WO2008032956A1 - Composite sintering materials using carbon nanotube and manufacturing method thereof - Google Patents
Composite sintering materials using carbon nanotube and manufacturing method thereof Download PDFInfo
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- WO2008032956A1 WO2008032956A1 PCT/KR2007/004341 KR2007004341W WO2008032956A1 WO 2008032956 A1 WO2008032956 A1 WO 2008032956A1 KR 2007004341 W KR2007004341 W KR 2007004341W WO 2008032956 A1 WO2008032956 A1 WO 2008032956A1
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
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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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
- C22C2026/002—Carbon nanotubes
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- the present invention relates to a composite sintering materials using a carbon nanotube (including carbide nano particles, hereinafter the same) and a manufacturing method thereof.
- the present invention is characterized by strengthening the mechanical characteristics of composite sintering materials by repeatedly performing processes of combining the carbon nanotubes with metal powders or generating the carbon nanotubes in the metal powders, impregnating and combining the carbon nanotubes in the pores of a compacted product or generating the carbon nanotubes in the pores, or impregnating and combining the carbon nanotubes in the pores of a sintered product or growing and alloying carbon nanotubes after generating the carbon nanotubes in the pores.
- Composite sintering materials using a carbon nanotube of the present invention are completed by uniformly dispersing and combining the carbon nanotubes in metal powder particles, a compacted product, or a sintered product or generating the carbon nanotubes therein, and growing and alloying the carbon nanotubes, and then sintering them to have excellent mechanical, thermal, and electric and electronic characteristics as well as to have effects of material cost reduction and manufacturing cost reduction due to lowered sintering temperature so that they are useful as materials for automotive parts, electric and electronic parts, space and aircraft parts, and molding and cutting tools, all of which include the composite sintering materials.
- a representative carbon nanotube (CNT) among nanotubes has very excellent mechanical, thermal, and electrical characteristics and it is very thermally and chemically stable so that it can be applied as high elastic, high strength, and conductive composite material. Therefore, the carbon nanotube has been spotlighted as a new material usable in various fields such as polymer, ceramic composite material, etc., and it is a material that many studies have been made. Since the carbon nanotube (CNT) known up to now has strong aggregation and high chemical stability, it is difficult to uniformly disperse it in a composite material matrix so that it is difficult to obtain carbon nano composite materials, making it impossible to effectively use the carbon nanotube(CNT).
- a first aspect of the present invention comprises the steps of: manufacturing master alloys by combining carbon nanotubes with metal powders; growing or alloying the carbon nanotubes by compacting and then sintering the master alloy; generating the carbon nanotubes in the pores of a sintered product or impregnating and combining the carbon nanotubes therein; and strengthening mechanical characteristics by repeatedly performing the sintering process and the generating process of the carbon nanotubes in the sintered product or the impregnating and combining processes of the carbon nanotubes.
- a second aspect of the present invention comprises the steps of: generating carbon nanotubes in metal powders; growing or alloying the carbon nanotubes by compacting and then sintering the metal powders in which the carbon nanotubes are generated; generating the carbon nanotubes in the pores of a sintered product or impregnating and combining the carbon nanotubes therein; and strengthening mechanical characteristics by repeatedly performing the sintering process and the generating process of the carbon nanotubes in the sintered product or the impregnating and combining processes of the carbon nanotubes.
- a third aspect of the present invention comprises the steps of: generating carbon nanotubes in the pores of a compacted product after compacting metal powders or impregnating the carbon nanotubes therein to combine the metal powders with the carbon nanotubes in the pores of the compacted product; growing or alloying the carbon nanotubes by sintering the compacted product in which the carbon nanotubes are generated or with which the carbon nanotubes are combined; generating the carbon nanotubes in the pores of a sintered product or impregnating and combining the carbon nanotubes therein; and strengthening mechanical characteristics by repeatedly performing the sintering process and the generating process of the carbon nanotubes in the sintered product or the impregnating and combining processes of the carbon nanotubes.
- a fourth aspect of the present invention comprises the steps of: generating carbon nanotubes in the pores of a finished product which is sintered after compacting metal powders or impregnating the carbon nanotubes therein to combine the metal powders with the carbon nanotubes in the pores of a sintered product; growing or alloying the carbon nanotubes by resintering the sintered product in which the carbon nanotubes are generated or with which the carbon nanotubes are combined; generating the carbon nanotubes in the pores of the sintered product or impregnating and combining the carbon nanotubes therein; and strengthening mechanical characteristics by repeatedly performing the sintering process and the generating process of the carbon nanotubes in the sintered product or the impregnating and combining processes of the carbon nanotubes.
- a fifth aspect of the present invention comprises the steps of: manufacturing master alloys by combining carbon nanotubes with metal powders or generating the carbon nanotubes in metal powders; mixing the master alloy or the metal powders, wherein the carbon nanotubes are generated, with another metal powders or ceramic materials; growing or alloying the carbon nanotubes by compacting and then sintering the mixture; impregnating and combining the carbon nanotubes in the pores of a sintered product or generating the carbon nanotubes therein; and strengthening mechanical characteristics by repeatedly performing the sintering process and the generating process of the carbon nanotubes in the sintered product or the impregnating and combining processes of the carbon nanotubes.
- a sixth aspect of the present invention comprises the steps of: mixing metal powders with ceramic materials; compacting the mixture or compacting and then sintering it; impregnating and combining the carbon nanotubes in the pores of a compacted product or a sintered product or generating the carbon nanotubes therein; growing or alloying the carbon nanotubes by sintering the molded product or the sintered product in which the carbon nanotubes are generated or with which the carbon nanotubes are combined; generating the carbon nanotubes in the pores of the sintered product or impregnating and combining the carbon nanotubes therein; and strengthening mechanical characteristics by repeatedly performing the sintering process and the generating process of the carbon nanotubes in the sintered product or the impregnating and combining processes of the carbon nanotubes.
- a seventh invention of the present invention comprises the steps of: manufacturing master alloys by mixing and combining carbon nanotubes and metal powders or generating the carbon nanotubes in the metal powders; mixing the master alloy or the metal powders, wherein the carbon nanotubes are generated, with polymer materials; growing the carbon nanotubes by melting the mixture by a heater; injection-molding the mixed melting material; and aging the injection-molded product.
- the composite sintering materials using the carbon nanotubes of the present invention has excellent mechanical, thermal, and electric and electronic characteristics by manufacturing master alloys by mixing the carbon nanotubes with the metal powder particles, impregnating and combining the carbon nanotubes in the compacted product or the sintered product, or generating the carbon nanotubes in the metal powder particles, the compacted product, or the sintered product; interposing the carbon nanotubes suffering from the compacting process or the sintering process under proper conditions in the metal powder particles, the compacted product, or the sintered product; and then combining, growing, and alloying the carbon nanotubes.
- the carbon nanotubes in the dispersed state through the physical and chemical processes, and in the step of generating the carbon nanotubes in the metal powder particles, the compacted product, or the sintered product, it is preferable to chemically process the metal powder particles, the compacted product, or the sintered product and then process them by injecting liquid or gas having carbon group.
- acidic solution such as natal, phosphoric acid, sulfuric acid, HF solution, etc.
- liquid or gas having carbon group such as ammonia, carbonic acid gas, carbonated water, methane gas, methanol, acetylene, benzene, glucose, sugar etc.
- the metal powder particles in the step of combining the carbon nanotubes or the matrix ingredients of the compacted product and the sintered product in the step of impregnating the carbon nanotubes are preferably Fe, Ni, Co, W, and Si, but may also be alloy powders in which Fe, Ni, Co, W, and Si are alloyed.
- metal powders Mo, Th, Ti, etc.
- metal powders with high melting point or metal powders with low melting point Al, Cu, Bi, Pb, Cd, Zn, Ce, Cs, K, Na, etc.
- the metal powder particles in the step of generating the carbon nanotubes or the matrix ingredients of the molded product and the sintered product is preferably Fe, Ni, Co, W, and Si, but may also be alloy powders in which Fe, Ni, Co, W, and Si are alloyed.
- metal powders of the alloy powders metal powders (Mo, Th, Ti, etc.) with high melting point or metal powders with low melting point (Al, Cu, Bi, Pb, Cd, Zn, Ce, Cs, K, Na, etc.) may be used.
- the master alloys are manufactured by drying it at a temperature of up to 300 ° C under an inert gas atmosphere or by directly growing the carbonano particles into the carbon nanotubes in the metal powder particles, in the step of generating the carbon nanotubes in the metal powders, the molded product, or the sintered product, it is preferable to generate the carbon nanotubes at a temperature of up to 1200 ° C under an inert gas atmosphere, in the step of impregnating the carbon nanotubes in the compacted product or the sintered product, it is preferable to impregnate the carbon nanotubes using an impregnating machine at a temperature of up to 200 ° C, in the step of growing the carbon nanotubes, it is preferable to grow the carbon nanotubes at a temperature of up to 800 ° C under an inert gas atmosphere, and in the step of alloying the carbon nanotubes, it is preferable to alloy the carbon nanotubes at a temperature of
- Fig. 1 is an electron microscope photograph (200 magnifications) at a sintering temperature of 400 ° C of specimen (density of 6.2g/cm 3 ) obtained from an embodiment 1 of the present invention
- Fig. 2 is an electron microscope photograph (200 magnifications) at a sintering temperature of 500 ° C of specimen (density of 6.2g/cm 3 ) obtained from an embodiment 1 of the present invention
- Fig. 3 is an electron microscope photograph (400 magnifications) at a sintering temperature of 400 ° C of specimen (density of 6.2g/cm 3 ) obtained from an embodiment 1 of the present invention
- Fig. 4 is a scanning electron microscope photograph (SEM) (500 magnifications) at a sintering temperature of 400 ° C of specimen (density of 6.2g/cm 3 ) obtained from an embodiment 1 of the present invention
- Fig. 5 is a scanning electron microscope photograph (10000 magnifications) at a sintering temperature of 300 ° C of specimen (density of 6.2g/cm 3 ) obtained from an embodiment 1 of the present invention
- Fig. 6 is a scanning electron microscope photograph (10000 magnifications) at a sintering temperature of 500 ° C of specimen (density of 6.2g/cm 3 ) obtained from an embodiment 1 of the present invention
- Fig. 7 is a scanning electron microscope photograph (500 magnifications) at a sintering temperature of 500 ° C of specimen (density of 6.2g/cm 3 ) obtained from an embodiment 1 of the present invention
- FIG. 8 is a magnified view of the combining sites of FIG. 7;
- Fig. 9 is a scanning electron microscope photograph (a: 5000 magnifications/b: 25000 magnifications) at a sintering temperature of 750 ° C of AHC 100.29 powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention;
- Fig. 10 is a scanning electron microscope photograph (a: 2000 magnifications/b: 5000 magnifications) at a sintering temperature of 900 ° C of AHC 100.29 powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention;
- Fig. 11 is a scanning electron microscope photograph (a: 2500 magnifications/b: 25000 magnifications) at a sintering temperature of 1000°C of AHC 100.29 powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention;
- Fig. 12 is a scanning electron microscope photograph (a: 1500 magnifications/b: 20000 magnifications) at a sintering temperature of 1100 " C of AHC 100.29 powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention
- Fig. 13 is a scanning electron microscope photograph (a: 2000 magnifications/b: 35000 magnifications) at a sintering temperature of 1000°C of ABC100.30 powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention;
- Fig. 14 is a scanning electron microscope photograph (a: 5000 magnifications/b: 20000 magnifications) at a sintering temperature of 1000 ° C of DAB powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention;
- Fig. 15 is a scanning electron microscope photograph (a: 2500 magnifications/b: 15000 magnifications) at a sintering temperature of 1000 ° C of DAE powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention;
- Fig. 16 is a scanning electron microscope photograph (a: 5000 magnifications/b: 20000 magnifications) at a sintering temperature of 1000 ° C of KAP powder specimen (density of 6.8g/cm 3 ) obtained from an embodiment 1 of the present invention;
- FIG. 17 is a Bending photograph of toughness added specimens (density of 6.8g/cm 3 ) after being sintered at 1000 ° C, which are obtained from an embodiment 2 of the present invention
- FIG. 18 is a scanning electron microscope photograph (50 magnifications) of a fracture surface which is fractured after sintering PASC60 powder specimen (density of 6.8g/cm 3 ), at a sintering temperature of 1000 ° C, which is obtained from an embodiment 2 of the present invention;
- FIG. 19 is a scanning electron microscope photograph (a: 5000 magnif ⁇ cations/b:20000 magnifications) of toughness added specimen after sintering DAE powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention;
- FIG. 20 is a scanning electron microscope photograph (a: 5000 magnifications/b:20000 magnifications) of toughness added specimen after sintering PASC60 powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention;
- FIG. 21 is a scanning electron microscope photograph (1000 magnifications) of toughness added specimen after sintering AHC 100.29 powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention
- FIG. 22 is a scanning electron microscope photograph (1000 magnifications) of toughness added specimen after sintering ABC 100.30 powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention
- FIG. 23 is a scanning electron microscope photograph (1000 magnifications) of toughness added specimen after sintering DAB powder specimen (density of 6.8g/cm 3 ) at 1000 ° C , which is obtained from an embodiment 2 of the present invention;
- FIG. 24 is a scanning electron microscope photograph (1000 magnifications) of toughness added specimen after sintering DAE powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention;
- FIG. 25 is a scanning electron microscope photograph (1000 magnifications) of toughness added specimen after sintering PASC60 powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention;
- FIG. 26 is a scanning electron microscope photograph (1000 magnifications) of toughness added specimen after sintering KAP powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention
- FIG. 27 is a scanning electron microscope photograph (1000 magnifications) of toughness added specimen after sintering pure copper powder specimen (density of 6.8g/cm 3 ) at 1000 ° C, which is obtained from an embodiment 2 of the present invention
- FIG. 28 is a scanning electron microscope photograph (25000 magnifications) of toughness added specimen after resintering DAE powder specimen (density of 6.8g/cm 3 ) at 1100 ° C , which is obtained from an embodiment 3 of the present invention;
- FIG. 29 is a scanning electron microscope photograph (15000 magnifications) of specimen sintering specimen (density of 6.8g/cm ) generating carbon nanotubes in PASC60 powder at a sintering temperature of 600 ° C, which is obtained from an embodiment 4 of the present invention
- FIG. 30 is a scanning electron microscope photograph (a: 20000 magnifications/b:
- FIG. 31 is a scanning electron microscope photograph (a: 5000 magnifications/b: 25 magnifications) of specimen sintering specimen (density of 6.8g/cm 3 ) generating carbon nanotubes in DAE powder molded product at a sintering temperature of 600 °C, which is obtained from an embodiment 9 of the present invention;
- FIG. 32 is a scanning electron microscope photograph (a: 5000 magnif ⁇ cations/b: 25000 magnifications) of specimen generating carbon nanotubes in PASC60 powder sintered product, which is obtained from an embodiment 14 of the present invention.
- FIG. 33 is a scanning electron microscope photograph (a: 5000 magnifications/b: 20000 magnifications) of specimen generating carbon nanotubes in DAE powder sintered product, which is obtained from an embodiment 14 of the present invention
- Embodiment 1 Manufacture of Sample (a) Process of manufacturing master alloy
- the master alloy is manufactured by mixing and drying dispersed carbon nanotubes with AHC 100.29 powder and ABC 100.30 powder being used as a sintering alloy for an automotive structure, which are pure iron powder from Hoganas Co., DAB powder which is an alloy powder of iron, copper, nickel and molybdenum, DAE powder, PASC60 powder which is an alloy powder of iron and phosphorus, KAP powder which is an alloy powder of iron and tin, and pure copper powder.
- the mixing method in the present embodiment 1 mixes the carbon nanotubes using a spraying non-gravity mixer to be able to uniformly distribute the dispersed carbon nanotubes, and the drying method performs a dry under an inert gas atmosphere. Also, in the used carbon nanotube, its average diameter is 20 nano, and length is ⁇ 0 ⁇ m.
- the commercialized metal powder particle has a powder size of 50 ⁇ m to 250 ⁇ an.
- the metal powders and the carbon nanotubes are mixed by means of a spray method so that in the mixing ratio of the metal powder to the carbon nanotube, the carbon nanotube is 0.1 wt% based on weight ratio.
- AHC100.29 powder to have density of 6.2g/cm 3 , 6.4g/cm 3 , 6.6g/cm 3 , 6.8g/cm 3 by being pressed by means of the press of 200ton.
- ASC 100.30, DAE, DAB, KAP and pure copper powder are pressed by means of the press of 200 ton to have density of 6.8g/cm 3 .
- the density measuring method measures the density after performing a sintering process according to KS D 0033 (method for determination of density of metal powder sintered materials).
- 6.2g/cm 3 , 6.4g/cm 3 , 6.6g/cm 3 is sintered for one hour at a temperature of 100 ° C, 200 ° C, 300 ° C, 400 ° C, and 500 ° C.
- the manufactured specimens (AHC 100.29, ABC 100.30, DAE, DAB, KAP, pure copper powder) at a density of 6.8g/cm 3 are sintered for one hour at a temperature of 750 "C , 900 ° C , 1000 ° C , and 1100 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- a wafer polishing is performed at final I/an powder, but only four types of 200 ° C, 300 ° C, 400 ° C, and 500 ° C maintain mechanical strength capable of standing the polishing.
- the polishing cannot be performed on the specimen sintered at 100 ° C since the particles are come off during the polishing.
- Fig. 1 is an electron microscope photograph (200 magnifications) at a sintering temperature of 400 ° C of specimen (density of 6.2g/cm 3 ) obtained from the embodiment 1 of the present invention
- Fig. 2 is an electron microscope photograph (200 magnifications) at a sintering temperature of 500 "C
- Fig. 3 is an electron microscope photograph (400 magnifications) at a sintering temperature of 400 °C .
- Fig. 4 is a scanning electron microscope (SEM) photograph (500 magnifications) at a sintering temperature of 400 ° C of specimen (density of 6.2g/cm 3 ) obtained from the embodiment 1 of the present invention
- Fig. 5 is a scanning electron microscope (SEM) photograph (10000 magnifications) at a sintering temperature of 300 ° C
- Fig. 6 is a scanning electron microscope photograph (10000 magnifications) at a sintering temperature of 500 ° C
- Fig. 7 is a scanning electron microscope photograph (500 magnifications) at a sintering temperature of 500 ° C
- FIG. 8 is a magnified view of the combining sites of FIG. 7.
- the carbon nanotubes are uniformly distributed over all the specimens. It can be found from FIGS. 4 to 8 that as the temperature is high, the growth speed of the carbon nanotubes is increased so that the carbon nanotubes are grown and many carbon nanotubes remain in a non-combined shape, at the temperature of 300 ° C upon rupturing, however, at a temperature of 500 ° C, most of carbon nanotubes are combined to be ruptured upon cutting the specimens. Also, it can be found that the ends of the carbon nanotubes (or growth compounds) are alloyed with the powder particles to be combined and the ruptured shape of the growth compound has an orthorhombic shape of carbide (cementite, Fe3C). Also, the sintered combination between the powder particles around the combining sites is made.
- cementite cementite
- the distribution shape of carbon nanotubes, the growth of carbon nanotubes, the alloying shape, and the carbon nanotube upon rupturing, at each sintering temperature (750 ° C, 900 ° C, 1000 ° C, and 1100 ° C), are examined by the scanning electron microscope (SEM).
- Fig. 9 is a scanning electron microscope (SEM) photograph (5000 magnifications and 25000 magnifications) at a sintering temperature of 750 "C of AHC 100.29 powder specimen (density of 6.8g/cm 3 ) obtained from the embodiment 1 of the present invention
- Fig. 10 is a scanning electron microscope (SEM) photograph (2000 magnifications and 5000 magnifications) at a sintering temperature of 900 ° C
- Fig. 11 is a scanning electron microscope photograph (2500 magnifications and 25000 magnifications) at a sintering temperature of 1000 ° C
- Fig. 9 is a scanning electron microscope (SEM) photograph (5000 magnifications and 25000 magnifications) at a sintering temperature of 750 "C of AHC 100.29 powder specimen (density of 6.8g/cm 3 ) obtained from the embodiment 1 of the present invention
- Fig. 10 is a scanning electron microscope (SEM) photograph (2000 magn
- Fig. 12 is a scanning electron microscope photograph (1500 magnifications and 20000 magnifications) at a sintering temperature of 1100 " C
- Fig. 13 is a scanning electron microscope (SEM) photograph (2000 magnifications and 35000 magnifications) at a sintering temperature of 1000 ° C of AHC 100.30 powder specimen (density of 6.8g/cm 3 )
- Fig. 14 is a scanning electron microscope (SEM) photograph (5000 magnifications and 20000 magnifications) at a sintering temperature of 1000 ° C of DAB powder specimen (density of 6.8g/cm 3 )
- Fig. 15 is a scanning electron microscope (SEM) photograph (2500 magnifications and 15000 magnifications) at a sintering temperature of 1000°C of DAE powder specimen (density of 6.8g/cm 3 ), and Fig. 16 is a scanning electron microscope (SEM) photograph (5000 magnifications and 20000 magnifications) at a sintering temperature of 750 ° C of KAP powder specimen (density of 6.8g/cm 3 ).
- SEM scanning electron microscope
- the shape of large carbon nanotubes in the sintering temperature of 750 ° C to 900 ° C still remains.
- the carbon nanotubes are changed into a shape where the large nanotubes get entangled in the small carbon nanotubes and are then changed into a shape covering the surfaces of the metal particles.
- the alloying is progressed in the portions where the carbon nanotubes are combined so that it can be found that as the sintering temperature is increased, the alloyed portions are widened.
- the master alloy powders uniformly dispersing and combining the carbon nanotubes in the powder particles are sintered, as the sintering temperature is raised, the alloying of the carbon nanotubes and the powder particles is progressed as well as the carbon nanotubes are combined and at the same time, grown, and when exceeding a particular temperature, the shape of the carbon nanotubes is broken, and then the carbon nanotubes then cover the surfaces of the powder particles and the alloying of the carbon nanotubes and the powder particles is continuously progressed.
- the master alloy powders dispersing and combining the carbon nanotubes in the KAP powders and the pure copper powders are sintered, it cannot be confirmed whether there are the carbon nanotubes.
- the test method follows KS B 0811 (Method of Vickers hardness test). A test load of 98.1N (10kg) is performed and a ten-point measurement is used. Each of two values from the top and bottom of the measured values is discarded so that the hardness is computed by performing an arithmetic mean using the remaining six points.
- the Vickers hardness test results per the sintering temperature for the AHC 100.29 powder specimen whose density is 6.2g/cm 3 , 6.4g/cm 3 , and 6.6g/cm 3 are indicated in Table 1.
- the hardness values can be measured in 400 ° C to 500 ° C . Also, as the density is increased, the hardness values per the sintering temperature become high.
- the hardness values are very highly measured even in temperature (up to 1000 "C) lower than that of the conventional powder metallurgy (footnote 1). It can be found that the sintered product can be manufactured in temperature lower than that of the conventional powder metallurgy. However, the difference in the hardness values between two specimens sintered at 1000 ° C and 1100 ° C, respectively, are different according to the powders. Accordingly, it can be found that there is the difference in the alloying temperature of the carbon nanotubes according to the powders. [Table 1]
- the Vickers hardness values are as follows. SMF 4020M is at least 60, SMF 4030M is at least 80, SMF 4040M is at least 100, and SMF 9060M is at least 200, based on the sintered finished product (approximately sintering temperature 1150 "C).
- KAP, pure copper specimens with density of 6.8 g/cm 3 among the specimens manufactured according to the process is performed by means of a universal testing machine.
- test specimen follows JIS Z 2550 (sintered materials for structural parts) and the test method performs the tensile test according to KS B 0802 (method of tensile test for metallic materials).
- the Vickers hardness values are as follows. SMF 4020M is at least 20, SMF 4030M is at least 30, SMF 4040M is at least 40, and SMF 9060M is at least 60, based on the sintered finished product (approximately sintering temperature 1150 "C).
- Embodiment 2 is described below.
- the manufactured master alloy is compacted in a tensile specimen shape to allow AHC100.29, ASC 100.30, DAE, DAB, KAP, and pure copper powders to have density of 6.8g/cm 3 by being pressed by means of the press of 200ton.
- the remaining processes are the same as the embodiment 1.
- This measurement is performed by the scanning electron microscope (SEM) of 50 magnifications, 1000 magnifications, 5000 magnifications, or 20000 magnifications.
- FIG. 17 is a Bending photograph of toughness added specimens after being sintered at 1000 ° C, which are obtained from the embodiment 2 of the present invention
- FIG. 18 is a scanning electron microscope photograph (50 magnifications) of a fracture surface fractured after being sintered at a sintering temperature of 1000 ° C and adding toughness
- FIG. 19 is a scanning electron microscope photograph (5000 magnifications and 20000 magnifications) of toughness added DAE powder specimen after being sintered at 1000 ° C,
- FIG. 20 is a scanning electron microscope photograph (5000 magnifications and 20000 magnifications) of toughness added PASC60 powder specimen after being sintered at 1000 ° C
- FIG. 21 is a scanning electron microscope photograph (1000 magnifications) of toughness added AHC 100.30 powder specimen after being sintered at 1000 ° C
- FIG. 22 is a scanning electron microscope photograph (1000 magnifications) of toughness added ABC 100.30 powder specimen after being sintered at 1000 "C
- FIG. 23 is a scanning electron microscope photograph (1000 magnifications) of toughness added DAB powder specimen after being sintered at 1000 ° C
- FIG. 24 is a scanning electron microscope photograph (1000 magnifications) of toughness added DAE powder specimen after being sintered at 1000 ° C
- FIG. 25 is a scanning electron microscope photograph (1000 magnifications) of toughness added PASC60 powder specimen after being sintered at 1000 " C
- FIG. 26 is a scanning electron microscope photograph (1000 magnifications) of toughness added KAP powder specimen after being sintering at 1000 ° C
- FIG. 27 is a scanning electron microscope photograph (1000 magnifications) of toughness added pure copper powder specimen after being sintered at 1000 ° C .
- the carbon nanotubes are generated and combined over all the specimens and are generated in a gauze form on the surfaces of the metal powders so that the ruptured sites are torn upon rupturing. Therefore, it is judged that the sintered product has toughness. However, it can not be judged whether there are the carbon nanotubes in the KAP powder specimen and the pure copper powder specimen. In order to strengthen mechanical, electric and electronic, and thermal characteristics using the carbon nanotubes in Cu or Cu alloy powders, it is judged that after the carbon nanotubes are generated in Fe or Ni master alloy powders or in Fe or Ni powder, they should mixed and sintered.
- the tensile test results are indicated in the following table 4.
- the tensile strength measurement results after suffering from the toughness adding process indicates that the change in tensile strength before/after adding the toughness is small, but the elongation is very increased.
- Table 4 ⁇ The tensile strength and elongation measurement results according to the change in sintering temperature per powder types>
- the elongation is as follows. SMF 4020M is at least 1.0%, SMF 4030M is at least 2.0%, SMF 4040M is at least 1.2%, and SMF 9060M is at least 1.5%, based on the sintered finished product (approximately sintering temperature 1150 ° C ) .
- the present invention generates and combines the carbon nanotubes in the metal powders adjacent to the pores which exists in the sintered product to increase the toughness, making it possible to obtain the composite sintering materials with more excellent mechanical characteristics than the conventional sintered materials with strong brittleness.
- PASC60 and DAE powders to have density of 6.8g/cm 3 by being pressed by means of the press of 200ton.
- the remaining processes are the same as the embodiment 1.
- the manufactured specimens are sintered for one hour at a temperature of 1100 ° C .
- the remaining processes are the same as the embodiment 1.
- the manufactured toughness added finished product is resintered for one hour at a temperature of 1100 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- the tensile test results are indicated in the following table 5.
- the elongation is slightly changed as compared to the toughness added sintered product, but the tensile strength is very increased.
- the present invention resinters, grows, and alloys the carbon nanotubes in the metal powders adjacent to the pores which exists in the sintered product to increase the strength and maintain the toughness, making it possible to obtain the composite sintering materials with more excellent mechanical characteristics with the intensified toughness and strength.
- the manufactured master alloy is compacted in a tensile specimen shape to allow PASC60 and DAE powders to have density of 6.8g/cm 3 by being pressed by means of the press of 200ton.
- the remaining processes are the same as the embodiment 1.
- the manufactured specimens are sintered for one hour at a temperature of 1100 ° C .
- the remaining processes are the same as the embodiment 1.
- the generation, growth, and alloying shape of the carbon nanotubes are examined by means of the scanning electron microscope (SEM).
- FIG. 28 is a scanning electron microscope photograph (25000 magnifications) of retoughness added DAE powder specimen after being resintered at 1100 ° C, which is obtained from the embodiment 4 of the present invention.
- the carbon nanotubes mixed in the metal powder particles and the carbon nanotubes generated in the step of adding the toughness are grown and alloyed, and the carbon nanotubes are regenerated by suffering from the retoughness adding step after being resintered.
- the mechanical properties are further strengthened by the repetition of sintering-toughness adding- resintering-retoughness adding -resintering processes
- the carbon nanotubes are generated in PASC60 powder by uniformly mixing the PASC60 powder used as the sintered alloy for the automotive structure, which is an alloy powder of iron and phosphorous from Hoganas Co., with diluted HF solution, natal, diluted sulfuric acid or phosphoric acid using a spraying non-gravity mixer, and injecting ammonia while applying heat at a proper temperature and then injecting acetylene, methane gas, or carbonic acid gas.
- (b) Compacting process The manufactured master alloy is compacted in a tensile specimen shape to have density of 6.8g/cm 3 by being pressed by means of the press of 200ton.
- the density measuring method measures density after performing a sintering process according to KS D 0033 (method for determination of density of metal powder sintered materials).
- the manufactured specimen is sintered for one hour at a temperature of 600 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- FIG. 29 is a scanning electron microscope photograph (15000 magnifications) of specimen generating carbon nanotubes in the metal powder particles at a sintering temperature of 600 ° C, which is obtained from the embodiment 4 of the present invention;
- the carbon nanotubes covers the metal powder particles by being generated along with the carbon particles in the metal powder particles, but unlike the master alloy powder uniformly dispersing and combining the carbon nanotubes, they are not grown as large carbon nanotubes even at a sintering temperature of 600 ° C .
- the manufactured specimen is sintered for one hour at a temperature of 1100 " C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- the tensile test results are indicated in the following table 6. As in the table 6, it can be found that the tensile strength and elongation are more increased than the specimen of the embodiment 1 made by mixing and combining the carbon nanotubes of 0.1%. It is judged that it is difficult to quantitatively measure the amount of the carbon nanotubes generated in the metal powder particles, but the larger amount of the carbon nanotubes is formed than the case where the carbon nanotubes of 0.1% is mixed.
- Embodiment 7 Manufacture of sample (a) Process of generating carbon nanotube in metal powder particle (the same as the embodiment 5)
- the manufactured toughness adding finished product is resintered for one hour at a temperature of 600 "C and 1100 "C .
- the remaining processes are the same as the embodiment 3.
- the tensile test results are indicated in the following table 7.
- Table 7 in the tensile strength and elongation measurement results after suffering from the resintering process and the generating process of the carbon nanotubes, the difference in the tensile strength and elongation are not large as compared to the specimen sintered after generating the carbon nanotubes in the metal powder particles. Also, the difference in the tensile strength of the specimen resintered at 600 ° C is not large, but the tensile strength of the specimen resintered at 1100 ° C is increased by about 10%.
- PASC60 powder used as the sintered alloy for the automotive structure which is an alloy powder of iron and phosphorous from Hoganas Co., and DAE powders are compacted in a tensile specimen shape to have density of 6.8g/cm 3 by being pressed by means of the press of 200ton.
- the density measuring method measures density after performing a sintering process according to KS D 0033 (method for determination of density of metal powder sintered materials).
- the manufactured specimen is sintered for one hour at a temperature of 1100 0 C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- (2) Mechanical physical property measurement by tensile test (the measurement method is the same as the embodiment 1)
- the mechanical strength in the case where the carbontubes are impregnated and sintered in the compacted product is weaker as compared to that in the case where the carbon nanotubes are mixed and sintered in metal powder particles. It is judged that since the carbon nanotubes are combined in the pores existing in the molded product to grow and alloy when the carbon tubes are impregnated in the compacted product, the disperse of the carbon nanotubes are more non-uniform and the amount of the carbon nanotubes is little to have a lower mechanical strength, as compare to the case where the carbon nanotubes are mixed and sintered in the metal powder particles.
- the manufactured toughness adding finished product is resintered for one hour at a temperature of 600 ° C and 1100 ° C .
- the remaining processes are the same as the embodiment 3.
- the tensile strength of the specimen resintered at a temperature of 1000 ° C is much more increased as compared to the specimen obtained from the embodiment 8. It can be found that the strength is increase only when the generated carbon nanotubes are resintered above the temperature that the alloy is made. Also, it can be found that although the elongation is different according to the resintering temperature, if the carbon nanotubes are generated, it is not greatly affected by the resintering temperature but has similar elongations.
- the manufactured specimen is sintered for one hour at a temperature of 600 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- FIG. 30 is a scanning electron microscope photograph (20000 magnifications and
- FIG 31 is a scanning electron microscope photograph (a: 5000 magnifications and 25000 magnifications) of specimen sintering specimen generating carbon nanotubes in DAE powder molded product at a sintering temperature of 600 ° C .
- the manufactured specimen is sintered for one hour at a temperature of 1100 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- the manufactured toughness adding finished product is resintered for one hour at a temperature of 600 ° C and 1100 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and as a sintering furnace a Mesh Belt sintering furnace is used.
- the tensile strength of the specimens additionally generating carbon nanotubes after impregnating and sintering the carbon nanotubes in the compacted product and then generating the carbon nanotubes in a compacted product are higher as compared to that of the specimens generating the carbon nanotubes after impregnating and sintering the carbon nanotubes in the compacted product, but their elongation is almost the same.
- the brittlness which is a weak point of the sintered product, can be improved by forming the carbon nanotubes in the pores of the compacted product.
- PASC60 powder used as the sintered alloy for the automotive structure which is an alloy powder of iron and phosphorous from Hoganas Co., and DAE powders are mixed with diluted HF solution, natal, diluted sulfuric acid or phosphoric acid using a spraying non-gravity mixer.
- the commercialized PASC60 powder uses a particle with a powder size
- the density measuring method measures density after performing a sintering process according to KS D 0033 (method for determination of density of metal powder sintered materials). (c) Process of generating carbon nanotube in compacted product
- the carbon nanotubes are generated by injecting ammonia while applying heat at a proper temperature and then injecting acetylene, methane gas, or carbonic acid gas.
- the tensile test results are indicated in the following Table 12.
- the mechanical strength of the specimens generating carbon nanotubes by being chemically processed in a mixing step is higher as compared to that of the specimens generating carbon nanotubes by being molded and then chemically processed. It is judged that it is more advantageous for generating the carbon nanotubes when gas of carbon group generating the carbon nanotubes are chemically processed in a metal powder particle state.
- PASC60 powder used as the sintered alloy for the automotive structure which is an alloy powder of iron and phosphorous from Hoganas Co., and DAE powders are compacted in a tensile specimen shape to have density of 6.8g/cm 3 by being pressed by means of the press of 200ton.
- the density measuring method measures density after performing a sintering process according to KS D 0033 (method for determination of density of metal powder sintered materials). (b) Sintering process
- the manufactured specimen is sintered for one hour at a temperature of 1100 ° C .
- organic solution where carbon nanotubes are dispesed is impregnated in the pores of the sintered product by using a vacuum impregnating machine and is heated at a proper temperature so that the carbon nanotubes are combined in the metal powder particles adjacent to the pores of the molded product.
- the manufactured sintered product in which the carbon nanotubes are impregnated and combined is resintered for one hour at a temperature of 1100 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and a Mesh Belt sintering furnace is used.
- (2) Mechanical physical property measurement by tensile test (the measurement method is the same as the embodiment 1)
- the mechanical strength of the specimens mixing and sintering the carbon nanotubes in the metal powder particles, and then resintering them is higher as compared to that of the specimens resintering the specimens impregnating the carbon nanotubes in the sintered product.
- the specimens resintering the specimens impregnating the carbon nanotubes in the sintered product has little elongation. It can be found that although the carbon nanotubes impregnated in the sintered product are impregnated and combined in the pores in the sintered product, the tube shape thereof is broken when they are sintered at a temperature of 1100 * 0, having no effects to increase the elongation.
- Embodiment 15 ( 1 ) Manufacture of sample
- PASC60 powder used as the sintered alloy for the automotive structure which is an alloy powder of iron and phosphorous from Hoganas Co., and DAE powders are compacted in a tensile specimen shape to have density of 6.8g/cm 3 by being pressed by means of the press of 200ton.
- the remaining processes are the same as the embodiment 1.
- the manufactured specimen is sintered for one hour at a temperature of 1100 ° C .
- the sintering atmosphere is performed under nitrogen atmosphere and as a sintering furnace a Mesh Belt sintering furnace is used.
- FIG. 32 is a scanning electron microscope photograph (5000 magnifications and
- FIG. 33 is a scanning electron microscope photograph (a: 5000 magnifications/b: 20000 magnifications) of DAE powder sintered product in which carbon nanotubes are generated.
- the sintering atmosphere is performed under nitrogen atmosphere and as a sintering furnace a Mesh Belt sintering furnace is used.
- (2) Mechanical property measurement by tensile test (the measurement method is the same as the embodiment 1)
- the tensile strength is largely increased by generating the carbon nanotubes in the pores of the sintered product and then resintering and alloying them. It can be found that the mechanical physical property values can be increased by repeatedly performing the sintering process and the generating process of the carbon nanotubes.
- the sintered finished product is manufactured as SMF 4040M material, which is the sintered alloy for the automotive structure.
- SMF 4040M material which is the sintered alloy for the automotive structure.
- the sintering atmosphere is performed under nitrogen atmosphere and as a sintering furnace a Mesh Belt sintering furnace is used.
- (2) Mechanical property measurement by tensile test (the measurement method is the same as the embodiment 1)
- the tensile test results are indicated in the following table 16. As in the table 16, it can be found that the mechanical characteristics of the existing sintered product can be strengthened by generating the carbon nanotubes in the pores of the existing sintered product or impregnating and combinging the carbon nanotubes therein and then repeatedly performing the sintering process and the generating process of the carbon nanotubes or the impregnating and combining processes of the carbon nanotubes. [Table 16] ⁇ The tensile strength and elongation measurement results>
- the composite sintering materials using the carbon nanotubes of the present invention is completed by uniformly combining the carbon nanotubes in the metal powder particles or generating the carbon nanotubes therein and growing, alloying, and sintering them or by impregnating and combining the carbon nanotubes in the compacted product or the sintered product or generating the carbon nanotubes in the pores in the compacted product or the sintered product and growing, alloying, and sintering them so that they can be used as the material of the automotive parts, etc. [Industrial Applicability]
- the composite sintering materials and a manufacturing method thereof have excellent mechanical, thermal, and electric and electronic characteristics as well as have effects of lowered sintering temperature and material cost reduction so that they are useful as materials for automotive parts, electric and electronic parts, space and aircraft parts, and molding and cutting tools.
Abstract
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JP2009527304A JP5254978B2 (en) | 2006-09-11 | 2007-09-07 | A composite sintered material utilizing carbon nanotubes and a method for producing the same. |
US12/440,744 US8119095B2 (en) | 2006-09-11 | 2007-09-07 | Composite sintering materials using carbon nanotube and manufacturing method thereof |
US13/344,308 US8562938B2 (en) | 2006-09-11 | 2012-01-05 | Composite sintering materials using carbon nanotube and manufacturing method thereof |
US13/344,270 US8506922B2 (en) | 2006-09-11 | 2012-01-05 | Composite sintering materials using carbon nanotube and manufacturing method thereof |
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