Production method and production device for a composite metal powder using the gas spraying method

Patent metadata

Field	Value
Publication number	US-9267190-B2
Application number	US-200913378756-A
Country	US
Kind code	B2
Filing date	Dec 16, 2009
Priority date	Dec 15, 2009
Publication date	Feb 23, 2016
Grant date	Feb 23, 2016

Abstract

Disclosed herein are a method and an apparatus for preparing a metal composite powder by using gas spraying. The method of preparing a metal composite powder by using gas spraying includes introducing a matrix phase in a chamber, including a reinforcing phase in the chamber, melting the introduced matrix phase to form a melt, adding the reinforcing phase in the melt, stirring the melt with the added reinforcing phase to form a melt mixture, atomizing the melt mixture together with a gas to form a metal composite powder containing the reinforcing phase, and collecting the metal composite powder formed.

First claim

What is claimed is:

1. A method of preparing a metal composite powder by gas spraying, the method comprising:
preparing a melt by melting an aluminum material, wherein the aluminum material is selected from the group consisting an aluminum ingot and an aluminum-silicon (Al—Si) based alloy, at a melt temperature to produce a melt;
adding a SiC reinforcing phase material to the melt to form a reinforced metal melt;
increasing the melt temperature to a temperature above 700° C. and below 800° C. within 5 minutes to 30 minutes.
wherein no additional heat treatments exceed 800° C.; and
atomizing the reinforcing metal melt with a gas to prepare a metal composite powder.

2. The method of claim 1 , wherein the method further comprises adding a metal selected from the group consisting of a metal ingot and an alloy ingot, to the melt, wherein the metal ingot comprises a metal selected from the group consisting of aluminum (Al), tin (Sn), and copper (Cu), and wherein the alloy ingot comprises a metal alloy selected from the group consisting of an aluminum-silicon (Al—Si) alloy, an aluminum-copper (Al—Cu) alloy, and an aluminum-iron (Al—Fe) alloy.

3. The method of claim 1 , wherein the metal composite powder has a size range of 10 μm to 5000 μm.

4. The method of claim 1 , wherein the reinforcing phase material in the metal composite powder is in a range of 0.001 μm to 50 μm.

5. The method of claim 1 , wherein the reinforcing phase material is added at a temperature in which a crystal structure is generated in the metal composite powder.

6. The method of claim 1 , wherein the reinforcing metal melt has a range of 0.1 vol % to 70 vol % of the reinforcing phase material.

7. The method of claim 1 , wherein the gas is a mixed gas in which a volume fraction ratio between nitrogen and oxygen is in a range of 7:3 to 9:1.

8. The method of claim 1 , wherein the atomizing is performed in a pressure range of 5 bars to 100 bars.

9. The method of claim 2 , wherein the metal is a metal ingot and wherein the metal ingot is an aluminum-silicon (Al—Si) based alloy, and wherein the reinforcing phase material is aluminum-silicon (Al—Si).

Assignees

• Kim Yong-Jin
• Yang Sangsun
• Lim Tae-Soo
• Korea Mach & Materials Inst

Inventors

• Kim Yong-Jin
• Yang Sangsun
• Lim Tae-Soo

Classifications

• B22F2009/0816

  by casting with pressure or pulsating pressure on the metal bath · CPC title

• C22C1/1042 Primary

  by atomising · CPC title