Al-P系中间合金粉末冶金合成工艺研究
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摘要
为了解决熔铸法制备Al-P系中间合金含磷量低、AlP颗粒粗大和呈团簇状分布的问题,本文提出了粉末冶金法制备Al-P系中间合金的新工艺。利用光学显微镜(OM)及电子探针微成分分析仪(EPMA)等手段对粉末冶金法制备的Al-P系中间合金微观组织进行了研究,并对该中间合金的变质效果进行了检验。
粉末冶金法制备Al-P系中间合金的主要工艺是将高磷合金(Cu-40Si-20P、Si-20Mn-20P和Cu-P)粉末与铝粉配料—混匀—压块—烧结,使之在500-660℃温度条件下发生扩散反应。
研究了高磷合金/Al热扩散偶中AlP的形成与扩散行为,发现在较低的扩散温度下(500℃左右),AlP在高磷合金/Al界面处析出。Cu-8P中间合金与铝反应生成的AlP呈细小弥散分布;Cu-14P中间合金与铝反应生成的AlP呈小块状分布:Cu-40Si-20P三元合金与铝反应生成的AlP则在界面处呈小片状分布。
在此基础上,系统研究了粉末冶金法制备Al-P系中间合金的新工艺:高磷合金粉末粒度、成形压力、烧结温度、烧结时间和真空度对生成的AlP形貌和分布的影响。结果表明:(1)成形压力过小,试块空隙率高,烧结过程易氧化膨胀;成形压力过大,烧结后加入Al-Si合金熔体中试块不易熔化。(2)高磷合金粉末的粒度大,反应生成AlP颗粒较大且呈团簇状;高磷合金粉末的粒度小,则生成的AlP颗粒较小而且呈弥散状分布。(3)烧结温度越高(在试块熔化温度以下),完全反应所需时间越短;烧结时间越长,反应越充分,在基体中可以看到初晶硅的析出。(4)真空度低,试块氧化严重,形成氧化膜使试块加入熔体中不易熔化。
确定了粉末冶金法制备Al-P系中间合金的最佳工艺参数为:高磷合金粉末的粒度为50-75μm;压力为10MPa;烧结温度为650℃;烧结时间为40min。此工艺方法制备Al-P系中间合金其含磷量可以达到10%。
与熔铸法制备的Al-P系中间合金相比,粉末冶金法制备的Al-P系中间合金具有AlP颗粒细小、分布均匀、含磷量高等优点。在加入相同量磷时,对Al-Si合金的变质效果可以与熔铸法制备的Al-P系中间合金的变质效果相当,但是变质时间缩短了近三分之一。
The disadvantages of the Al-P master alloy produced by casting are mainly as follows: AlP particles are coarse and present cluster-like morphology, their distribution is uneven in Al-P master alloy and phosphorus level is relatively low. A new technology preparing Al-P master alloy by powder metallurgy has been put forward. The microstructures of the Al-P master alloy fabricated by powder metallurgy were investigated, using optical microscopy (OM) and electron probe micro-analyzer (EPMA), etc. Moreover, the modification effect of the Al-P master alloy on hypereutectic Al-Si alloys was also investigated.
The new technology of producing Al-P master alloy is as follows: the mixed powders of phosphorus-rich alloys (Cu-40Si-20P, Si-20Mn-20P and Cu-P) and aluminum are extruded into columned pallets, which are then put into a sintering furnace where the diffusion and reactions in pallets can occur at 500-660℃.
The diffusion couples of phosphorus-rich alloys/Al was studied. At 500℃or so, phosphorus in phosphorus-rich alloys reacted with aluminum, which formed AlP. Specifically, AlP precipitated along the interface between phosphorus-rich and aluminum, dispersing distribution for Cu-8P master alloy, small block-like distribution for Cu-14P master alloy and fine flake-like distribution for Cu-40Si-20P master alloy.
Based on the experiments mentioned above, the influences of such factors as the particle size of phosphorus-rich alloys, forming pressure, sintering temperature, sintering time and the degree of vacuum in furnace on the morphology and distribution of AlP particles were studied. It has been shown that if the forming pressure is low, the amount of ventage is large, so the samples are easily oxidized during the sintering process. On the other hand, if the forming pressure is high, the sintered samples is not prone to melt in the Al-Si alloy melts. In order to make AlP particles dispersed in the master alloy, the powder sizes of phosphorus-rich alloys should be controlled. The longer the sintering time is, the more sufficient the reaction is. When the reaction is sufficient, silicon phases can be observed. But at high temperature (below melting temperature of samples), the time of complete reaction is short. And the degree of vacuum is low, the severe oxidization prevents the samples from melting in the melt of Al-Si alloys.
The optimum parameters of fabricating Al-P master alloys by powder metallurgy are as follows: paricles size of phosphorus-rich alloys are 50-75um, the forming pressure is 10MPa, the sintering temperature is 650℃and the sintering time is 40 minutes. The content of phosphorus in Al-P master alloys fabricated by powder metallurgy can reach up to 10%.
Comparing with the Al-P master alloy produced by casting, the size of AlP particle is finer, the distribution is more homogeneous and the content of phosphorus is higher in the Al-P master alloy prepared by powder metallurgy. Adding the same amount of phosphorus into Al-Si alloy, the modification effects of these two kinds Al-P master alloys are equivalent. However, the modification time is reduced by 1/3 with adding the Al-P master alloy fabricated by power metallurgy.
粉末冶金法制备Al-P系中间合金的主要工艺是将高磷合金(Cu-40Si-20P、Si-20Mn-20P和Cu-P)粉末与铝粉配料—混匀—压块—烧结,使之在500-660℃温度条件下发生扩散反应。
研究了高磷合金/Al热扩散偶中AlP的形成与扩散行为,发现在较低的扩散温度下(500℃左右),AlP在高磷合金/Al界面处析出。Cu-8P中间合金与铝反应生成的AlP呈细小弥散分布;Cu-14P中间合金与铝反应生成的AlP呈小块状分布:Cu-40Si-20P三元合金与铝反应生成的AlP则在界面处呈小片状分布。
在此基础上,系统研究了粉末冶金法制备Al-P系中间合金的新工艺:高磷合金粉末粒度、成形压力、烧结温度、烧结时间和真空度对生成的AlP形貌和分布的影响。结果表明:(1)成形压力过小,试块空隙率高,烧结过程易氧化膨胀;成形压力过大,烧结后加入Al-Si合金熔体中试块不易熔化。(2)高磷合金粉末的粒度大,反应生成AlP颗粒较大且呈团簇状;高磷合金粉末的粒度小,则生成的AlP颗粒较小而且呈弥散状分布。(3)烧结温度越高(在试块熔化温度以下),完全反应所需时间越短;烧结时间越长,反应越充分,在基体中可以看到初晶硅的析出。(4)真空度低,试块氧化严重,形成氧化膜使试块加入熔体中不易熔化。
确定了粉末冶金法制备Al-P系中间合金的最佳工艺参数为:高磷合金粉末的粒度为50-75μm;压力为10MPa;烧结温度为650℃;烧结时间为40min。此工艺方法制备Al-P系中间合金其含磷量可以达到10%。
与熔铸法制备的Al-P系中间合金相比,粉末冶金法制备的Al-P系中间合金具有AlP颗粒细小、分布均匀、含磷量高等优点。在加入相同量磷时,对Al-Si合金的变质效果可以与熔铸法制备的Al-P系中间合金的变质效果相当,但是变质时间缩短了近三分之一。
The disadvantages of the Al-P master alloy produced by casting are mainly as follows: AlP particles are coarse and present cluster-like morphology, their distribution is uneven in Al-P master alloy and phosphorus level is relatively low. A new technology preparing Al-P master alloy by powder metallurgy has been put forward. The microstructures of the Al-P master alloy fabricated by powder metallurgy were investigated, using optical microscopy (OM) and electron probe micro-analyzer (EPMA), etc. Moreover, the modification effect of the Al-P master alloy on hypereutectic Al-Si alloys was also investigated.
The new technology of producing Al-P master alloy is as follows: the mixed powders of phosphorus-rich alloys (Cu-40Si-20P, Si-20Mn-20P and Cu-P) and aluminum are extruded into columned pallets, which are then put into a sintering furnace where the diffusion and reactions in pallets can occur at 500-660℃.
The diffusion couples of phosphorus-rich alloys/Al was studied. At 500℃or so, phosphorus in phosphorus-rich alloys reacted with aluminum, which formed AlP. Specifically, AlP precipitated along the interface between phosphorus-rich and aluminum, dispersing distribution for Cu-8P master alloy, small block-like distribution for Cu-14P master alloy and fine flake-like distribution for Cu-40Si-20P master alloy.
Based on the experiments mentioned above, the influences of such factors as the particle size of phosphorus-rich alloys, forming pressure, sintering temperature, sintering time and the degree of vacuum in furnace on the morphology and distribution of AlP particles were studied. It has been shown that if the forming pressure is low, the amount of ventage is large, so the samples are easily oxidized during the sintering process. On the other hand, if the forming pressure is high, the sintered samples is not prone to melt in the Al-Si alloy melts. In order to make AlP particles dispersed in the master alloy, the powder sizes of phosphorus-rich alloys should be controlled. The longer the sintering time is, the more sufficient the reaction is. When the reaction is sufficient, silicon phases can be observed. But at high temperature (below melting temperature of samples), the time of complete reaction is short. And the degree of vacuum is low, the severe oxidization prevents the samples from melting in the melt of Al-Si alloys.
The optimum parameters of fabricating Al-P master alloys by powder metallurgy are as follows: paricles size of phosphorus-rich alloys are 50-75um, the forming pressure is 10MPa, the sintering temperature is 650℃and the sintering time is 40 minutes. The content of phosphorus in Al-P master alloys fabricated by powder metallurgy can reach up to 10%.
Comparing with the Al-P master alloy produced by casting, the size of AlP particle is finer, the distribution is more homogeneous and the content of phosphorus is higher in the Al-P master alloy prepared by powder metallurgy. Adding the same amount of phosphorus into Al-Si alloy, the modification effects of these two kinds Al-P master alloys are equivalent. However, the modification time is reduced by 1/3 with adding the Al-P master alloy fabricated by power metallurgy.
引文
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