder is essentially none during the spraying process Splitting gas With cold gas spraying, this is due to the short dwell time of the Powder also due to the low process temperature of cold gas spraying guaranteed a few 100 ° C heated carrier gas jet. The cold gas spraying is therefore preferably used.
Durch die Erfindung wird ein einfach und vielseitig anwendbares Verfahren zur Herstellung der aufschäumbaren Metallkörper zur Verfügung gestellt. Die so hergestellten Metallkörper können durch Aufheizen auf eine Temperatur gleich oder bevorzugt oberhalb der Zersetzungstemperatur des Treibmittels und anschließendem Abkühlen zur Herstellung von porösen Metallkörpern oder Metallschäumen verwendet werden. In der Regel ist die Zersetzungstemperatur des Treibmittels keine scharfer Temperaturwert sondern ein Temperaturbereich. Im Rahmen der Erfindung wird daher unter einer Temperatur gleich oder bevorzugt oberhalb der Zersetzungstemperatur des Treibmittels in diesen Fällen eine Temperatur im Zersetzungstemperaturbereich oder bevorzugt oberhalb der Zersetzungstemperaturbereichs des Treibmittels verstanden.The invention provides a simple and versatile method of manufacture of the foamable metal body. The so produced Metal bodies can be heated to a temperature equal to or preferred above the decomposition temperature of the blowing agent and then cooling can be used for the production of porous metal bodies or metal foams. In As a rule, the decomposition temperature of the blowing agent is not a sharp temperature value but a temperature range. In the context of the invention is therefore under a Temperature equal to or preferably above the decomposition temperature of the blowing agent in these cases a temperature in the decomposition temperature range or preferably understood above the decomposition temperature range of the blowing agent.
Beim erfindungsgemäßen Verfahren kann die Pulvermischung aus Metall plus Treibmittel in nahezu beliebigen Mischungsverhältnissen gespritzt werden. Das ermöglicht, daß das Mischungsverhältnis von Metallpulver und Treibmittelpulver jeweils an die gewünschten Bedingungen angepaßt wird.In the method according to the invention, the powder mixture can consist of metal plus blowing agent can be sprayed in almost any mixing ratio. This allows, that the mixing ratio of metal powder and blowing agent powder to each desired conditions is adjusted.
In Ausgestaltung der Erfindung kann das Pulvergemisch aus Metallpulver und Treibmittelpulver bei der Herstellung des aufschäumbaren Metallkörpers bezüglich seiner Parameter wie der Zusammensetzung, aber insbesondere bezüglich des Mischungsverhältnisses verändert werden. Besondere Vorteile ergeben sich, wenn das Pulvergemisch mit verändertem Treibmittelanteil gespritzt wird. Denn durch eine Veränderung des Mischungsverhältnisses von Metall und Treibmittel können Schichten und Strukturen mit einem sich vorzugsweise definiert verändernden Treibmittelanteil gespritzt werden (gradierte Schichten, Strukturen).In an embodiment of the invention, the powder mixture of metal powder and blowing agent powder in the manufacture of the foamable metal body with respect to it Parameters such as the composition, but especially with regard to the mixing ratio to be changed. Particular advantages arise when the powder mixture is injected with a different proportion of propellant. Because through a change The mixing ratio of metal and blowing agent can layers and Structures are injected with a preferably changing propellant proportion (graded layers, structures).
Im Rahmen der Erfindung hat sich gezeigt, daß ein Treibmittelanteil im Pulvergemisch zwischen 0,01 und 1,0 Gew.-%, vorzugsweise zwischen 0,05 und 0,5 Gew.-%, besonders bevorzugt zwischen 0,1 und 0,3 Gew.-%, geeignet ist.Within the scope of the invention it has been shown that a proportion of blowing agent in the powder mixture between 0.01 and 1.0% by weight, preferably between 0.05 and 0.5% by weight, particularly preferably between 0.1 and 0.3% by weight.
In Ausgestaltung der Erfindung umfaßt das gasabspaltende Treibmittelpulver als Treibmittel Metallhydride, wie beispielsweise Titanhydrit (TiH2), Karbonate, wie beispielsweise Calziumkarbonat, Kaliumkarbonat, Natriumkarbonat oder Natriumbikarbonat, Hydrate, wie beispielsweise Aluminiumsulfathydrat, Alaun, Aluminiumhydroxid oder leicht verdampfende Stoffe wie beispielsweise Quecksilberverbindungen oder pulverisierte organische Substanzen oder Mischungen der vorgenannten Stoffe.In an embodiment of the invention, the gas-releasing blowing agent powder comprises, as blowing agent, metal hydrides, such as, for example, titanium hydrite (TiH 2 ), carbonates, such as, for example, calcium carbonate, potassium carbonate, sodium carbonate or sodium bicarbonate, hydrates, such as, for example, aluminum sulfate hydrate, alum, aluminum hydroxide or easily evaporating substances such as, for example, mercury compounds or powdered mercury compounds organic substances or mixtures of the aforementioned substances.
Mit Vorteil kann das Pulvergemisch auf einen Substratträger gespritzt werden, wobei zumindest zeitweise eine Relativbewegung zwischen dem Substratträger und der Vorrichtung zum thermischen Spritzen des Pulvergemisches mittels Hochgeschwindigkeits-Flammspritzens oder Kaltgasspritzens erfolgt. Es können beispielsweise mit dem Pulvergemisch Formteile gespritzt werden, wobei beispielsweise die Spritzpistole der Vorrichtung zum thermischen Spritzen und/oder der Substratträger bewegt werden. The powder mixture can advantageously be sprayed onto a substrate carrier, wherein at least temporarily a relative movement between the substrate carrier and the device for thermal spraying of the powder mixture using high-speed flame spraying or cold gas spraying. For example, with the Powder mixture molded parts are injected, for example the spray gun Device for thermal spraying and / or the substrate carrier are moved.
Das Pulvergemisch kann erfindungsgemäß auf jeden geeigneten Substratträger insbesondere auf ein Trägermaterial aus Metall, Kunststoff, Keramik und/oder Glas gespritzt werden. Mit Vorteil kann der kompakte Körper vom Trägermaterial gelöst werden, bevor durch Erwärmung eine Gasabspaltung aus dem Treibmittel zum Aufschäumen des kompakten Körpers erfolgt.According to the invention, the powder mixture can be applied to any suitable substrate carrier in particular on a carrier material made of metal, plastic, ceramic and / or glass be injected. The compact body can advantageously be detached from the carrier material are, before a release of gas from the propellant by heating Foaming of the compact body takes place.
In Weiterbildung der Erfindung kann der kompakte Körper vor der Gasabspaltung aus dem Treibmittel zum Aufschäumen des kompakten Körpers unter Änderung des Druckes und/oder der Temperatur verformt oder umgeformt werden. Als Umformungen kommen beispielsweise Strangpressen oder Walzen in Frage.In a further development of the invention, the compact body can be released before the gas is released the blowing agent for foaming the compact body by changing the Pressure and / or temperature are deformed or reshaped. As transformations For example, extrusion presses or rollers can be used.
In einer anderen Weiterbildung der Erfindung wird das Pulvergemisch auf die Innenseite einer Form gespritzt, die mit Metallschaum ganz oder teilweise ausgeschäumt werden soll. Durch Aufheizen auf eine Temperatur gleich oder bevorzugt oberhalb der Zersetzungstemperatur des Treibmittels wird der Metallschaum gefertigt.In another development of the invention, the powder mixture is on the inside injected into a mold that was wholly or partially foamed with metal foam shall be. By heating to a temperature equal to or preferably above that The foaming agent's decomposition temperature is used to manufacture the metal foam.
In einer anderen Weiterbildung der Erfindung werden zumindest zwei Lagen gespritzt, wobei zumindest eine Lage mit dem Metallpulver und gasabspaltendes Treibmittelpulver umfassenden Pulvergemisch und zumindest eine weitere Lage mit Metallpulver ohne gasabspaltendes Treibmittels thermisch gespritzt werden. Beispielsweise kann das Pulvergemisch aus Metall und Treibmittel nur lagenweise zwischen zwei Metallschichten gespritzt werden.In another development of the invention, at least two layers are injected, wherein at least one layer with the metal powder and gas-releasing blowing agent powder comprehensive powder mixture and at least one further layer with metal powder can be thermally sprayed without gas-releasing blowing agent. For example the powder mixture of metal and blowing agent only in layers between two metal layers be injected.
Durch Aufheizen des kompakten Körpers, der nach dem oben beschriebenen Verfahren hergestellt ist, auf eine Temperatur gleich oder bevorzugt oberhalb der Zersetzungstemperatur des Treibmittels und durch eine nachfolgende Abkühlung kann ein Metallschaum hergestellt werden. Bevorzugt erfolgt ein Aufheizen des kompakten Körpers auf eine Temperatur oberhalb der Schmelztemperatur des Metalls oder oberhalb der Sollidustemperatur der Metallegierung. In diesem Fall schäumt das als Gas entweichende Treibmittel die Metallschmelze auf. Dieser Schaum bildet nach dem Erkalten einen porösen Hohlkörper. Bevorzugt wird also das beim Zersetzen des Treibmittels frei werdende Gas das Metall oder die Metallegierung als Schmelze aufschäumen. By heating the compact body using the procedure described above is produced, to a temperature equal to or preferably above the decomposition temperature of the blowing agent and a subsequent cooling can Metal foam can be made. The compact is preferably heated Body to a temperature above the melting temperature of the metal or above the target alloy temperature of the metal alloy. In this case it foams as a gas escaping blowing agent on the molten metal. This foam forms after Cool a porous hollow body. So is preferred when decomposing the Blowing agent released gas the metal or the metal alloy as a melt lather up.
Es können Formteile hergestellt werden, die zumindest einen Metallschaum umfassen. Andererseits sind Verbundkörper herstellbar, die zumindest einen Metallschaum als Schicht auf oder zwischen einem Substratträger umfassen. Bei Formteilen oder Verbundkörpern können neben der zumindest einen aufgeschäumten Metallschicht zumindest eine weitere thermisch gespritzte Schicht vorhanden sein.Molded parts can be produced which comprise at least one metal foam. On the other hand, composite bodies can be produced which are at least one metal foam Include layer on or between a substrate support. For molded parts or composite bodies can in addition to the at least one foamed metal layer at least there is another thermally sprayed layer.
Als Treibmittel eignet sich insbesondere Titanhydrid (TiH2).Titanium hydride (TiH 2 ) is particularly suitable as a blowing agent.
Titanhydrid kann beispielsweise mittels Kaltgasspritzens zusammen mit anderen Metallpulvern aus Aluminium (Al), Kupfer (Cu), Nickel (Ni), Eisen (Fe), Titan (Ti) sowie Legierungen die eines oder mehrere dieser Metalle enthalten, gespritzt werden. In der Regel reicht ein relativ kleiner Mengenanteil des Treibmittels zum Aufschäumen des kompakten Körpers aus. Beispielsweise führt ein Pulvergemisch mit 0,2 Gew.-% TiH2 und mit im wesentlichen Al als Metallpulver zu einem Schaumkörper mit etwa fünffacher Volumenvergrößerung. Ein Treibmittelanteil von 1,0 Gew.-% TiH2 vergrößert das Volumen von Al um mehr als das Zehnfache.Titanium hydride can, for example, be sprayed using cold gas spraying together with other metal powders made of aluminum (Al), copper (Cu), nickel (Ni), iron (Fe), titanium (Ti) and alloys that contain one or more of these metals. As a rule, a relatively small proportion of the blowing agent is sufficient to foam the compact body. For example, a powder mixture with 0.2% by weight of TiH 2 and with essentially Al as the metal powder leads to a foam body with about five times the volume increase. A blowing agent content of 1.0% by weight of TiH 2 increases the volume of Al by more than ten times.
Das für das thermische Spritzen benötigte Gas kann Stickstoff, Helium, Argon, Neon, Krypton, Xenon, ein Wasserstoff enthaltendes Gas, ein kohlenstoffhaltiges Gas, insbesondere Kohlendioxid, Sauerstoff, ein Sauerstoff enthaltendes Gas, Luft, Wasserdampf oder Mischungen der vorgenannten Gase enthalten. Neben den aus der EP 0 484 533 B1 bekannten Gasen Luft und/oder Helium eignen sich auch für das den pulverförmigen Zusatzwerkstoff tragende Gas ein Stickstoff, Argon, Neon, Krypton, Xenon, Sauerstoff, ein Wasserstoff enthaltendes Gas, ein kohlenstoffhaltiges Gas, insbesondere Kohlendioxid, Wasserdampf oder Mischungen der vorgenannten Gase und Mischungen dieser Gase mit Helium. Der Anteil des Helium am Gesamtgas kann bis zu 90 Vol.-% betragen. Bevorzugt wird ein Heliumanteil von 10 bis 50 Vol.-% im Gasgemisch eingehalten.The gas required for thermal spraying can be nitrogen, helium, argon, neon, Krypton, xenon, a gas containing hydrogen, a gas containing carbon, in particular carbon dioxide, oxygen, an oxygen-containing gas, air, Contain water vapor or mixtures of the aforementioned gases. In addition to those from the Gases known from EP 0 484 533 B1 are also suitable for the powdered filler gas carrying a nitrogen, argon, neon, krypton, Xenon, oxygen, a gas containing hydrogen, a carbon-containing gas, in particular carbon dioxide, water vapor or mixtures of the aforementioned gases and mixtures of these gases with helium. The proportion of helium in the total gas can up to 90 vol .-%. A helium content of 10 to 50% by volume is preferred Gas mixture observed.
Claims (18)
daß die Mittel zur Herstellung des kompakten Körpers aus dem Pulvergemisch eine Vorrichtung zum thermischen Spritzen des Pulvergemisches mittels Hochgeschwindigkeits-Flammspritzens oder mittels Kaltgasspritzens umfassen.Device for producing metal foams, comprising
that the means for producing the compact body from the powder mixture comprise a device for thermal spraying of the powder mixture by means of high-speed flame spraying or by means of cold gas spraying.
Applications Claiming Priority (2)
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DE19942916 | 1999-09-08 | ||
DE19942916A DE19942916A1 (en) | 1999-09-08 | 1999-09-08 | Manufacture of foamable metal bodies and metal foams |
Publications (3)
Publication Number | Publication Date |
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EP1083013A2 true EP1083013A2 (en) | 2001-03-14 |
EP1083013A3 EP1083013A3 (en) | 2004-01-21 |
EP1083013B1 EP1083013B1 (en) | 2005-07-27 |
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EP00119602A Expired - Lifetime EP1083013B1 (en) | 1999-09-08 | 2000-09-07 | Preparation of foamable metal bodies and metal foams |
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US (1) | US6408928B1 (en) |
EP (1) | EP1083013B1 (en) |
AT (1) | ATE300378T1 (en) |
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DE10246454A1 (en) * | 2002-10-04 | 2004-04-15 | Rwth Aachen | Making coated foamed components used in e.g. automobile or building industries, employs surface treatment, coating and profiling by thermal foaming |
EP1903127A1 (en) * | 2006-09-21 | 2008-03-26 | Siemens Aktiengesellschaft | Process of manufacturing of workpieces by cold gas spraying and turbine workpiece |
DE102008058142A1 (en) * | 2008-11-20 | 2010-05-27 | Mtu Aero Engines Gmbh | Method for producing and / or repairing a rotor of a turbomachine and rotor for this purpose |
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EP1903127A1 (en) * | 2006-09-21 | 2008-03-26 | Siemens Aktiengesellschaft | Process of manufacturing of workpieces by cold gas spraying and turbine workpiece |
DE102008058142A1 (en) * | 2008-11-20 | 2010-05-27 | Mtu Aero Engines Gmbh | Method for producing and / or repairing a rotor of a turbomachine and rotor for this purpose |
DE102008058141A1 (en) * | 2008-11-20 | 2010-05-27 | Mtu Aero Engines Gmbh | Method for producing a blade for a rotor of a turbomachine |
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Also Published As
Publication number | Publication date |
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ATE300378T1 (en) | 2005-08-15 |
DE19942916A1 (en) | 2001-03-15 |
EP1083013A3 (en) | 2004-01-21 |
EP1083013B1 (en) | 2005-07-27 |
US6408928B1 (en) | 2002-06-25 |
DE50010812D1 (en) | 2005-09-01 |
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