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WO2008119696A1 - Structures composites poreuses en aluminium ou alliage d'aluminium - Google Patents

Structures composites poreuses en aluminium ou alliage d'aluminium Download PDF

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Publication number
WO2008119696A1
WO2008119696A1 PCT/EP2008/053486 EP2008053486W WO2008119696A1 WO 2008119696 A1 WO2008119696 A1 WO 2008119696A1 EP 2008053486 W EP2008053486 W EP 2008053486W WO 2008119696 A1 WO2008119696 A1 WO 2008119696A1
Authority
WO
WIPO (PCT)
Prior art keywords
aluminium
porous
metal
layer
structure according
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.)
Ceased
Application number
PCT/EP2008/053486
Other languages
English (en)
Inventor
Guy Buytaert
Erik Dekempeneer
Griet De Winter
Karel Hubau
Jan Mestdagh
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.)
Bekaert NV SA
Bekaert Combustion Technology BV
Original Assignee
Bekaert NV SA
Bekaert Combustion Technology BV
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 Bekaert NV SA, Bekaert Combustion Technology BV filed Critical Bekaert NV SA
Publication of WO2008119696A1 publication Critical patent/WO2008119696A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the present invention relates to bonded aluminium or aluminium alloy metal materials. More specifically, the invention relates to a structure of porous aluminium or aluminium alloy material attached to a solid aluminium or aluminium alloy carrier.
  • the present invention provides a method for attaching a porous metal body to a solid metal carrier by sintering and the use of those structures in heat exchangers, radiators, electronic assemblies and heat sinks. More specifically, the invention provides a firmly bonded aluminium construction containing porous aluminium material and a solid aluminium carrier. Even more specifically, the present invention provides a firmly bonded aluminium construction containing porous aluminium material and a solid aluminium carrier that can withstand high temperatures, temperature shocks and is corrosion resistant.
  • a porous aluminium or aluminium alloy body is properly attached to a solid aluminium or aluminium alloy carrier when one cannot pull the porous structure off the solid structure, i.e. there is a good mechanical bonding.
  • brazing Another way of achieving a firm bonding between a porous body and a solid metal carrier is brazing.
  • This technique uses an extra material either in the form of a three-layer sheet, which is put between the porous metal structure and the solid metal carrier when put in an oven; or in the form of a brazing paste, which also brings extra material in the form of fluxes and filler material into the brazing process thereby also making the bonding process more complex.
  • Both brazing methods result in a lower heat transfer capacity of the system, in comparison with a sintered porous metal/solid carrier connection.
  • the present invention provides an alternative joined structure of aluminium or aluminium alloy materials.
  • the present invention provides a novel metallic structure having an optimal heat conductance throughout the complete structure, thereby providing a heat transfer path from the metal carrier to the porous metal material or vice versa. Accordingly, in a further aspect the invention provides a novel heat exchanger.
  • the invention provides a condensing boiler wherein the heat exchanger part comprises such an alternative joined structure of aluminium or aluminium alloy materials.
  • the composite structure is built up from a porous metal body which is at least partially made of aluminium or an aluminium alloy and a solid metal carrier material made of aluminium or an aluminium alloy.
  • a formed in situ layer obtainable by thermal spraying, e.g. starting from a metal powder or a metal wire.
  • This layer is bonded directly to at least a portion of said solid metal carrier material and the porous structure is sintered to said layer which is bonded to the solid metal carrier material.
  • the porous structure is an open- or closed- cell metal foam, a metallic spacer material, a knitted wire mesh or a metal fibre fabric.
  • the thermal sprayed metal powder or wire is preferably aluminium or an aluminium alloy, more preferably AISi.
  • the thickness of the thermal sprayed layer is preferably from 20 ⁇ m to 500 ⁇ m, more preferably the layer is between 50 ⁇ m to 250 ⁇ m, even more preferably between 75 ⁇ m and 150 ⁇ m.
  • the invention provides a method for firmly joining a porous metal body to a solid metal carrier. The method for attaching this porous metal body to a solid metal carrier wherein the porous metal body is made of aluminium or an aluminium alloy and the solid metal carrier is made of aluminium or an aluminium alloy.
  • the method comprises thermal spraying a layer of aluminium or aluminium alloy, e.g.
  • the metal (powder or wire) used for thermal spraying is an AISi.
  • the porous body is an open- or closed- cell metal foam, a metallic spacer, a knitted wire mesh or a metal fibre fabric.
  • the invention thus provides a method for attaching a porous aluminium or aluminium alloy body to a solid aluminium or aluminium alloy carrier forming a good metallurgical bonding.
  • the novel metal structure is an assembly of a porous aluminium or aluminium alloy body attached to a solid aluminium or aluminium alloy carrier wherein the solid metal carrier has a layer of aluminium or aluminium alloy particles obtained via thermal spraying.
  • thermal spray processing is used to form the aluminium or aluminium alloy layer in situ on a solid aluminium or aluminium alloy carrier.
  • Thermal spray processing is a generic term for a broad class of related processes in which molten droplets of metals, ceramics, glasses and/or polymers, singly or in combinations, are sprayed onto a surface.
  • any material with a stable molten phase can be thermally sprayed.
  • Deposition rates are very high in comparison to alternative coating technologies.
  • Deposit thicknesses of, for example, 0.1 to 1.0 mm for fully continuous layers are common. If desired, thicknesses greater than 1 cm can be achieved with some materials.
  • Thickness is controlled, for example, by rastering the spray nozzle back and forth over the part, and although this is a line-of-sight process, all areas can be coated by reorienting the substrate and the spray nozzle relative to one another, manually or robotically. Various irregular surface configurations can thus be accommodated.
  • In situ formation is to be distinguished from a process where the skin is formed at some other location and applied to the porous substrate as a pre-formed sheet.
  • An in situ process of formation according to the present invention deposits a fluid form of the material that forms the layer at the site where the layer is to be formed, and the layer is formed by the build up of solidified material at that site.
  • metallurgical bonds can be achieved between the carrier and the layer. That is, the material of either the layer or the carrier is soluble to some extent in that of the other. Such bonds are extremely strong.
  • the thickness of the layer is defined by the structural requirements of the application and is obtained by rastering the thermal spray nozzle over the part until the required thickness is achieved.
  • Thermal spray techniques are well known. See, for example, Lech Pawlowski, “Science & Engineering Of Thermal Spray Coatings", (J. Wiley & Sons, 1995).
  • Plasma spraying appears to be the most common form of the thermal spraying operations for powders.
  • an inert gas is passed through an electric arc, thus creating an extremely hot ionized gas.
  • the desired coating material in powder form, is injected into the hot ionized gas stream.
  • the gas stream In the gas stream at least a substantial portion of the powdered coating material becomes partially molten or plastic.
  • the particles are not fully melted.
  • the fluid particles are quenched and bonded when they strike the surface of the substrate.
  • the inert gas is delivered under pressure to the electric arc so that it picks up the molten or plastic coating material and accelerates it onto the surface of the substrate.
  • a layer-by-layer build-up takes place through interparticle bonding and sintering reactions as the spray nozzle is rastered back and forth over the surface.
  • High velocity oxy-fuel (HVOF) thermal spray deposition processes involve the combustion of an oxygen-fuel mixture to generate a stream of gas that heats and accelerates the powdered feed to supersonic velocities.
  • the combination of very high particle velocities and relatively low flame temperatures makes possible the production of coatings with improved mechanic properties and good thermal properties.
  • This process is particularly suited to the application of ceramic coatings on silicon carbide foam substrates.
  • other means of heating such as, resistance heaters, induction heaters and the like, can be used.
  • One type of wire thermal spraying is combustion wire thermal spraying.
  • the process entails feeding a wire stock material through a combustion chamber.
  • the wire is generally fed axially through the gun at a controlled rate by a pair of feed rollers which grip the wire and rotate to push the wire through the combustion chamber, which may include a gas head nozzle arrangement and an air cap.
  • the nozzle arrangement generally includes a ring of burner jets or other heating mechanism surrounding the wire passage through which a combustible gas mixture is passed and burned.
  • the heat of the flame heat-softens the leading tip of the wire as the tip passes into the air cap and a high velocity stream of blast gas is directed against and impinges on the softened tip atomizing the metal (or other heat-fusible material) in the form of particles. These molten particles are propelled from the gun onto a substrate to form a coating.
  • the controlling parameters in thermal spraying operations generally include the amount of arc energy or combustion energy, and the feed (powder or wire) material composition, size, shape, feed rate, and velocity.
  • the adjustment of these parameters to achieve a desired result is well understood in the art.
  • the particles that are projected onto a substrate in a thermal spraying operation are not melted completely through.
  • particles that do not melt can be incorporated into the powders to form inclusions in meltable matrix materials in the coatings.
  • the spraying parameters are optimized for a particular application based on preliminary tests. For example, in general, for an otherwise constant system, increasing the velocity of the carrier gas increases the density of the thermal sprayed coating.
  • the powdered feed materials that are suitable for use in thermal spray procedures generally range in size from approximately 250 to 2 microns.
  • Wire feed material is commercially available as wires of 1 ,6mm in diameter.
  • the carrier gas that entrains and carries the particles is generally the same as the plasma or combustion gas.
  • the layer formed in situ according to the present invention conforms exactly to the surface of the solid carrier and, therefore, is bonded tightly and directly to the surface of the solid carrier.
  • AISi means any aluminium silicon mixture or alloy containing enough silicon to have considerably lower melting point than the other bodies to be joint (porous metal and solid carrier).
  • FIG. 1 schematic representation of one embodiment of a composite porous structure
  • the invention provides a structure having a porous metal body firmly attached to a solid metal carrier material as in figure 1.
  • This composite structure is built up from a porous structure (10) which is at least partially made of aluminium or an aluminium alloy and a solid metal carrier material (20) made of aluminium or an aluminium alloy.
  • a formed in situ layer (30) obtainable by thermal spraying starting from a metal powder or metal wire. This layer is bonded directly to at least a portion of said solid metal carrier material (20).
  • the porous structure (10) is sintered to said layer (30) which is bonded to the solid metal carrier material.
  • Tests were set up to compare the heat transfer obtained when using different techniques for joining an AISi 6060 carrier with an open-celled
  • These sintered + AISi thermal sprayed composites of the invention can then be used in a novel heat exchanger.
  • These composites, having a good metallurgical and corrosion resistant bonding, can also be incorporated in a condensing boiler, thereby enabling the system of condensing the flue gasses to retain as much energy as possible from the flue gasses. Due to the high heat transfer capacity of the sintered composite structure of the invention, a volume reduction of a condensing boiler can be obtained, without giving in on the condensation capacity of the system.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

L'invention concerne une structure munie d'un corps métallique poreux solidement fixé à un support métallique plein tel que représenté sur la figure 1. Cette structure composite est constituée d'un corps poreux (10) au moins partiellement fait d'aluminium ou d'un alliage d'aluminium et d'un support métallique plein (20) fait d'aluminium ou d'un alliage d'aluminium. Une couche formée in situ (30) pouvant être obtenue par pulvérisation thermique est également prévue. Cette couche est liée directement à au moins une partie dudit matériau de support métallique plein (20) ; le corps poreux (10) est fritté à ladite couche (30) liée au support métallique plein. En outre, la présente invention concerne un procédé pour fixer solidement un corps métallique poreux à un support métallique plein et l'utilisation de ces structures dans des échangeurs thermiques, des ensembles électroniques et des puits thermiques. Plus spécifiquement, l'invention concerne une construction en aluminium solidement liée contenant un matériau poreux en aluminium et un support plein en aluminium.
PCT/EP2008/053486 2007-03-29 2008-03-25 Structures composites poreuses en aluminium ou alliage d'aluminium Ceased WO2008119696A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP07105271 2007-03-29
EP07105271.6 2007-03-29

Publications (1)

Publication Number Publication Date
WO2008119696A1 true WO2008119696A1 (fr) 2008-10-09

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ID=38268888

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2008/053486 Ceased WO2008119696A1 (fr) 2007-03-29 2008-03-25 Structures composites poreuses en aluminium ou alliage d'aluminium

Country Status (1)

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WO (1) WO2008119696A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2400252A1 (fr) 2010-06-24 2011-12-28 Valeo Vision Dispositif à échange de chaleur, notamment pour véhicule automobile
CN102368482A (zh) * 2011-10-10 2012-03-07 李再林 多孔金属结构的高效散热器
CN102371355A (zh) * 2010-08-11 2012-03-14 施瓦本冶金工程汽车有限公司 烧结复合物及其制造方法
EP2434246A1 (fr) 2010-09-22 2012-03-28 Valeo Vision Dispositif à échange de chaleur, notamment pour véhicule automobile
WO2014197009A1 (fr) * 2013-06-05 2014-12-11 Hybrid Coatings And Components Llc Ensemble bouclier pour protéger un vaisseau spatial
CN112201893A (zh) * 2020-10-13 2021-01-08 浙江吉利控股集团有限公司 一种泡沫铝复合防爆结构、防爆装置及锂电池
CN113799470A (zh) * 2021-04-02 2021-12-17 吉林三环新材料有限公司 一种全通孔多孔泡沫铝制备方法

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2424557A (en) * 1944-06-27 1947-07-29 Gen Motors Corp Composite article and method of manufacture
US3703763A (en) * 1970-11-18 1972-11-28 Ethyl Corp Method of making a composite metal article
EP0486427A1 (fr) * 1990-11-12 1992-05-20 Rieter Automotive (International) Ag Bouclier thermique recyclable
US6397450B1 (en) * 1998-06-17 2002-06-04 Intersil Americas Inc. Method of cooling an electronic power module using a high performance heat exchanger incorporating metal foam therein
US6411508B1 (en) * 2000-01-29 2002-06-25 Korea Institute Of Science And Technology Foam metal heat sink
EP1500450A1 (fr) * 2003-07-24 2005-01-26 Efoam S.A. Méthode pour joindre une mousse métallique à une pièce métallique
EP1553379A1 (fr) * 2004-01-08 2005-07-13 Balcke-Dürr GmbH Echangeur de chaleur pour équipement industriel

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2424557A (en) * 1944-06-27 1947-07-29 Gen Motors Corp Composite article and method of manufacture
US3703763A (en) * 1970-11-18 1972-11-28 Ethyl Corp Method of making a composite metal article
EP0486427A1 (fr) * 1990-11-12 1992-05-20 Rieter Automotive (International) Ag Bouclier thermique recyclable
US6397450B1 (en) * 1998-06-17 2002-06-04 Intersil Americas Inc. Method of cooling an electronic power module using a high performance heat exchanger incorporating metal foam therein
US6411508B1 (en) * 2000-01-29 2002-06-25 Korea Institute Of Science And Technology Foam metal heat sink
EP1500450A1 (fr) * 2003-07-24 2005-01-26 Efoam S.A. Méthode pour joindre une mousse métallique à une pièce métallique
EP1553379A1 (fr) * 2004-01-08 2005-07-13 Balcke-Dürr GmbH Echangeur de chaleur pour équipement industriel

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2400252A1 (fr) 2010-06-24 2011-12-28 Valeo Vision Dispositif à échange de chaleur, notamment pour véhicule automobile
US9103605B2 (en) 2010-06-24 2015-08-11 Valeo Vision Heat exchange device
CN102371355A (zh) * 2010-08-11 2012-03-14 施瓦本冶金工程汽车有限公司 烧结复合物及其制造方法
CN102371355B (zh) * 2010-08-11 2016-06-29 施瓦本冶金工程汽车有限公司 烧结复合物及其制造方法
EP2434246A1 (fr) 2010-09-22 2012-03-28 Valeo Vision Dispositif à échange de chaleur, notamment pour véhicule automobile
CN102368482A (zh) * 2011-10-10 2012-03-07 李再林 多孔金属结构的高效散热器
WO2014197009A1 (fr) * 2013-06-05 2014-12-11 Hybrid Coatings And Components Llc Ensemble bouclier pour protéger un vaisseau spatial
CN112201893A (zh) * 2020-10-13 2021-01-08 浙江吉利控股集团有限公司 一种泡沫铝复合防爆结构、防爆装置及锂电池
CN113799470A (zh) * 2021-04-02 2021-12-17 吉林三环新材料有限公司 一种全通孔多孔泡沫铝制备方法

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