Aluminum-based composite material and method for producing the same

Patent metadata

Field	Value
Publication number	US-11607729-B2
Application number	US-202117213547-A
Country	US
Kind code	B2
Filing date	Mar 26, 2021
Priority date	Oct 30, 2015
Publication date	Mar 21, 2023
Grant date	Mar 21, 2023

Abstract

An aluminum-based composite material includes a plurality of coarse crystalline grains (3) of pure aluminum, and a plurality of fine crystalline grains (4) each having an aluminum matrix (1), and a dispersion material (2) dispersed inside the aluminum matrix and formed by reacting a portion or all of an additive with aluminum in the aluminum matrix. The fine crystalline grains exist among the coarse crystalline grains, and the fine crystalline grains have crystalline grain diameters smaller than crystalline grain diameters of the coarse crystalline grains.

First claim

What is claimed is:

1. A method for manufacturing an aluminum-based composite material, the method comprising:
mixing an aluminum powder having a purity of 99% by mass or more with at least one additive selected from the group consisting of carbon nanotubes, carbon nanohorns, carbon blacks, boron carbides, and boron nitrides to form a first mixture
milling the first mixture to obtain a fine crystal grain precursor;
mixing the fine crystal grain precursor with a coarse crystal grain precursor made of pure aluminum powder having a purity of 99% by mass or more to obtain a second mixture,
compacting the second mixture to obtain a compact; and
heating the compact at a temperature of 600 to 660° C. to obtain an aluminum-based composite material,
wherein a shape of the aluminum powder in the fine crystal grain precursor is flat in which a ratio of a maximum major axis to a thickness of the aluminum powder is within a range of 10 or more and 100 or less.

2. The method for manufacturing the aluminum-based composite material according to claim 1 , wherein
the aluminum-based composite material comprises coarse crystal grains of aluminum and fine crystal grains of aluminum,
the fine crystal grains of the aluminum-based composite material having (a) an aluminum matrix, and (b) a dispersion material dispersed inside the aluminum matrix and formed by reacting a portion or all of an additive with aluminum in the aluminum matrix during the heating of the compact,
the fine crystal grains exist among the coarse crystal grains,
the fine crystal grains have crystal grain diameters less than 1 μm, and the coarse crystal grains have crystal grain diameters of 1 μm to 5 μm.

3. The method for manufacturing the aluminum-based composite material according to claim 2 , wherein
a ratio of a long axis to a short axis (long axis/short axis) of the dispersion material is 1 to 30,
the long axis ranges from 0.01 nm to 500 nm, and
the short axis ranges from 0.01 nm to 200 nm.

4. The method for manufacturing the aluminum-based composite material according to claim 2 , wherein
a content of carbon in the dispersion material in the fine crystal grains is 0.1 to 2.0% by mass based on a total mass of the fine crystal grains.

5. The method for manufacturing the aluminum-based composite material according to claim 2 , wherein
a mass ratio of the coarse crystal grains to the fine crystal grains is 1:2 to 1:1.

Assignees

• Yazaki Corp

Inventors

• Kondoh Katsuyoshi
• Otsuka Yasufumi
• Yoshinaga Satoru

Classifications

• C22C32/0047

  with carbides, nitrides, borides or silicides as the main non-metallic constituents · CPC title

• C22C1/1084 Primary

  by mechanical alloying (blending, milling) · CPC title

• B22F1/00 Primary

  Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties · CPC title

• C22C2026/002

  Carbon nanotubes · CPC title

• C22C26/00

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title