粉末冶金1粉末的制備(1)

第1部分 粉末的制備（1）Powder Metallurgy PrincipleRuan Jianming Powder Metallurgy Research Institute 2007Particle Science and Engineering粉末冶金原理(課程分布) 40學(xué)時(shí)教學(xué)方式: 雙語講學(xué) Chinese/English課程內(nèi)容: Part I Powder fabrication 粉體制備 Part Powder characterization 性能 How do the powders fabricate？ Main methods to fabricate powders What physio-chemical phenomenon could be observed during powder fabrication？Which method is suitable to sphere particles？ How about the particle morphologies？How can we obtain the high purity？What takes place during the powder fabri.?Which condition to control the particle size?What can we do? related powder makings.Continuers What are the microstructures of the particles?What is the apparent density of the powders? Which equipment can measure the fine particles?課時(shí)安排 Talking arrangements 序言 Introduction 2hrsPart粉末制備 28hrs 機(jī)械研磨 Mechanical grinding 4hrs 霧化制粉 Atomization 4hrs 快速冷凝 RST Rapid solidification 4hrs 化學(xué)沉積 Chemistry precipitation 4hrs 電解制粉 Electrical fabrication 4hrs 還原制粉 Reduction 8hrsPart Powder Characterization 12hrs 顆粒結(jié)構(gòu) Particle microstructure 4hrs 粒度分布 Particle size and distribution 4hrs 比表面 Specific surface 2hrs 考試 Testing 2hrs (close book) 參考書籍:References Powder Metallurgy Science 粉末冶金原理 黃培云 P/M. Principle考核成績(jī) Score 作業(yè)30% 卷面考試70%What is Powder MetallurgyPowder metallurgy Study of the processing of metal powders, including the fabrication, characterization, and conversion of metal powders into useful engineering components.Study of the basic laws and mechanisms of powder fabri., powder compaction, sintering and surface treatments.R&D of novel materials and products.Powder Metallurgy ProcessingReasons for using powder metallurgyThe future of powder metallurgyA comparison of the relative production for some common metal powders, logarithmic scale. Further considerations 1High volume production of precise, high quality structural parts from ferrous alloys;Consolidation of high performance materials, where full density and reliability are primary concerns;Fabrication of difficulty to process materials, where fully dense high performance alloys can be fabricated with uniform microstructure; Further considerations 2Economic consolidation of specially alloys, typically composites containing mixed phase;Synthesis of non equilibrium materials such as amorphous, microcrystalline, or some special alloys;Processing of complex parts with unique ingredients (組元）or uncommon shapes.粉末冶金發(fā)展 History and development of P/M 歷史部分: 武器, 生活用具, 藝術(shù)建筑Weapon, life facilities, arts-construction, etc. 現(xiàn)代部分: 硬質(zhì)合金, 高溫材料, 汽車部件, 軍事工程Cement carbide, refractory materials, automobile parts, equipments in defensive, civilization products, etc.目前, 粉末冶金最發(fā)達(dá)的國(guó)家瑞典(Sweden)硬質(zhì)合金工業(yè)非常發(fā)達(dá)Hoganess, 建立許多子公司, Be number one 其次是北美(North American)和西歐(western European) 。德國(guó)的粉末冶金工業(yè)也是處于世界前列-工具鋼., tooling steel.美國(guó)的粉末冶金公司主要產(chǎn)品用戶是汽車制造商producer，汽車工業(yè)auto vehicle industry發(fā)達(dá)，帶動(dòng)了美國(guó)的粉末冶金工業(yè)發(fā)展，這是因?yàn)榘l(fā)達(dá)的汽車工業(yè)，大量a huge of application 用粉末冶金部件。Same to American，日本Japan的汽車工業(yè)的發(fā)展帶動(dòng)了粉末冶金工業(yè)發(fā)展。Different to China與中國(guó)不一樣，the western countries and Japan西方或日本的粉末冶金工業(yè)是由兩部分構(gòu)成 conbined by two part制粉公司：制備各種粉末：Companies to fabricate and supply powders制品公司：買進(jìn)粉末，制備零部件： Companies to fabricate final parts 粉末冶金技術(shù)的優(yōu)越性與局限性 advantages and limitation能夠大量節(jié)約材料、low cast無切削、less cuting少切削，普通鑄造合金切削量在30-50%，粉末冶金產(chǎn)品可少于5%。Less or absent cutting machining. “Net shaping”能夠大量節(jié)省能源 energy saving能夠大量節(jié)省勞動(dòng) labor saving能夠制備其他方法不能制備的材料 specific materials and/or products 能夠制備其他方法難以生產(chǎn)的零部件 the material and part that are difficultly to be produced by other methods 粉末冶金的特點(diǎn) particularly points 能生產(chǎn)用普通熔煉方法無法生產(chǎn)的具有特殊性能的材料；ability to produce materials which can not be produced by other method. Porous materials and products, parts within lubricantsRefractory metals such as tungsten, molybdenum, etcPesudo-alloys, such as, tungsten-copper alloysComposite materials, such as 316 ss + bioceramicNano-crystalline, sub-micrometer crystalline grain metalSpecial functional materials and products, such as magnetic products, supper alloys applied in airo-industry. Powder metallurgy disadvantages and limitationRather lower mechanical properties, for their pores in partsSize and morphological limitation, for press machine.Rather lower wrought properties, for the products may contain oxide that induce materials brittle.Rather small industry background compared with casting and conventional materials industry, such iron and steel produced on big scale. 1+12, new materials and high performancePowder metallurgy plus conventional material processing 粉末冶金新技術(shù) Novel techniques of powder metallurgy 快速原形制備技術(shù), RSP粉末注射成形、PIM快速冷凝技術(shù)獲得非晶粉末、RST粉末濺射成形、powder spray forming機(jī)械合金化技術(shù)、MA 溫壓成形技術(shù), Worm Comp.納米粉末技術(shù), Namo-Tech等靜壓成形-燒結(jié)技術(shù), ISP-sintering 高性能材料研發(fā)，等等.A Interest ComparisonMetal powders: 109 kg/yearIndustry minerals: 300 times 109 kg/yearCoffee, tea, and tobacco: 1010 kg/yearPowder metallurgy is a prolonged growth phase;Iron and steel, aluminum, copper, nickel, and tungsten are the main consumption, worldwide. Automobile industry Gear partsMechanical industryP/M Industry 2005 粉末冶金未來 The future of the powder metllurgy 1）鐵基結(jié)構(gòu)合金的高精度high precise高質(zhì)量high quality大數(shù)量產(chǎn)品。2）致密高性能材料，主要是理想的密度和牢固性full density and reliability。 3）難加工材料的制造，difficulty to process materials全密度具有統(tǒng)一微觀結(jié)構(gòu)的高性能合金。 4）特殊合金，主要為包含有多相的組分multi-composites containing mixed phase，通過增強(qiáng)密度的工藝來制造。These will often be fabricated by enhanced densification.5）非平衡nonequilibrium材料的合成例如such s amorphous非晶，micro-crystalline, or metastable alloys微晶和亞穩(wěn)合金。 6）具有獨(dú)特組分或不常用形狀的特殊附件的工藝。 Copper and Copper base powder in North AmericaCopper and copper-base powder in 2004 increased 11.3% and copper powder base parts increased 7%.International iron and steel powder Metal powder in 2004 increased by 6.5% to 527,918(mt), figure Iron powder increased 7% over 2003 to 430,119mt. International copper and copper base powders in 2004P/M parts content in a typical vehicleNorth America copper and copper base powderStainless steel powder increased 5% to an estimated 8,488 mt. Tungsten powder increased 16% to 3,177 mt and tungsten carbide powder increased almost 12%.Although there are about 10 companies making aluminum P/M parts, two players dominated the market in North America.European iron and steel powder in 2004 fared better than North America, increasing by 8.8% to 172,952mt.Increases in iron powder in Japan did not match North America.Estimate that that the iron powder market now exceeds 908，000mt Impact of China In the last several years, China poses both a competitive threat and potentially huge opportunity.It has an estimated 680 P/M part makers, but only about five of these are considered capable of making high quality P/M parts.The Chinese P/M parts industry is experiencing an estimated 19% annual growth rate.The typical passenger car in China contains about 4.7kg of P/M parts.China produced about 85000mt of P/M parts.Chinese P/M industry will undoubtedly increase its quality capability as more funds are invested, particularly by Western companies. Currently more than 20 non-Chinese firms representing the U.S, Europe, Japan, Korea, and Taiwan have P/M plants in China mainland. On the other hand, China is beginning to impact the European automotive market, selling inexpensive cars. Chapter 2 粉末制備方法 Powder fabrication methods 1 物理機(jī)械法 Physio-Mechanical Protocol1.1 機(jī)械研磨法制備粉末 Milling 1.2 高溫霧化法制備粉末 Atomization2 物理化學(xué)法制備粉末2.1 氧化物還原法制備粉末 reduction of metallic oxides2.2 氣相沉積法制備粉末 precipitation from atmosphere phase2.3 液相沉積法制備粉末 precipitation from liquid phase2.4 電解法制備粉末 electrolytic fabrication techniques from the electrode2.5 納米及超細(xì)粉末制備技術(shù) nano/ultro fine powder preparation從過程的實(shí)質(zhì)來看，大體上可以歸納為兩大類，即物理機(jī)械法mechanical 和物理化學(xué)physio-chemical 法粉末的生產(chǎn)方法很多，從工業(yè)規(guī)模industrial scale而言，應(yīng)用最廣泛pervasive used method的是還原法reducing、霧化