Process for producing porous sintered aluminum, and porous sintered aluminum

Patent metadata

Field	Value
Publication number	US-9815116-B2
Application number	US-201414551613-A
Country	US
Kind code	B2
Filing date	Nov 24, 2014
Priority date	Mar 30, 2009
Publication date	Nov 14, 2017
Grant date	Nov 14, 2017

Abstract

This method for producing porous sintered aluminum includes: mixing aluminum powder with a sintering aid powder containing titanium to obtain a raw aluminum mixed powder; mixing the raw aluminum mixed powder with a water-soluble resin binder, water, and a plasticizer containing at least one selected from polyhydric alcohols, ethers, and esters to obtain a viscous composition; drying the viscous composition in a state where air bubbles are mixed therein to obtain a formed object prior to sintering; and heating the formed object prior to sintering in a non-oxidizing atmosphere, wherein when a temperature at which the raw aluminum mixed powder starts to melt is expressed as Tm (° C.), a temperature T (° C.) of the heating fulfills Tm−10 (° C.)≦T≦685 (° C.).

First claim

The invention claimed is:

1. A method for producing porous sintered aluminum comprising:
mixing aluminum powder with a sintering aid powder containing titanium to obtain a raw aluminum mixed powder;
mixing the raw aluminum mixed powder with a water-soluble resin binder, water, and a plasticizer containing at least one selected from polyhydric alcohols, ethers, and esters to obtain a viscous composition;
drying the viscous composition in a state where air bubbles are mixed therein to obtain a formed object prior to sintering; and
heating the formed object prior to sintering in a non-oxidizing atmosphere,
wherein when a temperature at which the raw aluminum mixed powder starts to melt is expressed as Tm (° C.), a temperature T (° C.) of the heating fulfills Tm−10 (° C.)≦T≦685 (° C.).

2. The method for producing porous sintered aluminum according to claim 1 ,
wherein an average particle diameter of the aluminum powder is in a range of 2 to 200 μm.

3. The method for producing porous sintered aluminum according to claim 1 ,
wherein when an average particle diameter of the sintering aid powder is expressed as r (μm), and a mixing ratio of the sintering aid powder is expressed as W (% by mass), r and W fulfill 1 (μm)≦r≦30 (μm), 1 (% by mass)≦W≦20 (% by mass), and 0.1≦W/r≦2.

4. The method for producing porous sintered aluminum according to claim 1 ,
wherein the sintering aid powder is either one or both of titanium and titanium hydride.

5. The method for producing porous sintered aluminum according to claim 1 ,
wherein non-water-soluble hydrocarbon system organic solvent containing 5 to 8 carbons is added to the viscous composition.

6. The method for producing porous sintered aluminum according to claim 1 ,
wherein the water-soluble resin binder is contained at a content in a range of 0.5% to 7% of a quantity (mass) of the raw aluminum mixed powder.

7. The method for producing porous sintered aluminum according to claim 1 ,
wherein surfactant is added to the raw aluminum mixed powder at a content in a range of 0.02 to 3% of a quantity (mass) of the raw aluminum mixed powder.

8. The method for producing porous sintered aluminum according to claim 1 ,
wherein the viscous composition is extended to have a thickness of 0.05 mm to 5 mm, and then the viscous composition is dried to produce the formed object prior to sintering as a plate shape formed object.

Assignees

• Mitsubishi Materials Corp

Inventors

• Hoshino Koji
• Yang Ji-Bin
• Orito Kenji
• Ohmori Shinichi

Classifications

• C22C1/0416

  Aluminium-based alloys · CPC title

• B22F3/1003

  Use of special medium during sintering, e.g. sintering aid · CPC title

• C22C21/16

  with magnesium · CPC title

• B22F1/0059

  Operations & Transport · mapped topic

• C22C1/08

  Alloys with open or closed pores · CPC title