Metal fusion bonding – Process – Diffusion type
Reexamination Certificate
1999-04-23
2001-12-11
Dunn, Tom (Department: 1725)
Metal fusion bonding
Process
Diffusion type
C228S121000, C228S122100
Reexamination Certificate
active
06328198
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of manufacturing a joint body constructed of at least one pair of substrates comprised of an aluminum matrix composite. The aluminum matrix composite is made of an aluminum or aluminum alloy matrix and a reinforcing ceramic.
2. Description of Related Art
The idea that a metal matrix composite is produced by reinforcing metal with ceramic fiber is well known. However, since ceramic generally has no wettability with melted metal, it has been difficult to form a composite of ceramic and metal. Traditionally, the melted metal is pressed and inserted into a porous ceramic shaped body (a preform), or ceramic particles are mixed with the melted metal to forcedly be dispersed. In such a metal matrix composite, ceramic and metal are not necessarily joined strongly to each other at their joint boundary, and a uniform dispersion of ceramic is difficult.
Further, a method of producing a ceramic matrix or a metal matrix composite by a Lanxide process is known (for example, “Net Shape Manufacturing of CMC and MMC by Lanxide Processes” in “ceramics” 32 (1997) No. 2 p93-97). The Lanxide process, which is a non-pressurized metal infiltration process, increases the wettability between melted aluminum and ceramic in each composite of silicon carbide/aluminum and alumina/aluminum systems.
In the Lanxide method, a preform having an almost final objective shape is formed by using silicon carbide or alumina as reinforcing material, a barrier film for stopping growth is applied on every surface, except for those surfaces which are put into contact with an aluminum alloy. This preform is usually put into contact with the aluminum alloy in nitrogen at a temperature of about 800° C. Aluminum infiltrates into the pores of the preform while wetting the ceramic to form a composite. The resulting composite is confirmed to have an aluminum nitride layer at the boundary between the ceramic and aluminum.
However, problems still remain in expanding the use of aluminum matrix composite to additional markets. For example, in order to form a semiconductor or conductor circuit on a liquid crystal panel, it is necessary to enlarge a susceptor with a liquid crystal panel having a diameter of not less than 1 m. Further the susceptor needs to additionally be attached with a shaft or backboard. When the susceptor, shaft and backboard are integrated, they must be integrated at preforming stage.
As mentioned above, in order to extend usage of the aluminum material composite, to manufacture a preform having a large size or an unusual shape is required. However, it is difficult to make the large and unusual shaped preform and appropriately infiltrate the aluminum alloy into the preform.
Therefore, the inventors studied to manufacture relatively small substrates and then join each other. Further, a technique of joining the aluminum matrix materials each other strongly and airtightly for preventing leakage of air has not been studied.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention to provide a novel method of manufacturing a joint body constructed of at least one pair of substrates comprised of an aluminum matrix composite which is made of an aluminum or aluminum alloy matrix and a reinforcing ceramic.
According to a preferred aspect of the present invention, there is provided a method of manufacturing a joint body constructed of at least one pair of substrates comprised of an aluminum matrix composite which is made of an aluminum or aluminum alloy matrix and a reinforcing ceramic, in which an infiltrating material made of an aluminum alloy containing aluminum of not less than 70 mol % is placed between joint surfaces of the substrates, and then the substrates and the infiltrating material are subjected to a heat treatment in a high level vacuum at a temperature such that both the matrix and the infiltrating material are melted simultaneously.
According to yet another aspect of the invention, there is also provided a method of manufacturing a joint body constructed of at least one pair of substrates comprised of an aluminum matrix composite which is made up of an aluminum or aluminum alloy matrix and a reinforcing ceramic, in which each joint surface of each substrate is put into contact with the other, the infiltrating material made of an aluminum alloy containing aluminum of not less than 70 mol % is put into contact with at least one of the substrates, and then the substrates and the infiltrating material are subjected to the heat treatment in a high level vacuum at a temperature capable of melting the matrix and causing the infiltrating material to infiltrate the aluminum alloy constituting the infiltrating material into the substrate, and the melted aluminum or aluminum alloy is diffused across each joint surface of each substrate.
In the method of the present invention, a joint body made of the aluminum matrix composite having a trace of impurities or an undetectable amount of impurities at the joint boundary surface of each substrate can be obtained. The joint portion has a high heat resistance and joint strength, and does not have brittleness.
REFERENCES:
patent: 3993238 (1976-11-01), Brook et al.
patent: 4552301 (1985-11-01), Liehr et al.
patent: 4611745 (1986-09-01), Nakahashi et al.
patent: 4764435 (1988-08-01), Hosizaki et al.
patent: 4838474 (1989-06-01), Ohashi et al.
patent: 4923832 (1990-05-01), Newkirk
patent: 4946090 (1990-08-01), Hepburn
patent: 5188164 (1993-02-01), Kantner et al.
patent: 5234152 (1993-08-01), Glaeser
patent: 5392982 (1995-02-01), Li
patent: 5451279 (1995-09-01), Kohinata et al.
patent: 5614043 (1997-03-01), Ritland
patent: 5794838 (1998-08-01), Ushikoshi et al.
patent: 5807626 (1998-09-01), Naba
patent: 5906897 (1999-05-01), Tanaka et al.
patent: 0 164 830 (1985-12-01), None
patent: 0 238 758 (1987-09-01), None
patent: 0 378 501 (1990-07-01), None
patent: 0 409 764 A2 (1991-01-01), None
patent: 7-25675 (1995-01-01), None
patent: 92 00937 (1992-01-01), None
patent: 94 10351 (1994-05-01), None
Fujii Tomoyuki
Ohashi Tsuneaki
Burr & Brown
Dunn Tom
Johnson Jonathan
NGK Insulators Ltd.
LandOfFree
Method of manufacturing joint body does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Method of manufacturing joint body, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method of manufacturing joint body will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2556828