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GB2148270A - Cermet materials - Google Patents

Cermet materials Download PDF

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Publication number
GB2148270A
GB2148270A GB08424583A GB8424583A GB2148270A GB 2148270 A GB2148270 A GB 2148270A GB 08424583 A GB08424583 A GB 08424583A GB 8424583 A GB8424583 A GB 8424583A GB 2148270 A GB2148270 A GB 2148270A
Authority
GB
United Kingdom
Prior art keywords
metal
ceramic material
sintering
aluminium
alloy
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.)
Withdrawn
Application number
GB08424583A
Other versions
GB8424583D0 (en
Inventor
David Emrys Lloyd
Robert Swindells
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
British Ceramic Research Association Ltd
Original Assignee
British Ceramic Research Association Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by British Ceramic Research Association Ltd filed Critical British Ceramic Research Association Ltd
Publication of GB8424583D0 publication Critical patent/GB8424583D0/en
Publication of GB2148270A publication Critical patent/GB2148270A/en
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F3/26—Impregnating
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/51—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C04B41/88—Metals
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Metallurgy (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)

Abstract

A method of manufacturing a cermet material comprises forming a porous article of a ceramic material (e.g. alumna or silicon carbide) by sintering, and infiltrating at elevated pressure and temperature a metal (e.g. aluminium or an alloy thereof) into the pores of the sintered article.

Description

SPECIFICATION Cermets The invention relates to a method of making cermet materials and materials made in accordance with the method.
It is difficult to produce cermets of ceramic material and aluminium and/or aluminium alloys because the melting point of the metal (approximately 660"C) is much lower than the temperature at which wetting of the ceramic material occurs (generally greater than 1200"C). Without a well-developed bond between the ceramic material and the metal, the strength of the composite cermet is low.
The invention provides in one aspect a method of making a cermet material, comprising the steps of forming a porous article of ceramic material by sintering, and infiltrating metal or metal alloy into pores of the sinter.
The sintering is preferably carried out at elevated temperature and/or pressure. Pressures of up to 137MN/m2 (20,000 psi), desirably 103MN/m2 (15,000 psi) being preferred. The sintering may be carried out at a temperature of from 900"C up to a temperature just below melting point of the ceramic material, preferably 1500"C to 2100"C. Preferably the metal is chosen from groups 2, 3, or 4 of the periodic table, and is desirably aluminium, due to its low bulk density. An alloy of 10% magnesium, 90% aluminium by weight may be desirably also be used.
The infiltration is advantageously carried out under pressure, and is preferably carried out at a temperature somewhat in excess of melting point of the metal or alloy so as to prevent premature solidification. The pressure is preferably in the range 15-60MN/m2 (1-4 tons per square inch).
The ceramic material is preferably silicon carbide but could for example be tungsten carbide, or alumina, the great virtue of the latter being its low cost.
The invention also provides a cermet material comprising a continuous first phase of porous ceramic material into pores of which is infiltrated a continous second phase of metal or metal alloy, the two phases being intermingled throughout the material.
The porous article of ceramic material may be made in any convenient manner, for example, by pressing typically up to 137MN/m2 (20,000psi), followed by sintering at up to 2000"C or simultaneously applying heat and pressure i.e. hot pressing.
The ceramic material is preferably tungsten carbide, alumina or silicon carbide, the metal being aluminium or an aluminium alloy, especially, though not exclusively, an alloy containing 10% by weight of magnesium and 90% by weight of aluminium.
Examples of the invention will now be described by way of illustration only and not by way of limitation of the invention.
Example 1 A porous silicon carbide body was prepared by mixing a silicon carbide powders of three different size fractions in the following proportions:35% of through 100BSS (British Standard Sieve) 40% of through 240BSS 25% of through 1200BSS This mixture was hot pressed in a graphite dye at 2100"C giving a sintered body of 29% porosity.
The modulus of rupture of the ceramic body was found to be 34.5MN/m2 (5000psi).
This was then infiltrated with pure aluminium at 700"C under a pressure of 46MN/m2 (6720psi). The modulus of rupture was found to be 262MN/m2 (38,000psi) for the composite cermet material.
Example 2 A porous alumina body was prepared by compacting 20BSS TA60 Tabular alumina at 103MN/m2 (15,000psi) and sintering the compact in air at 1500 C. The fired alumina had a 25% porosity and a modulus of rupture of 34MN/m2 (5,000psi). The sintered body was then infiltrated in the same way as for example 1 and the resulting composite sintered material had a modulus of rupture of 220MN/ m2 (32,000psi).
Various modifications can be made without departing from the scope of the invention. For example the cermets may be infiltrated with any suitable metal or metal alloy, such as an alloy of aluminium 90%, magnesium 10% by weight. Pressures and temperatures may be varied but it is important that the temperature during infiltration of the sinter is not in excess of the melting point of the ceramic material of the sinter.
The ceramic material need not be alumina or silicon carbide but could be provided by any other suitable ceramic material.
The porous article may be made in any convenient manner, for example by pressing, typically at pressures up to 20,000psi followed by sintering at up to 200000 or by simultaneously applying heat and pressure, i.e. hot pressing.
1. A method of making a cermet material, comprising the steps of forming a porous article of ceramic material by sintering, and infiltrating metal or metal alloy into pores of the sinter.
2. A method as claimed in claim 1, in which the sintering is carried out at elevated temperature.
3. A method as claimed in claim 1 or claim 2, in which the sintering is carried out at elevated pressure.
4. A method as claimed in claim 3, in which the sintering is carried out at a pressure of up to 137MN/m2.
5. A method as claimed in claim 4, in which sintering is carried out at a pressure in the range 15-60MN/m2.
6. A method as claimed in claim 4, in which sintering is carried out at a pressure of 103MN/m2.
7. A method as claimed in any one of claims 2
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (23)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Cermets The invention relates to a method of making cermet materials and materials made in accordance with the method. It is difficult to produce cermets of ceramic material and aluminium and/or aluminium alloys because the melting point of the metal (approximately 660"C) is much lower than the temperature at which wetting of the ceramic material occurs (generally greater than 1200"C). Without a well-developed bond between the ceramic material and the metal, the strength of the composite cermet is low. The invention provides in one aspect a method of making a cermet material, comprising the steps of forming a porous article of ceramic material by sintering, and infiltrating metal or metal alloy into pores of the sinter. The sintering is preferably carried out at elevated temperature and/or pressure. Pressures of up to 137MN/m2 (20,000 psi), desirably 103MN/m2 (15,000 psi) being preferred. The sintering may be carried out at a temperature of from 900"C up to a temperature just below melting point of the ceramic material, preferably 1500"C to 2100"C. Preferably the metal is chosen from groups 2, 3, or 4 of the periodic table, and is desirably aluminium, due to its low bulk density. An alloy of 10% magnesium, 90% aluminium by weight may be desirably also be used. The infiltration is advantageously carried out under pressure, and is preferably carried out at a temperature somewhat in excess of melting point of the metal or alloy so as to prevent premature solidification. The pressure is preferably in the range 15-60MN/m2 (1-4 tons per square inch). The ceramic material is preferably silicon carbide but could for example be tungsten carbide, or alumina, the great virtue of the latter being its low cost. The invention also provides a cermet material comprising a continuous first phase of porous ceramic material into pores of which is infiltrated a continous second phase of metal or metal alloy, the two phases being intermingled throughout the material. The porous article of ceramic material may be made in any convenient manner, for example, by pressing typically up to 137MN/m2 (20,000psi), followed by sintering at up to 2000"C or simultaneously applying heat and pressure i.e. hot pressing. The ceramic material is preferably tungsten carbide, alumina or silicon carbide, the metal being aluminium or an aluminium alloy, especially, though not exclusively, an alloy containing 10% by weight of magnesium and 90% by weight of aluminium. Examples of the invention will now be described by way of illustration only and not by way of limitation of the invention. Example 1 A porous silicon carbide body was prepared by mixing a silicon carbide powders of three different size fractions in the following proportions:35% of through 100BSS (British Standard Sieve) 40% of through 240BSS 25% of through 1200BSS This mixture was hot pressed in a graphite dye at 2100"C giving a sintered body of 29% porosity. The modulus of rupture of the ceramic body was found to be 34.5MN/m2 (5000psi). This was then infiltrated with pure aluminium at 700"C under a pressure of 46MN/m2 (6720psi). The modulus of rupture was found to be 262MN/m2 (38,000psi) for the composite cermet material. Example 2 A porous alumina body was prepared by compacting 20BSS TA60 Tabular alumina at 103MN/m2 (15,000psi) and sintering the compact in air at 1500 C. The fired alumina had a 25% porosity and a modulus of rupture of 34MN/m2 (5,000psi). The sintered body was then infiltrated in the same way as for example 1 and the resulting composite sintered material had a modulus of rupture of 220MN/ m2 (32,000psi). Various modifications can be made without departing from the scope of the invention. For example the cermets may be infiltrated with any suitable metal or metal alloy, such as an alloy of aluminium 90%, magnesium 10% by weight. Pressures and temperatures may be varied but it is important that the temperature during infiltration of the sinter is not in excess of the melting point of the ceramic material of the sinter. The ceramic material need not be alumina or silicon carbide but could be provided by any other suitable ceramic material. The porous article may be made in any convenient manner, for example by pressing, typically at pressures up to 20,000psi followed by sintering at up to 200000 or by simultaneously applying heat and pressure, i.e. hot pressing. CLAIMS
1. A method of making a cermet material, comprising the steps of forming a porous article of ceramic material by sintering, and infiltrating metal or metal alloy into pores of the sinter.
2. A method as claimed in claim 1, in which the sintering is carried out at elevated temperature.
3. A method as claimed in claim 1 or claim 2, in which the sintering is carried out at elevated pressure.
4. A method as claimed in claim 3, in which the sintering is carried out at a pressure of up to 137MN/m2.
5. A method as claimed in claim 4, in which sintering is carried out at a pressure in the range 15-60MN/m2.
6. A method as claimed in claim 4, in which sintering is carried out at a pressure of 103MN/m2.
7. A method as claimed in any one of claims 2 to 6, in which the sintering is carried out at a temperature of from 900"C up to a temperature just below melting point of the ceramic material.
8. A method as claimed in claim 7, in which the maximum temperature lies within the range 1500"C to 2100"C.
9. A method as claimed in any one of the preceding claims, in which the metal is chosen from groups 2, 3 or 4 of the periodic table.
10. A method as claimed in claim 9, in which the metal is aluminium.
11. A method as claimed in claim 9, in which the metal is a 10% magnesium 90% aluminium alloy.
12. A method as claimed in any one of the preceding claims, in which infiltration of metal into the porous ceramic material is carried out at a temperature somewhat in excess of melting point of the metal or alloy so as to prevent premature solidification.
13. A method as claimed in any one of the preceding claims, in which the ceramic material is silicon carbide.
14. A method as claimed in any one of claims 1 to 12, in which the ceramic material is tungsten carbide.
15. A method as claimed in any one of claims 1 to 12, in which the ceramic material is alumina.
16. A method of making a cermet material substantially as hereinbefore described.
17. A cermet material comprising a continuous first phase of porous ceramic material into pores of which is infiltrated a continuous second phase of metal or metal alloy, the two phases being intermingled throughout the material.
18. A cermet material as claimed in claim 17, in which the ceramic material is tungsten carbide.
19. A cermet material as claimed in claim 17, in which the ceramic material is silicon carbide.
20. A cermet material as claimed in claim 17, in which the ceramic material is alumina.
21. A cermet material as claimed in any one of claims 17 to 20, in which the metal is aluminium.
22. A cermet material as claimed in any one of claims 17 to 20, in which the metal alloy is an alloy of 10% by weight magnesium and 90% by weight aluminium.
23. A cermet material substantially as hereinbefore described.
GB08424583A 1983-10-22 1984-09-28 Cermet materials Withdrawn GB2148270A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB8328316 1983-10-22

Publications (2)

Publication Number Publication Date
GB8424583D0 GB8424583D0 (en) 1984-11-07
GB2148270A true GB2148270A (en) 1985-05-30

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0239520A1 (en) * 1986-03-07 1987-09-30 Lanxide Technology Company, Lp. Process for preparing self-supporting bodies and products made thereby
EP0268120A1 (en) * 1986-11-03 1988-05-25 Asulab S.A. Composite material
WO1989004239A1 (en) * 1987-11-07 1989-05-18 J.H. Fenner & Co, Ltd. A process for modifying the surface of hard engineering ceramic materials
DE3914010A1 (en) * 1989-04-26 1990-10-31 Vaw Ver Aluminium Werke Ag METHOD FOR PRODUCING CERAMIC-METAL COMPOSITIONS
DE3924267C1 (en) * 1989-07-22 1994-12-22 Vaw Ver Aluminium Werke Ag Arrangement for use as protection against projectiles
US7879285B2 (en) * 1997-03-31 2011-02-01 Lawrence Livermore National Security, Llc Process for fabrication of cermets
US8268234B2 (en) 1997-03-31 2012-09-18 Lawrence Livermore National Security, Llc Cermets from molten metal infiltration processing
CN108129169A (en) * 2016-12-01 2018-06-08 比亚迪股份有限公司 A kind of ceramic-metal combination and preparation method thereof
DE102017010910A1 (en) 2017-11-23 2019-05-23 Technische Universität Bergakademie Freiberg Pin mill with slices with pins

Citations (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB643653A (en) * 1942-03-19 1950-09-27 Saint Gobain Refractory or abrasive materials and methods for their manufacture
GB729342A (en) * 1952-10-23 1955-05-04 Morgan Crucible Co Metal-ceramic bodies
GB742182A (en) * 1951-12-07 1955-12-21 Sintercast Corp America Improvements in or relating to turbine blades and materials therefor
GB767879A (en) * 1954-10-20 1957-02-06 Metro Cutanit Ltd Temperature, oxidation and corrosion resisting material and method of making the same
GB770490A (en) * 1954-03-01 1957-03-20 Sintercast Corp America Improved methods of infiltrating high melting skeleton bodies
GB825454A (en) * 1955-03-04 1959-12-16 Sintercast Corp America Improved method and means for the production of heat resistant articles
GB930269A (en) * 1959-04-30 1963-07-03 Gen Dynamics Corp Improvements in the production of fired ceramic or cermet objects
GB1004608A (en) * 1961-06-16 1965-09-15 Haeger Potteries Inc Ceramic materials and methods of making same
GB1124020A (en) * 1964-09-17 1968-08-14 Haeger Potteries Inc Porous ceramic bodies and method for making same
GB1344485A (en) * 1972-06-26 1974-01-23 Borax Cons Ltd Production of a hard body of a refractory boron-containing compound
US3808012A (en) * 1971-04-19 1974-04-30 Carborundum Co Dense composite ceramic bodies
US3864154A (en) * 1972-11-09 1975-02-04 Us Army Ceramic-metal systems by infiltration
GB1469878A (en) * 1973-07-05 1977-04-06 Eaton Corp Manufacture of composite materials
GB1491118A (en) * 1974-12-06 1977-11-09 Norton Co Semi-conductor diffusion furnace components
GB1525037A (en) * 1976-07-06 1978-09-20 Inst Vysokikh Temperatur Akade Manufacture of heat-resistant materials
GB1582574A (en) * 1977-05-14 1981-01-14 Permanence Corp Method of forming a metal-metallic carbide composite

Patent Citations (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB643653A (en) * 1942-03-19 1950-09-27 Saint Gobain Refractory or abrasive materials and methods for their manufacture
GB742182A (en) * 1951-12-07 1955-12-21 Sintercast Corp America Improvements in or relating to turbine blades and materials therefor
GB729342A (en) * 1952-10-23 1955-05-04 Morgan Crucible Co Metal-ceramic bodies
GB770490A (en) * 1954-03-01 1957-03-20 Sintercast Corp America Improved methods of infiltrating high melting skeleton bodies
GB767879A (en) * 1954-10-20 1957-02-06 Metro Cutanit Ltd Temperature, oxidation and corrosion resisting material and method of making the same
GB825454A (en) * 1955-03-04 1959-12-16 Sintercast Corp America Improved method and means for the production of heat resistant articles
GB930269A (en) * 1959-04-30 1963-07-03 Gen Dynamics Corp Improvements in the production of fired ceramic or cermet objects
GB1004608A (en) * 1961-06-16 1965-09-15 Haeger Potteries Inc Ceramic materials and methods of making same
GB1124020A (en) * 1964-09-17 1968-08-14 Haeger Potteries Inc Porous ceramic bodies and method for making same
US3808012A (en) * 1971-04-19 1974-04-30 Carborundum Co Dense composite ceramic bodies
GB1344485A (en) * 1972-06-26 1974-01-23 Borax Cons Ltd Production of a hard body of a refractory boron-containing compound
US3864154A (en) * 1972-11-09 1975-02-04 Us Army Ceramic-metal systems by infiltration
GB1469878A (en) * 1973-07-05 1977-04-06 Eaton Corp Manufacture of composite materials
GB1491118A (en) * 1974-12-06 1977-11-09 Norton Co Semi-conductor diffusion furnace components
GB1525037A (en) * 1976-07-06 1978-09-20 Inst Vysokikh Temperatur Akade Manufacture of heat-resistant materials
GB1582574A (en) * 1977-05-14 1981-01-14 Permanence Corp Method of forming a metal-metallic carbide composite

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0239520A1 (en) * 1986-03-07 1987-09-30 Lanxide Technology Company, Lp. Process for preparing self-supporting bodies and products made thereby
EP0268120A1 (en) * 1986-11-03 1988-05-25 Asulab S.A. Composite material
US4822694A (en) * 1986-11-03 1989-04-18 Asulab S.A. Composite material
WO1989004239A1 (en) * 1987-11-07 1989-05-18 J.H. Fenner & Co, Ltd. A process for modifying the surface of hard engineering ceramic materials
DE3914010A1 (en) * 1989-04-26 1990-10-31 Vaw Ver Aluminium Werke Ag METHOD FOR PRODUCING CERAMIC-METAL COMPOSITIONS
US5043182A (en) * 1989-04-26 1991-08-27 Vereinigte Aluminum-Werke Aktiengesellschaft Method for the producing of ceramic-metal composite materials by plasma spraying several layers of ceramic particles onto a base body and infiltrating molten metal into the pores of the ceramic material
DE3924267C1 (en) * 1989-07-22 1994-12-22 Vaw Ver Aluminium Werke Ag Arrangement for use as protection against projectiles
US7879285B2 (en) * 1997-03-31 2011-02-01 Lawrence Livermore National Security, Llc Process for fabrication of cermets
US8268234B2 (en) 1997-03-31 2012-09-18 Lawrence Livermore National Security, Llc Cermets from molten metal infiltration processing
US8530363B2 (en) 1997-03-31 2013-09-10 Lawrence Livermore National Security, Llc. Cermets from molten metal infiltration processing
CN108129169A (en) * 2016-12-01 2018-06-08 比亚迪股份有限公司 A kind of ceramic-metal combination and preparation method thereof
CN108129169B (en) * 2016-12-01 2021-01-19 比亚迪股份有限公司 Metal ceramic product and preparation method thereof
DE102017010910A1 (en) 2017-11-23 2019-05-23 Technische Universität Bergakademie Freiberg Pin mill with slices with pins
WO2019101907A1 (en) 2017-11-23 2019-05-31 Technische Universität Bergakademie Freiberg Pinned disc mill comprising discs with pins

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