铝基多孔材料的反重力渗流铸造制备及其相关性能研究
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摘要
铝基多孔材料的独特金属特点和孔隙特性使其兼具了功能材料与结构材料的特征,因而其应用前景广阔。渗流铸造法是目前铝基多孔材料的重要制备方法,但传统工艺难避免“渗流过度”与“渗流不足”等缺陷。为了解决现有渗流铸造中存在的问题,本文结合帕斯卡原理与压力浸渗原理创新性地设计了反重力渗流铸造系统,研究了反重力渗流铸造工艺以及工艺参数的确定原则；采用该系统成功制备出了多孔铝裸材、氧化铝空心球/铝基轻质材料(即Al203k/Al材料)以及多孔铝芯夹芯材料等系列铝基多孔材料,并研究了相关材料的力学、热学与声学性能,分析了导致反重力铸造法与传统工艺所制备多孔铝材料性能方面差异的原因。所获得的主要研究结果如下：
(1)设计的反重力渗流铸造系统具有上下结构,上面部分为渗流室,下面为加热熔化室,加热熔化室与渗流室之间通过导流部件连通,创新性地采用了石墨纸来保证系统各部分之间的密封；所设计渗流铸造系统中,可包含一个以上不同尺寸的渗流室,从而可实现不同尺寸多孔金属的间歇与半连续渗流生产；渗流室的有效渗流空间可根据渗流产品的尺寸需要来确定。
(2)反重力渗流铸造制备铝基多孔材料的工艺主要包括基体金属的熔化、造孔材料在渗流室的安装与预热、熔体自下而上加压渗流进入造孔材料的孔隙以及保压结晶等步骤,该工艺所制备铝基多孔材料几乎没有明显的宏观铸造缺陷。反重力渗流法可实现无缺陷铸造的根本原因是：熔体采用了自下而上的运动模式,以及铝基熔体是在可控压力下进行的充型和结晶。
(3)创新性地开发了一种强度及刚度可满足渗流铸造要求的全新造孔材料MOD,它不仅易溶于水,而且其熔点、沸点均高于氯化钠与氯化钾,更为重要的是该材料对基体金属无腐蚀、价格低廉、对环境无污染。
(4)系统对比研究了传统渗流铸造法与反重力渗流铸造法所制备开孔多孔铝裸材的声学与热学性能。声学性能研究表明,反重力渗流铸造所得样品在高频段的吸声性能明显优于传统真空渗流法所制备材料,造成这个差别的根本原因是反重力渗流法使试样中相邻孔洞之间的连通空间减小；热学性能研究表明,在使用同一规格造孔粒子时,反重力渗流铸造所制备试样的导热系数明显高于传统真空渗流法所制备样品,这主要由于反重力渗流铸造法所制备样品的空隙度小、以及由于采用了保压等工序使基体金属更加结晶致密的原因。
(5)采用氧化铝空心球作为造孔材料,通过反重力渗流铸造技术制备出了基本无宏观铸造缺陷的氧化铝／铝基轻质复合材料(即Al203k/Al材料)；且还发现,渗流长度随熔体温度和空心球预热温度的提高以及空心球粒径的增大而增加,空隙度随着空心球粒径的增大而降低；增加充型与保压压力、延长保压时间以及添加金属Mg等均是改善渗流效果的有效手段。
(6)对比研究Al203k/Al材料与多孔铝裸材的准静态压缩性能后发现,两种材料的应力-应变曲线均表现出了包括线弹性阶段、屈服平台阶段和密实化阶段在内的“三阶段”特征,造孔粒子粒径、相对密度与应变速率等都是影响两种材料压缩性能的重要因素,所制备材料的屈服应力和平台应力均随造孔粒子粒径的减小、材料相对密度的增大以及空隙度的减小而增大；但是,Al203k/Al材料的屈服应力和平台应力远大于多孔铝裸材的,密实应变相对多孔铝裸材的略有减小。
(7)设计并制造出了可制备出大尺寸铝基多孔材料的装备,所制备大尺寸铝基多孔材料几乎没有宏观铸造缺陷；创造性地提出了由小尺寸造孔预制块构成大尺寸预制块、来制备大尺寸铝基多孔材料的方法,该法有效避免了大尺寸预制块在搬运过程中易碎的缺陷。
(8)对大尺寸Al203k/Al芯夹芯材料进行了三点弯曲测试,同时还研究了该夹芯材料的弯曲破坏过程。研究发现：①夹芯材料表现出了由线弹性阶段、弹塑性阶段与失稳阶段构成的经典多孔铝夹芯板的弯曲特性；②夹芯材料的失稳段较长,且其弯曲载荷高出Al203k/Al材料的一倍,达到了近18kN；夹芯材料的刚度超过了30KN/mm;③夹芯材料的弯曲破坏以芯部材料剪切开裂破坏和表层面板弯曲破坏为主,破坏过程中没有出现面板与芯材界面的拉裂现象。芯材和表层面板之间实现了冶金结合以及采用氧化铝空心球作为造孔材料,是Al203k/Al芯夹芯板抗弯性能优秀、刚度大以及弯曲破坏过程中界面没有出现拉裂的主要原因。
Due to its unique characteristics of metal and pore structure, aluminum based porous materials combine the characteristics of functional materials and structural materials, and has a broad prospect in application. At present, the infiltration casting is the main method of aluminum based porous materials preparation. However the traditional process has many unavoidable defects, such as "excessive infiltration " and "insufficient infiltration". In order to solve these problems, we innovatively designed a counter-gravity infiltration casting system based on the PASCAL principle and the pressure infiltration theory, then studied the counter-gravity infiltration casting process and found the principles to determinate the process parameters. In this paper, porous aluminum naked materials, Al2O3k/Al materials, porous aluminum core sandwich materials and other aluminum based porous materials were successfully prepared by this system. The related materials mechanics, heat and acoustic properties were studied and the explanations for the different properties of aluminum based porous materials prepared by counter-gravity infiltration casting system and the traditional process were analyzed. The main research results are as follows:
(1) The counter-gravity infiltration casting system has an up and down structure. The above section is an infiltration room while the lower section is a heating and melting room, between which is a diversion part for connection. Graphite paper is used to ensure the seal of system between the parts. There are more than one infiltration rooms with different sizes in the system, which can achieve different size of foam metal intermittent and semi-continuous infiltration productions. The effective infiltration space can be determined by the size of the infiltration products.
(2) The counter-gravity infiltration casting system mainly consists of the melting of metal matrix, the installing and preheating of porous materials in infiltration room, the process by bottom-up infiltration pressure to make melt into the hole of the porous materials, the holding crystallization steps and so on. Because of bottom-up movement patterns of metal and mould filling and crystallizing of aluminum melt, there is no obvious macro casting defect in the final product.
(3) A novel material—MOD was exploited as the pore-forming material, which can meet the requirements of strength and stiffness for infiltration casting. This material is not only soluble in water, but also has a higher melting point and boiling point than the sodium chloride and potassium chloride. Furthermore, it is non-corrosive to the based metal, low cost and environmentally friendly.
(4) Contrastive research was carried out to study the acoustics and thermal properties of the porous aluminum naked materials prepared by counter-gravity infiltration casting system and the traditional process respectively. The acoustics performance study suggested the product prepared by the former method is better than the product prepared by the latter. It was the decrease of connected space between adjacent holes in counter-gravity infiltration casting system that caused this difference. The thermal properties research showed the product prepared by counter-gravity infiltration casting had an obviously higher thermal conductivity, it was largely because the product had a low pore degrees and more dense crystallization of the based metal after some processes, for example the constant pressure process.
(5) Al2O3k/Al materials with no obvious macro casting defects were produced using alumina bubble brick as pore-forming materials through the counter-gravity infiltration casting system. It was found that along with the increase of the metal temperature and hollow balls preheating temperature and the particle size of hollow balls, the length of infiltration was getting longer. Besides, along with the increase of the particle size of the hollow ball, the pore degrees decreased. Improving the filling and holding pressure, lengthening the holding time and adding metal Mg were the effective measures to improve infiltration process.
(6) When compared the quasi-static compression performance of the Al2O3k/Al materials and the porous aluminum naked materials, it could be found that their stress-strain curves also had the "three stage" feature, which were linear elastic stage, yield platform stage and close-grained change stage. The particle size of porous materials, the relative density and the strain rate were the key factors for their compression performance, the smaller particle size of porous materials, the bigger of the relative density and the lower of the pore degrees, the greater of their yield stress and platform stress would be; However, compared with the porous aluminum naked materials, the yield stress and platform stress of the Al2O3k/Al materials were much greater, and its close-grained strain stress was only slightly reduced.
(7) A kind of equipment, which could be used to prepare aluminum based porous materials of large size with no obvious macro casting defects, was designed and manufactured. It was creatively to put forward the method that using the small size porous precast block to prepared large size aluminum based porous materials. This method could effectively avoid of the easily broken defects of large size and precast block during the handling process.
(8) The three point bending test was taken on the large size Al2O3k/Al core sandwich material, and its bend destructive process was also studied. The results were as follows:(1)The materials showed the classic bend characteristics of porous aluminum sandwich board, which consisted of linear elastic stage, elastic-plastic stage and Instability stage.(5)The materials had a long period of instability, and the bending load was twice as the Al2O3k/Al materials', nearly18KN; The stiffness of the sandwich material was more than30KN/mm;(3)Bending failure of the materials was mainly caused by the shear cracking destruction of the core materials and bending failure of surface panel, and the cracking phenomena did not appear between the interface of panel and core material during the process of destruction. The metallurgical combination between panel and core material and using alumina bubble brick as porous materials were the critical reasons why Al2O3k/Al core sandwich material had good flexural performance, large stiffness and why the cracking phenomena did not appear during the process of destruction.
(1)设计的反重力渗流铸造系统具有上下结构,上面部分为渗流室,下面为加热熔化室,加热熔化室与渗流室之间通过导流部件连通,创新性地采用了石墨纸来保证系统各部分之间的密封；所设计渗流铸造系统中,可包含一个以上不同尺寸的渗流室,从而可实现不同尺寸多孔金属的间歇与半连续渗流生产；渗流室的有效渗流空间可根据渗流产品的尺寸需要来确定。
(2)反重力渗流铸造制备铝基多孔材料的工艺主要包括基体金属的熔化、造孔材料在渗流室的安装与预热、熔体自下而上加压渗流进入造孔材料的孔隙以及保压结晶等步骤,该工艺所制备铝基多孔材料几乎没有明显的宏观铸造缺陷。反重力渗流法可实现无缺陷铸造的根本原因是：熔体采用了自下而上的运动模式,以及铝基熔体是在可控压力下进行的充型和结晶。
(3)创新性地开发了一种强度及刚度可满足渗流铸造要求的全新造孔材料MOD,它不仅易溶于水,而且其熔点、沸点均高于氯化钠与氯化钾,更为重要的是该材料对基体金属无腐蚀、价格低廉、对环境无污染。
(4)系统对比研究了传统渗流铸造法与反重力渗流铸造法所制备开孔多孔铝裸材的声学与热学性能。声学性能研究表明,反重力渗流铸造所得样品在高频段的吸声性能明显优于传统真空渗流法所制备材料,造成这个差别的根本原因是反重力渗流法使试样中相邻孔洞之间的连通空间减小；热学性能研究表明,在使用同一规格造孔粒子时,反重力渗流铸造所制备试样的导热系数明显高于传统真空渗流法所制备样品,这主要由于反重力渗流铸造法所制备样品的空隙度小、以及由于采用了保压等工序使基体金属更加结晶致密的原因。
(5)采用氧化铝空心球作为造孔材料,通过反重力渗流铸造技术制备出了基本无宏观铸造缺陷的氧化铝／铝基轻质复合材料(即Al203k/Al材料)；且还发现,渗流长度随熔体温度和空心球预热温度的提高以及空心球粒径的增大而增加,空隙度随着空心球粒径的增大而降低；增加充型与保压压力、延长保压时间以及添加金属Mg等均是改善渗流效果的有效手段。
(6)对比研究Al203k/Al材料与多孔铝裸材的准静态压缩性能后发现,两种材料的应力-应变曲线均表现出了包括线弹性阶段、屈服平台阶段和密实化阶段在内的“三阶段”特征,造孔粒子粒径、相对密度与应变速率等都是影响两种材料压缩性能的重要因素,所制备材料的屈服应力和平台应力均随造孔粒子粒径的减小、材料相对密度的增大以及空隙度的减小而增大；但是,Al203k/Al材料的屈服应力和平台应力远大于多孔铝裸材的,密实应变相对多孔铝裸材的略有减小。
(7)设计并制造出了可制备出大尺寸铝基多孔材料的装备,所制备大尺寸铝基多孔材料几乎没有宏观铸造缺陷；创造性地提出了由小尺寸造孔预制块构成大尺寸预制块、来制备大尺寸铝基多孔材料的方法,该法有效避免了大尺寸预制块在搬运过程中易碎的缺陷。
(8)对大尺寸Al203k/Al芯夹芯材料进行了三点弯曲测试,同时还研究了该夹芯材料的弯曲破坏过程。研究发现：①夹芯材料表现出了由线弹性阶段、弹塑性阶段与失稳阶段构成的经典多孔铝夹芯板的弯曲特性；②夹芯材料的失稳段较长,且其弯曲载荷高出Al203k/Al材料的一倍,达到了近18kN；夹芯材料的刚度超过了30KN/mm;③夹芯材料的弯曲破坏以芯部材料剪切开裂破坏和表层面板弯曲破坏为主,破坏过程中没有出现面板与芯材界面的拉裂现象。芯材和表层面板之间实现了冶金结合以及采用氧化铝空心球作为造孔材料,是Al203k/Al芯夹芯板抗弯性能优秀、刚度大以及弯曲破坏过程中界面没有出现拉裂的主要原因。
Due to its unique characteristics of metal and pore structure, aluminum based porous materials combine the characteristics of functional materials and structural materials, and has a broad prospect in application. At present, the infiltration casting is the main method of aluminum based porous materials preparation. However the traditional process has many unavoidable defects, such as "excessive infiltration " and "insufficient infiltration". In order to solve these problems, we innovatively designed a counter-gravity infiltration casting system based on the PASCAL principle and the pressure infiltration theory, then studied the counter-gravity infiltration casting process and found the principles to determinate the process parameters. In this paper, porous aluminum naked materials, Al2O3k/Al materials, porous aluminum core sandwich materials and other aluminum based porous materials were successfully prepared by this system. The related materials mechanics, heat and acoustic properties were studied and the explanations for the different properties of aluminum based porous materials prepared by counter-gravity infiltration casting system and the traditional process were analyzed. The main research results are as follows:
(1) The counter-gravity infiltration casting system has an up and down structure. The above section is an infiltration room while the lower section is a heating and melting room, between which is a diversion part for connection. Graphite paper is used to ensure the seal of system between the parts. There are more than one infiltration rooms with different sizes in the system, which can achieve different size of foam metal intermittent and semi-continuous infiltration productions. The effective infiltration space can be determined by the size of the infiltration products.
(2) The counter-gravity infiltration casting system mainly consists of the melting of metal matrix, the installing and preheating of porous materials in infiltration room, the process by bottom-up infiltration pressure to make melt into the hole of the porous materials, the holding crystallization steps and so on. Because of bottom-up movement patterns of metal and mould filling and crystallizing of aluminum melt, there is no obvious macro casting defect in the final product.
(3) A novel material—MOD was exploited as the pore-forming material, which can meet the requirements of strength and stiffness for infiltration casting. This material is not only soluble in water, but also has a higher melting point and boiling point than the sodium chloride and potassium chloride. Furthermore, it is non-corrosive to the based metal, low cost and environmentally friendly.
(4) Contrastive research was carried out to study the acoustics and thermal properties of the porous aluminum naked materials prepared by counter-gravity infiltration casting system and the traditional process respectively. The acoustics performance study suggested the product prepared by the former method is better than the product prepared by the latter. It was the decrease of connected space between adjacent holes in counter-gravity infiltration casting system that caused this difference. The thermal properties research showed the product prepared by counter-gravity infiltration casting had an obviously higher thermal conductivity, it was largely because the product had a low pore degrees and more dense crystallization of the based metal after some processes, for example the constant pressure process.
(5) Al2O3k/Al materials with no obvious macro casting defects were produced using alumina bubble brick as pore-forming materials through the counter-gravity infiltration casting system. It was found that along with the increase of the metal temperature and hollow balls preheating temperature and the particle size of hollow balls, the length of infiltration was getting longer. Besides, along with the increase of the particle size of the hollow ball, the pore degrees decreased. Improving the filling and holding pressure, lengthening the holding time and adding metal Mg were the effective measures to improve infiltration process.
(6) When compared the quasi-static compression performance of the Al2O3k/Al materials and the porous aluminum naked materials, it could be found that their stress-strain curves also had the "three stage" feature, which were linear elastic stage, yield platform stage and close-grained change stage. The particle size of porous materials, the relative density and the strain rate were the key factors for their compression performance, the smaller particle size of porous materials, the bigger of the relative density and the lower of the pore degrees, the greater of their yield stress and platform stress would be; However, compared with the porous aluminum naked materials, the yield stress and platform stress of the Al2O3k/Al materials were much greater, and its close-grained strain stress was only slightly reduced.
(7) A kind of equipment, which could be used to prepare aluminum based porous materials of large size with no obvious macro casting defects, was designed and manufactured. It was creatively to put forward the method that using the small size porous precast block to prepared large size aluminum based porous materials. This method could effectively avoid of the easily broken defects of large size and precast block during the handling process.
(8) The three point bending test was taken on the large size Al2O3k/Al core sandwich material, and its bend destructive process was also studied. The results were as follows:(1)The materials showed the classic bend characteristics of porous aluminum sandwich board, which consisted of linear elastic stage, elastic-plastic stage and Instability stage.(5)The materials had a long period of instability, and the bending load was twice as the Al2O3k/Al materials', nearly18KN; The stiffness of the sandwich material was more than30KN/mm;(3)Bending failure of the materials was mainly caused by the shear cracking destruction of the core materials and bending failure of surface panel, and the cracking phenomena did not appear between the interface of panel and core material during the process of destruction. The metallurgical combination between panel and core material and using alumina bubble brick as porous materials were the critical reasons why Al2O3k/Al core sandwich material had good flexural performance, large stiffness and why the cracking phenomena did not appear during the process of destruction.
引文
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