Method for manufacturing a composite of carbon nanomaterial and metallic material

• US 7,837,811 B2
• Filed: 05/11/2007
• Issued: 11/23/2010
• Est. Priority Date: 05/12/2006
• Status: Expired due to Fees

• Current Assignee: Chiba Institute of Technology, Nissei Plastic Industrial Co., Ltd.
• Original Assignee: Chiba Institute of Technology, Nissei Plastic Industrial Co., Ltd.
• Inventors: Anzai, Kazuo, Tanabe, Fumi, Motegi, Tetsuichi, Suganuma, Masashi
• Primary Examiner(s): WYSZOMIERSKI, GEORGE P
• Application Number:
  US11/803,139
• Publication Number:
  US 20080127777A1
• Time in Patent Office: 1,292 Days
• Field of Search: None
• US Class Current: 148/538
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2203/11 temperature, temperature profile
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: C22C 1/1036 starting from a melt
• CPC Class Codes: C22C 1/1084 by mechanical alloying (blending, milling)
• CPC Class Codes: C22C 32/0084 carbon or graphite as the main non-metallic constituent
• CPC Class Codes: C22C 47/14 by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments

Abstract

The present invention provides a method for manufacturing a composite of a carbon nanomaterial and a metallic material which has a homogeneous composite metal structure and thixotropic properties by compositing a metallic material of a non-ferrous metal alloy with a carbon nanomaterial by using both stirring and ultrasonic vibration. The method comprises compositing the metallic material of the non-ferrous metal alloy with the carbon nanomaterial by adding the carbon nanomaterial in a state where the metallic material shows thixotropic properties by spheroidization of solid phase in a semi-solid state, and the compositing is performed by a process for stirring and kneading the semi-solid metallic material while keeping the temperature thereof at a solid-liquid coexisting temperature, and a process for dispersing the carbon nanomaterial to liquid phase between solid phases by ultrasonic vibration.

Claims

1. A method for manufacturing a composite of a carbon nanomaterial and a metallic material, the method comprising:

compositing a metallic material of non-ferrous metal alloy with a carbon nanomaterial by adding the carbon nanomaterial in a state where the metallic material shows thixotropic properties by spheroidization of solid phase in a semi-solid state thereof,

the compositing being performed by;

adding the carbon nanomaterial to the metallic material in the semi-solid state while stirring, shearing, and kneading the metallic material in the semi-solid state to granulate the solid phase in the semi-solid metallic material to a granular solid phase and to spheroidize the granular solid phase while

maintaining the metallic material being stirred, sheared, and kneaded at a solid-liquid coexisting temperature; and

dispersing uniformly the carbon nanomaterial into the liquid phase between solid phases while refining grains of the solid phases, by applying ultrasonic vibration to the metallic material in the semi-solid state after said stirring, shearing, and kneading or concurrent therewith.

2. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the spheroidization of solid phase in the semi-solid state of the metallic material is performed in the process of cooling the metallic material into the semi-solid state by flowing down the metallic material, after melting it by heating to a temperature of a liquidus temperature or higher, over the plate surface of an inclined cooling plate.

3. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the spheroidization of solid phase in the semi-solid state of the metallic material is performed by melting the metallic material to the semi-solid state by heating to a solid-liquid coexisting temperature between a liquidus temperature or lower and a solidus temperature or higher, and shearing the solid phase by stirring the semi-solid metallic material.

4. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the stirring, shearing, and kneading is performed by the shearing the solid phase while stirring the semi-solid metallic material.

5. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the dispersion process by ultrasonic vibration comprises continuously and intermittently applying ultrasonic vibration for 60 to 900 seconds successively to the stirring and kneading process.

6. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the ultrasonic vibration is applied with a frequency of 5 to 30 kHz, an ultrasonic wave output of 500 to 3000 kW, an amplitude width of 5 to 30 μ

m, and a vibration application time of 60 to 900 seconds.

7. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the non-ferrous metal alloy is a magnesium alloy, the granularized and spheroidized grains in solid phase of the semi-solid metallic material have a size of 50 to 300 μ

m, and a refined solid phase produced by refining the spheroidized solid phase has a size of 5 to 50 μ

m.

8. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the carbon nanomaterial consists of carbon nanotubes or carbon nanofibers having a diameter of 10 to 150 nm and a length of 1 to 100 μ

m.

9. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, in which the addition amount of the carbon nanomaterial is 0.1 to 20 mass %.

10. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein the carbon nanomaterial is preheated before being added to the semi-solid metallic material.

11. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein:

the spheroidization of solid phase in the semi-solid state of the metallic material is performed in the process of cooling the metallic material into the semi-solid state by flowing down the metallic material, after melting it by heating to a temperature of a liquidus temperature or higher, over the plate surface of an inclined cooling plate;

the dispersion process by ultrasonic vibration comprises continuously and intermittently assigning ultrasonic vibration for 60 to 900 seconds successively to the stirring and kneading process;

the ultrasonic vibration is assigned with a frequency of 5 to 30 kHz, an ultrasonic wave output of 500 to 3000 kW, an amplitude width of 5 to 30 μ

m, and a vibration application time of 60 to 900 seconds;

the non-ferrous metal alloy is a magnesium alloy, grains in solid phase of the semi-solid metallic material have a size of 50 to 300 μ

m, and the grains are refined to 5 to 50 μ

m by the ultrasonic vibration.

12. The method for manufacturing a composite of a carbon nanomaterial and a metallic material according to claim 1, wherein:

the stirring, shearing, and kneading process is performed by shearing the solid phase while stirring the semi-solid metallic material;

the carbon nanomaterial consists of carbon nanotubes or carbon nanofibers having a diameter of 10 to 150 nm and a length of 1 to 100 μ

m;

the addition amount of the carbon nanomaterial is 0.1 to 20 mass %;

the carbon nanomaterial is preheated before being added to the semi-solid metallic material.