WO2012157514A1 - 金属-炭素複合材及びその製造方法 - Google Patents
金属-炭素複合材及びその製造方法 Download PDFInfo
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- WO2012157514A1 WO2012157514A1 PCT/JP2012/061992 JP2012061992W WO2012157514A1 WO 2012157514 A1 WO2012157514 A1 WO 2012157514A1 JP 2012061992 W JP2012061992 W JP 2012061992W WO 2012157514 A1 WO2012157514 A1 WO 2012157514A1
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- carbon
- particles
- carbon composite
- composite material
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- 229910052799 carbon Inorganic materials 0.000 title claims abstract description 163
- 239000002131 composite material Substances 0.000 title claims abstract description 107
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 114
- 239000002245 particle Substances 0.000 claims abstract description 100
- 229910052751 metal Inorganic materials 0.000 claims abstract description 62
- 239000002184 metal Substances 0.000 claims abstract description 62
- 239000002923 metal particle Substances 0.000 claims description 38
- 238000002156 mixing Methods 0.000 claims description 25
- 239000000203 mixture Substances 0.000 claims description 15
- 238000010304 firing Methods 0.000 claims description 14
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 239000011230 binding agent Substances 0.000 claims description 9
- 238000009694 cold isostatic pressing Methods 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 150000002739 metals Chemical class 0.000 claims description 4
- 229910052787 antimony Inorganic materials 0.000 claims description 3
- 229910052797 bismuth Inorganic materials 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 229910052709 silver Inorganic materials 0.000 claims description 3
- RQMIWLMVTCKXAQ-UHFFFAOYSA-N [AlH3].[C] Chemical compound [AlH3].[C] RQMIWLMVTCKXAQ-UHFFFAOYSA-N 0.000 description 32
- 238000000034 method Methods 0.000 description 28
- 229910002804 graphite Inorganic materials 0.000 description 22
- 239000010439 graphite Substances 0.000 description 22
- 238000000465 moulding Methods 0.000 description 9
- 239000000463 material Substances 0.000 description 8
- 229920003023 plastic Polymers 0.000 description 8
- 238000012545 processing Methods 0.000 description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 7
- 239000003575 carbonaceous material Substances 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- 238000005304 joining Methods 0.000 description 6
- 238000000879 optical micrograph Methods 0.000 description 6
- 239000002002 slurry Substances 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 239000007769 metal material Substances 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- 238000007613 slurry method Methods 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 2
- 229910021383 artificial graphite Inorganic materials 0.000 description 2
- ZIUHHBKFKCYYJD-UHFFFAOYSA-N n,n'-methylenebisacrylamide Chemical compound C=CC(=O)NCNC(=O)C=C ZIUHHBKFKCYYJD-UHFFFAOYSA-N 0.000 description 2
- 238000013001 point bending Methods 0.000 description 2
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 239000008247 solid mixture Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000905 alloy phase Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000012447 hatching Effects 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011302 mesophase pitch Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 229910021382 natural graphite Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 235000011835 quiches Nutrition 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
Images
Classifications
-
- 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
- B22F3/12—Both compacting and sintering
-
- 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
- B22F3/02—Compacting only
- B22F3/04—Compacting only by applying fluid pressure, e.g. by cold isostatic pressing [CIP]
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1084—Alloys containing non-metals by mechanical alloying (blending, milling)
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0084—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ carbon or graphite as the main non-metallic constituent
-
- 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
- B22F7/06—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 composite workpieces or articles from parts, e.g. to form tipped tools
Definitions
- the present invention relates to a metal-carbon composite material and a method for producing the same.
- Carbon material is a material that has excellent properties such as light weight, high chemical and thermal stability, non-metal, high thermal conductivity, high electrical conductivity, and self-lubricating properties. Widely used. Depending on the application, there is a need to use a composite of a carbon material and a metal material.
- the carbon material has a problem that it has poor wettability with a metal, is difficult to be combined with the metal material, and is brittle. For this reason, research and development on a composite method of a carbon material and a metal material has been actively conducted.
- Patent Document 1 discloses a method of impregnating a porous carbon material with aluminum.
- Patent Document 2 discloses a method of pressurizing and impregnating a graphite molded body with aluminum, copper, or an alloy thereof.
- Patent Document 3 discloses a method of stirring and mixing an aluminum alloy melt and graphite powder.
- Patent Document 4 discloses a method in which graphite particles are put into an aluminum alloy melt and then die-cast.
- Patent Documents 1 to 4 have a problem that it is difficult to produce a metal-carbon composite material having a high carbon content.
- the present invention has been made in view of such a point, and an object thereof is to provide a metal-carbon composite material having good workability and a high carbon content and a method for producing the same.
- the metal-carbon composite material of the present invention includes a continuous metal phase and carbon particles.
- the carbon particles are dispersed in the metal phase.
- the carbon content is 50% by volume or more.
- metal includes alloys. Therefore, “metal phase” includes “alloy phase”.
- the carbon particles may include particles that exist in a lump without using a metal phase.
- the metal phase of the metal-carbon composite according to the present invention is preferably made of at least one selected from the group consisting of Al, Cu, Ag, Ni, Bi, Sb and alloys containing at least one of these metals.
- the thickness of the metal phase of the metal-carbon composite material according to the present invention is preferably 10 nm to 100 ⁇ m.
- the particle diameter of the carbon particles of the metal-carbon composite material according to the present invention is preferably in the range of 50 nm to 500 ⁇ m.
- the method for producing a metal-carbon composite material according to the present invention comprises a mixing step of mixing metal particles and carbon particles to obtain a mixture containing carbon particles having metal particles attached to the surface, and molding the mixture to form a molded body. A step of obtaining, and a step of firing the molded body.
- the particle size of the metal particles is preferably in the range of 1/100 to 1/5 of the particle size of the carbon particles.
- the mixture is preferably formed by cold isostatic pressing.
- FIG. 1 is a schematic cross-sectional view showing a metal-carbon composite material in one embodiment according to the present invention.
- FIG. 2 is an optical micrograph of the aluminum-carbon composite material obtained in Example 1.
- FIG. 3 is an optical micrograph of the aluminum-carbon composite material obtained in Example 2.
- 4 is an optical micrograph of the bonding interface of the bonded body obtained in Experimental Example 1.
- FIG. 5 shows the processed aluminum-carbon composite material (left) obtained in Experimental Example 2 and the graphite mold used (right).
- FIG. 6 shows the graphite mold (right) used with the aluminum-carbon composite material (left) obtained in Example 3.
- FIG. 1 is a schematic cross-sectional view showing a metal-carbon composite material in an embodiment according to the present invention.
- hatching of the metal phase 3 is omitted.
- the metal-carbon composite 1 includes a continuous metal phase 3 and a plurality of carbon particles 2.
- the plurality of carbon particles 2 are dispersed in the metal phase 3.
- the carbon particle 2 is a particle mainly composed of carbon.
- the carbon particle 2 may contain components other than carbon.
- the carbon particles 2 can be composed of, for example, graphite particles.
- As the graphite particles for example, natural graphite, mesophase pitch graphite, artificial graphite, quiche graphite, and mesophase small sphere graphitized materials are preferably used.
- the carbon particles 2 may include only one type of carbon particle, or may include a plurality of types of carbon particles.
- the particle diameter of the carbon particles 2 is preferably about 50 nm to 500 ⁇ m, more preferably about 1 ⁇ m to 250 ⁇ m, and further preferably about 5 ⁇ m to 100 ⁇ m. If the particle diameter of the carbon particles 2 is too small, the carbon particles 2 tend to aggregate. If the carbon particles 2 are too agglomerated, not only the workability of the material is lowered, but also the strength may be lowered. If the carbon particles 2 are too large, the structure of the metal-carbon composite material 1 becomes rough, for example, the thickness of the metal phase 3 becomes nonuniform, which may lead to a decrease in workability and strength.
- the metal phase 3 is preferably composed of a metal that hardly reacts with carbon to form a carbide.
- Specific examples of the metal preferably used as the constituent material of the metal phase 3 include metals such as Al, Cu, Ag, Ni, Bi, and Sb, and alloys containing at least one of these metals.
- the thickness of the metal phase 3 is usually preferably in the range of about 10 nm to 100 ⁇ m, and more preferably in the range of about 1 ⁇ m to 10 ⁇ m.
- the “thickness of the metal phase 3” is a value measured by structural observation with an optical microscope or a scanning electron microscope.
- the carbon content in the metal-carbon composite 1 is 50% by volume or more.
- the carbon content in the metal-carbon composite 1 is preferably about 50% to 99% by volume, more preferably about 60% to 95% by volume, and about 70% to 90% by volume. More preferably.
- the carbon content in the metal-carbon composite 1 is a value calculated from the mixing ratio of the raw materials.
- the metal phase 3 of the metal-carbon composite 1 has a continuous structure.
- the metal phase 3 preferably has a three-dimensional network structure.
- the metal phase 3 is located between the plurality of carbon particles 2.
- a plurality of carbon particles 2 are connected and integrated by the metal phase 3. That is, the metal-carbon composite material 1 has a structure in which a plurality of carbon particles 2 are surrounded by a continuous metal phase 3. Therefore, the metal-carbon composite material 1 can contain 50% by volume or more of carbon.
- the metal phase 3 may be composed of one continuous metal phase, or may be composed of a plurality of isolated metal phases.
- the carbon particles 2 may be dispersed in the metal phase 3 as a lump. However, the carbon particles 2 are preferably dispersed in the metal phase 3 to such an extent that the metal-carbon composite 1 can be plastically processed.
- the metal-carbon composite material 1 has excellent workability. This is considered due to the fact that the carbon particles 2 exist as particles independent of the metal phase 3 in the metal-carbon composite material 1 of the present embodiment. That is, it is considered that the plastic deformation of the metal phase 3 is not hindered by the carbon particles 2 when an external force is applied to the metal-carbon composite material 1.
- the metal-carbon composite material 1 has high strength. This is considered to be because there is no fluidity of the metal at normal temperature and the metal phase 3 acts as an aggregate.
- the metal-carbon composite 1 contains 50% by volume or more of carbon. For this reason, the metal-carbon composite material 1 has a low specific gravity and self-lubricating properties that are characteristics of carbon.
- the metal-carbon composite material 1 includes carbon particles 2 and a metal phase 3 is continuous. For this reason, the metal-carbon composite 1 has excellent conductivity and excellent thermal conductivity.
- the metal-carbon composite material of the present embodiment has the excellent characteristics as described above, it can be preferably used as a sliding member, a heat dissipation material for semiconductors, LEDs, and the like, and a sealing material.
- carbon particles those described above can be used.
- the metal particles are particles made of a metal constituting the metal phase 3.
- the particle diameter of the metal particles is preferably in the range of 1/100 to 1/5 of the particle diameter of the carbon particles. In this case, substantially the entire surface of the carbon particles 2 can be covered with the metal particles.
- the particle diameter of the metal particles is more preferably in the range of 1/50 to 1/10 of the particle diameter of the carbon particles 2, and further preferably in the range of 1/40 to 1/20.
- the mixing ratio of the carbon particles 2 and the metal particles can be appropriately set according to the carbon content in the metal-carbon composite material 1 to be obtained.
- the ratio of the carbon particles 2 to the metal particles may be increased.
- the metal phase 3 may not be suitably formed.
- the mixing ratio of the carbon particles 2 and the metal particles is preferably such that the entire surface of the carbon particles 2 is substantially covered with the metal particles.
- the mixing of the metal particles and the carbon particles 2 can be performed by, for example, a mechanical mixing method, a slurry method, or a method combining these.
- the mechanical mixing method is a method in which metal particles and carbon particles 2 are mechanically mixed.
- Specific examples of the mechanical mixing method include a method of mixing metal particles and carbon particles 2 using, for example, a rotation / revolution mixer.
- a binder in addition to the carbon particles 2 and the metal particles.
- a known binder can be used as the binder.
- Specific examples of the binder that can be preferably used include PVA (polyvinyl alcohol), PVB (polyvinyl butyral), and the like.
- the slurry method is a method in which the carbon particles 2 and the metal particles are made into a slurry, and the carbon particles 2 and the metal particles are mixed.
- Specific examples of the slurry method include a gel cast method and a slip cast method.
- the gel casting method can be performed, for example, as follows.
- metal particles, a liquid solvent and a binder are mixed to form a slurry, and the carbon particles 2 are added to the slurry, mixed, and dried to obtain a solid mixture.
- metal particles and carbon particles 2 are added to an isopropanol organic solvent to which acryamide and N, N′-methylenebisacrylamide are added as binders, and the slurry is prepared by stirring with a rotating / revolving mixer, and the slurry is made into a mold. When placed and dried, a solid mixture is obtained.
- the molding of the mixture can be performed, for example, by press molding using a molding machine such as cold isostatic pressing (CIP molding).
- the mixing in the mixing step and the forming in the forming step may be performed simultaneously.
- the carbon particles 2 and the metal particles may be mixed and formed into a desired shape by a gel casting method.
- the molding material used as a mold in the molding machine is not particularly limited.
- a mold made of graphite is preferably used.
- the firing temperature and firing time of the molded body, the type of firing atmosphere, the pressure of the firing atmosphere, and the like can be appropriately set according to the material, shape, size, and the like of the metal particles and carbon particles 2.
- the firing temperature of the compact can be, for example, from the softening temperature to the melting temperature of the metal constituting the metal particles.
- the firing time of the molded body can be, for example, about 1 minute to 100 minutes.
- the kind of baking atmosphere can be made into vacuum, inert gas atmosphere, such as nitrogen and argon, for example.
- the pressure of the firing atmosphere can be, for example, about 0.2 MPa to 100 MPa.
- a plastic processing step may be further performed on the obtained metal-carbon composite material 1.
- the plastic processing step is a step of changing the shape of the metal-carbon composite material 1 by heating and pressurizing it while pressing it against a mold or the like.
- the shape of the molded body to be fired is set to a shape suitable for firing, and is suitably fired by processing into a desired shape in the plastic processing step, and the metal-carbon composite material 1 having the desired shape. Can be easily obtained.
- the processing temperature in the plastic processing step can be set from the softening temperature to the melting temperature of the metal constituting the metal particles.
- the pressure applied to the metal-carbon composite material 1 in the plastic processing step can be, for example, about 0.2 MPa to 100 MPa.
- the metal-carbon composite 1 includes a metal phase 3 surrounding the carbon particles 2. That is, the metal phase 3 is exposed on at least a part of the surface of the metal-carbon composite material 1. Therefore, for example, after the plurality of metal-carbon composite materials 1 are manufactured, the plurality of metal-carbon composite materials 1 can be easily bonded by bringing them into contact with each other and heating them while applying pressure. Accordingly, the large metal-carbon composite material 1 can be easily manufactured by forming a plurality of metal-carbon composite materials and then joining the plurality of metal-carbon composite materials.
- the heating temperature and pressure at the time of bonding can be appropriately set according to the type of the metal phase 3, the size of the metal-carbon composite material to be bonded, the bonding area, and the like.
- the heating temperature at the time of joining may be, for example, from the softening temperature to the melting temperature of the metal constituting the metal particles.
- the pressure applied at the time of joining can be, for example, about 0.2 MPa to 100 MPa.
- the content of carbon and metal in the metal-carbon composite material 1 is adjusted by adjusting the ratio of the metal particles attached to the carbon particles 2 to the carbon particles 2. can do.
- the metal particles only need to be present to such an extent that the plurality of carbon particles 2 can be joined in the firing step. For this reason, the content rate of the metal particle in a molded object can be 50 volume% or less. Therefore, the metal-carbon composite material 1 having a carbon content of 50% by volume or more can be obtained.
- the obtained metal-carbon composite 1 has a structure in which a plurality of carbon particles 2 are surrounded by a continuous metal phase 3.
- the metal-carbon composite material 1 in which the carbon particles 2 are uniformly dispersed in the metal phase 3 can be obtained.
- the particle diameter of the metal particles within the range of 1/100 to 1/5 of the particle diameter of the carbon particles 2 and covering substantially the entire surface of the carbon particles 2 with the metal particles.
- the continuity can be made higher.
- plasticity can be given by the fluidity
- Example 1 An aluminum powder (4.04 g) having a particle size of 1 ⁇ m, acrylamide (8 g), and a binder solution (4.5 g) in which N, N′-methylenebisacrylamide (1 g) was dissolved in isopropanol (45 g) were rotated. The mixture was obtained by stirring by revolving mixing. The rotation / revolution mixing was performed at 2000 rpm for 60 seconds. To the obtained mixture, 10 g of mesographite particles having a particle diameter of 20 ⁇ m was added, and the mixture was stirred and mixed at 2000 rpm for 180 seconds by rotation / revolution mixing. Next, the mixture was dried at 80 ° C. for 8 hours to obtain a dried product. The dried product was molded by cold isostatic pressing (CIP molding) to obtain a molded body. The pressure during CIP molding was 200 MPa.
- CIP molding cold isostatic pressing
- the obtained molded body was put into a cylindrical graphite mold and fired in a hot press furnace to obtain an aluminum-carbon composite material.
- this firing step first, heating was performed from room temperature at 20 ° C./min to 700 ° C., held at 700 ° C. for 20 minutes, and then cooled to room temperature at 10 to 15 ° C./min over about 2 hours.
- the shape of the obtained aluminum-carbon composite was a cylinder having a height of 10 mm and a diameter of 30 mm.
- the content of carbon in the aluminum-carbon composite was 75% by volume.
- FIG. 2 An optical micrograph of the aluminum-carbon composite material obtained in Example 1 is shown in FIG. In FIG. 2, dark portions are graphite particles, and light portions are aluminum. From the photograph shown in FIG. 2, it can be seen that the graphite particles are covered with aluminum, and the aluminum forms a continuous phase.
- Example 1 the bending strength, Shore hardness, Young's modulus, thermal conductivity, and electrical resistivity of the aluminum-carbon composite material obtained in Example 1 were measured as follows. The results are shown in Table 1 below together with the bulk density of the aluminum-carbon composite material.
- the aluminum-carbon composite material was cut into a size of 5 mm ⁇ 3 mm ⁇ 20 mm, and the bending strength was measured by a three-point bending strength test.
- the span length was 15 mm and the crosshead speed was 0.5 mm / min.
- Shore hardness was measured using a hardness tester Shore type D (manufactured by Nakai Seiki Seisakusho, Model No. 20309). Five points were measured for one test piece, and the average value of three points excluding the maximum value and the minimum value of the measured value was defined as Shore hardness. Specifically, the Shore hardness was measured according to JIS Z 2246.
- Young's modulus was evaluated by analyzing the results of a three-point bending strength test.
- the aluminum-carbon composite material was processed into a disk shape having a diameter of 10 mm and a thickness of 1 mm, and the thermal conductivity was measured by a laser flash method.
- Example 2 An aluminum-carbon composite was prepared in the same manner as in Example 1 except that graphite particles having a particle diameter of 50 ⁇ m (artificial graphite powder CCE07PB manufactured by Kojundo Chemical Laboratory Co., Ltd.) were used instead of mesographite particles having a particle diameter of 20 ⁇ m. A material was prepared. The content of carbon in the aluminum-carbon composite was 75% by volume.
- FIG. 3 shows an optical micrograph of the aluminum-carbon composite material obtained in Example 2.
- dark portions are graphite particles, and light portions are aluminum.
- FIG. 3 shows that the graphite particles are covered with aluminum, and aluminum forms a continuous phase.
- Example 2 For the aluminum-carbon composite material produced in Example 2, the bending strength, Shore hardness, Young's modulus, thermal conductivity, and electrical resistivity were also measured in the same manner as in Example 1. The results are shown in Table 2 below together with the bulk density of the aluminum-carbon composite material.
- Example 1 The joining test of the two types of aluminum-carbon composite materials obtained in Example 1 and Example 2 was performed. Specifically, the two aluminum-carbon composite materials were heated at 700 ° C. for 20 minutes while applying a pressure of 40 MPa while the end surfaces of the two aluminum-carbon composite materials were in contact with each other. As a result, these two types of aluminum-carbon composite materials were joined.
- An optical micrograph of the bonded interface of the bonded body obtained in Experimental Example 1 is shown in FIG. As is apparent from the photograph shown in FIG. 4, it can be seen that the joining surfaces of the two types of aluminum-carbon composite materials are joined without a gap.
- Example 2 The aluminum-carbon composite material obtained in Example 1 was plastic processed. Specifically, the aluminum-carbon composite material obtained in Example 1 was put into a graphite mold having grooves on the inner surface, and was plastically processed by heating at a temperature of 700 ° C. for 20 minutes while applying a pressure of 40 MPa. .
- a photograph of the processed aluminum-carbon composite material of Experimental Example 2 and the graphite mold used is shown in FIG. The left side of the photograph shown in FIG. 5 is the processed aluminum-carbon composite material, and the right side is the graphite mold used. From the photograph shown in FIG. 5, it can be seen that the graphite-shaped grooves are suitably transferred to the aluminum-carbon composite material. This shows that the aluminum-carbon composite material can be plastically processed.
- Example 3 An aluminum-carbon composite material was produced in the same manner as in Example 1 except that firing was performed while pressing a graphite T-convex shape (graphite mold) against the compact during firing. A photograph of the graphite mold used in Example 3 and the obtained aluminum-carbon composite material are shown in FIG. The left side of the photograph shown in FIG. 6 is the processed aluminum-carbon composite material, and the right side is the graphite mold used.
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Abstract
Description
まず、混合工程を行う。混合工程では、炭素粒子2と金属粒子とを混合し、金属粒子が表面に付着した炭素粒子2を含む混合物を得る。
次に、混合物を成形して成形体を得る。混合物の成形は、例えば、冷間等方加圧成形(CIP成形)などの成形機を用いたプレス成形により行うことができる。
次に、成形体を焼成する。これにより、連続している金属相3中に複数の炭素粒子2が分散した構造を有する金属-炭素複合材1を得ることができる。成形体の焼成温度や焼成時間、焼成雰囲気の種類、焼成雰囲気の圧力等は、金属粒子や炭素粒子2の材質や形状、大きさ等に応じて適宜設定することができる。成形体の焼成温度は、例えば、金属粒子を構成する金属の軟化温度~融解温度とすることができる。成形体の焼成時間は、例えば、1分間~100分間程度とすることができる。焼成雰囲気の種類は、例えば、真空や、窒素、アルゴンなどの不活性ガス雰囲気とすることができる。焼成雰囲気の圧力は、例えば、0.2MPa~100MPa程度とすることができる。
なお、得られた金属-炭素複合材1に対して可塑加工工程をさらに行ってもよい。可塑加工工程は、成形型などに押しつけながら加熱・加圧することにより、金属-炭素複合材1の形状を変化させる工程である。例えば、焼成する成形体の形状は、焼成に適した形状としておき、可塑加工工程において所望の形状に加工することにより、好適に焼成されており、かつ所望の形状を有する金属-炭素複合材1を容易に得ることができる。
金属-炭素複合材1は、炭素粒子2を包囲する金属相3を備えている。すなわち、金属-炭素複合材1の表面の少なくとも一部には、金属相3が露出している。よって、例えば、複数の金属-炭素複合材1を作製した後に、それら複数の金属-炭素複合材1を接触させて加圧しながら加熱することにより容易に接合することができる。従って、大型の金属-炭素複合材1は、金属-炭素複合材を複数作成した後に、それら複数の金属-炭素複合材を接合することにより容易に製造することができる。
粒子径が1μmのアルミニウム粉末(4.04g)と、アクリルアミド(8g)と、N,N’-メチレンビスアクリルアミド(1g)をイソプロパノール(45g)に溶解したバインダー溶液(4.5g)とを自転・公転ミキシングにより撹拌して混合物を得た。自転・公転ミキシングは、2000rpmで60秒間行った。得られた混合物に、粒子径が20μmのメソ黒鉛粒子を10g加え、自転・公転ミキシングにより、2000rpmで180秒間撹拌して混合した。次に、混合物を80℃で8時間乾燥して、乾燥物を得た。乾燥物を冷間等方加圧成形(CIP成形)により成形して成形体を得た。CIP成形時の圧力は、200MPaとした。
アルミニウム-炭素複合材を、5mm×3mm×20mmの大きさに切り出し、3点曲げ強度試験により曲げ強度を測定した。スパン長を15mm、クロスヘッド速度を0.5mm/分とした。
硬さ試験機ショア式D型(仲井精機製作所製、型番20309)を用いて、ショア硬さを測定した。1つの試験片に対し5点測定し、測定値の最大値及び最小値を除いた3点の平均値を、ショア硬さとした。具体的には、JIS Z 2246に従いショア硬さを測定した。
ヤング率は3点曲げ強度試験の結果を解析することで評価した。
アルミニウム-炭素複合材を直径10mm、厚さ1mmの円板状に加工し、レーザーフラッシュ法で熱伝導率を測定した。
アルミニウム-炭素複合材の表面の電気抵抗率を、直流四探針法で測定した。
粒子径が20μmのメソ黒鉛粒子の代わりに、粒子径が50μmの黒鉛粒子(高純度化学研究所社製人造黒鉛粉末CCE07PB)を使用したこと以外は、実施例1と同様にしてアルミニウム-炭素複合材を作製した。アルミニウム-炭素複合材中の炭素の含有量は、75体積%であった。
実施例1及び実施例2で得られた2種類のアルミニウム-炭素複合材の接合試験を行った。具体的には、これら2つのアルミニウム-炭素複合材の端面同士を接触させた状態で、40MPaの圧力を印加しつつ、700℃で20分間加熱した。その結果、これら2種類のアルミニウム-炭素複合材は、接合された。実験例1で得られた接合体の接合界面の光学顕微鏡写真を図4に示す。図4に示す写真からも明らかなように、2種類のアルミニウム-炭素複合材の接合面は、隙間なく接合されていることが分かる。
実施例1で得られたアルミニウム-炭素複合材を塑性加工した。具体的には、実施例1で得られたアルミニウム-炭素複合材を、内面に溝を有する黒鉛型に入れ、40MPaの圧力を印加しつつ、温度700℃で20分間加熱することにより塑性加工した。加工された実験例2のアルミニウム-炭素複合材と、使用した黒鉛型の写真を図5に示す。図5に示す写真の左側が加工されたアルミニウム-炭素複合材であり、右側が使用した黒鉛型である。図5に示す写真から、黒鉛形の溝がアルミニウム-炭素複合材に好適に転写されていることが分かる。このことから、アルミニウム-炭素複合材は、塑性加工が可能であることが分かる。
焼成時に黒鉛製のT凸字型(黒鉛型)を成形体に押しつけながら焼成したこと以外は、実施例1と同様にして、アルミニウム-炭素複合材を作製した。実施例3で使用した黒鉛型と、得られたアルミニウム-炭素複合材の写真を図6に示す。図6に示す写真の左が加工されたアルミニウム-炭素複合材であり、右側が使用した黒鉛型である。
2…炭素粒子
3…金属相
Claims (8)
- 連続している金属相と、
前記金属相中に分散している炭素粒子と、
を備え、
炭素の含有率が50体積%以上である金属-炭素複合材。 - 前記金属相は、Al、Cu、Ag、Ni、Bi、Sb及びこれらの金属を少なくとも1つ含む合金からなる群から選ばれる少なくとも一種からなる請求項1に記載の金属-炭素複合材。
- 前記金属相の厚みは、10nm~100μmである請求項1または2に記載の金属-炭素複合材。
- 前記炭素粒子の粒子径は、50nm~500μmの範囲内にある請求項1~3のいずれか一項に記載の金属-炭素複合材。
- 金属粒子と炭素粒子とを混合し、前記金属粒子が表面に付着した前記炭素粒子を含む混合物を得る混合工程と、
前記混合物を成形して成形体を得る工程と、
前記成形体を焼成する工程と、
を備える、金属-炭素複合材の製造方法。 - 前記混合工程において、バインダーをさらに混合する請求項5に記載の金属-炭素複合材の製造方法。
- 前記金属粒子の粒子径は、前記炭素粒子の粒子径の1/100~1/5の範囲内にある請求項5または6に記載の金属-炭素複合材の製造方法。
- 前記混合物の成形を、冷間等方加圧成形により行う請求項5~7のいずれか一項に記載の金属-炭素複合材の製造方法。
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US14/115,361 US20140072792A1 (en) | 2011-05-13 | 2012-05-10 | Metal-carbon composite material and method for producing same |
EP12786110.2A EP2708522A4 (en) | 2011-05-13 | 2012-05-10 | METAL CARBON COMPOSITE MATERIAL AND METHOD OF MANUFACTURING THEREOF |
CN201280021498.9A CN103502181A (zh) | 2011-05-13 | 2012-05-10 | 金属-碳复合材料及其制造方法 |
KR1020137029304A KR20140031891A (ko) | 2011-05-13 | 2012-05-10 | 금속-탄소 복합재 및 그의 제조 방법 |
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- 2012-05-10 WO PCT/JP2012/061992 patent/WO2012157514A1/ja active Application Filing
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EP2708522A1 (en) | 2014-03-19 |
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CN103502181A (zh) | 2014-01-08 |
TW201249565A (en) | 2012-12-16 |
JP2012236751A (ja) | 2012-12-06 |
KR20140031891A (ko) | 2014-03-13 |
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