Metal founding – Process – Shaping liquid metal against a forming surface
Reexamination Certificate
1998-11-06
2003-12-30
Lin, Kuang Y. (Department: 1722)
Metal founding
Process
Shaping liquid metal against a forming surface
C164S098000
Reexamination Certificate
active
06668905
ABSTRACT:
BACKGROUND OF THE INVENTION AND RELATED ART
The present invention relates to an aluminum nitride/aluminum base composite material and a method for producing thereof.
A composite material produced by sintering metal powder to obtain a porous metal sintered member, and immersing and solidifying an aluminum base material into pores in the porous metal sintered member, has been known, for example, from Japanese Laid-Open Patent Publications JPA-3-189063 and JPA-3-189064. Such a composite material has attracted a good deal of attention as a novel material and has been expected to be put into practical use in miscellaneous industrial fields including automotive parts for internal combustion engines.
Since such a composite material can have a large specific Young's modulus (Young's modulus divided by density), the composite material has a large characteristic sound velocity and an excellent vibration damping characteristic. Thus, this composite material with an excellent damping property will successfully be applied, for example, to industrial robot arms which move rapidly.
However, in the case where a higher anti-oxidative or anti-corrosive property is required for the composite material disclosed in the above Laid-Open Patent Publications, the composite material needs to be covered with a covering layer consisting of a ceramic material such as Al
2
O
3
or aluminum nitride. Nevertheless, there is a problem that cracks arise in the covering layer because of difference in the linear expansion coefficients between the composite and ceramic materials, when the composite material covered with the covering layer is rapidly changed in temperature. The composite material is versatile in various applications, besides automotive parts for internal combustion engines or robot arms, depending upon its characteristics, while it is also important to suppress production costs.
OBJECT AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an aluminum nitride/aluminum base composite material excellent in heat resistance, oxidation resistance and corrosion resistance, and suitable for use in portions or parts of structures for which a higher heat conductivity and a lower linear expansion coefficient are required, and to provide a method for producing thereof.
For achieving the above-described object, there is provided a method for producing an aluminum nitride/aluminum base composite material according to a first aspect of the present invention, which comprises the steps of;
(A) charging aluminum nitride powder into a container provided in a molten metal pressure apparatus,
(B) applying pressure to the aluminum nitride powder in the container,
(C) pouring a molten aluminum base material into the container, and,
(D) applying pressure to the molten aluminum base material in the container to fill the aluminum base material in space between the aluminum nitride powder particles.
For achieving the above-described object, there is provided a method for producing an aluminum nitride/aluminum base composite material according to a second aspect of the present invention, which comprises the steps of;
(A) preparing a preform obtained by sintering aluminum nitride powder,
(B) enclosing the preform in a container provided in a molten metal pressure apparatus,
(C) pouring a molten aluminum base material into the container, and,
(D) applying pressure to the molten aluminum base material in the container to fill the aluminum base material in pores of the preform.
For achieving the above-described object, there is provided a method for producing an aluminum nitride/aluminum base composite material according to a third aspect of the present invention, which comprises the steps of;
(a) charging aluminum nitride powder into a container provided in a molten metal pressure apparatus, applying pressure to the aluminum nitride powder in the container, pouring a molten aluminum base material into the container, and, then, applying pressure to the molten aluminum base material in the container to fill the aluminum base material in space between the aluminum nitride powder particles, thereby obtaining a base material, and
(b) covering the surface of the base material with a covering layer consisting of a ceramic material.
For achieving the above-described object, there is provided a method for producing an aluminum nitride/aluminum base composite material according to a fourth aspect of the present invention, which comprises the steps of;
(a) preparing a preform obtained by sintering aluminum nitride powder, enclosing the preform in a container provided in a molten metal pressure apparatus, pouring a molten aluminum base material into the container, and, then, applying pressure to the molten aluminum base material in the container to fill the aluminum base material in pores of the preform, thereby obtaining a base material, and
(b) covering the surface of the base material with a covering layer consisting of a ceramic material.
For achieving the above-described object, there is provided an aluminum nitride/aluminum base composite material according to a first aspect of the present invention, which is produced by the steps of;
(A) charging aluminum nitride powder into a container provided in a molten metal pressure apparatus,
(B) applying pressure to the aluminum nitride powder in the container,
(C) pouring a molten aluminum base material into the container, and,
(D) applying pressure to the molten aluminum base material in the container to fill the aluminum base material in space between the aluminum nitride powder particles.
For achieving the above-described object, there is provided an aluminum nitride/aluminum base composite material according to a second aspect of the present invention, which is produced by the steps of;
(A) preparing a preform obtained by sintering aluminum nitride powder,
(B) enclosing the preform in a container provided in a molten metal pressure apparatus,
(C) pouring a molten aluminum base material into the container, and,
(D) applying pressure to the molten aluminum base material in the container to fill the aluminum base material in pores of the preform.
For achieving the above-described object, there is provided an aluminum nitride/aluminum base composite material according to a third aspect of the present invention, which comprises;
(a) a base material obtained by charging aluminum nitride powder into a container provided in a molten metal pressure apparatus, applying pressure to the aluminum nitride powder in the container, pouring a molten aluminum base material into the container, and, then, applying pressure to the molten aluminum base material in the container to fill the aluminum base material in space between the aluminum nitride powder particles, and
(b) a covering layer consisting of a ceramic material and covering the surface of the base material.
For achieving the above-described object, there is provided an aluminum nitride/aluminum base composite material according to a fourth aspect of the present invention, which comprises;
(a) a base material obtained by preparing a preform obtained by sintering aluminum nitride powder, enclosing the preform in a container provided in a molten metal pressure apparatus, pouring a molten aluminum base material into the container, and, applying pressure to the molten aluminum base material in the container to fill the aluminum base material in pores of the preform, and
(b) a covering layer consisting of a ceramic material and covering the surface of the base material.
It is preferable to pour a molten aluminum base material together with silicon (Si) to control the linear expansion coefficient of the aluminum nitride/aluminum base composite material or the base material of the present invention. The aluminum nitride/aluminum base composite material according to the first to fourth aspects of the present invention is simply referred to as “the composite material”, hereinafter, in some cases. Further, “the composite material” in the phrase “the composite material or the base material” means the aluminum n
Hirano Shinsuke
Kadomura Shingo
Suzuki Nobuyuki
Takatsu Kei
Kananen, Esq. Ronald P.
Lin Kuang Y.
Rader & Fishman & Grauer, PLLC
Sony Corporation
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