Manufacturing method of metal product and metal product

• US 8,439,998 B2
• Filed: 12/02/2005
• Issued: 05/14/2013
• Est. Priority Date: 12/06/2004
• Status: Expired due to Fees

• Current Assignee: Ace Giken Co., Ltd., Nanopulus Co., Ltd., Sunrex Kogyo Co., Ltd.
• Original Assignee: Ace Giken Co., Ltd., Nanopulus Co., Ltd., Sunrex Kogyo Co., Ltd.
• Inventors: Ito, Kenzo, Yamamoto, Masahiro, Yamamoto, Etsuo
• Primary Examiner(s): KASTLER, SCOTT R
• Application Number:
  US11/791,231
• Publication Number:
  US 20080241568A1
• Time in Patent Office: 2,720 Days
• Field of Search: 148/301, 148/302, 752/55
• US Class Current: 75/255
• CPC Class Codes: B22F 1/068 Flake-like particles
• CPC Class Codes: B22F 2009/044 by jet milling
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• 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: B22F 3/02 Compacting only
• CPC Class Codes: B22F 3/10 Sintering only
• CPC Class Codes: B22F 9/002 amorphous or microcrystalline
• CPC Class Codes: B22F 9/04 starting from solid material, e.g. by crushing, grinding or milling C22C1/1084 takes precedence; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C
• CPC Class Codes: Y10T 428/12014 having metal particles

Abstract

In sintering a metal powder after pressure molding into a given configuration, random amorphous flaky metal fine powders (10) are used as metal powder materials. In addition, spherical particulate metal powders 11 are used as main materials, and random amorphous flaky metal fine powders 10 having finer particle size than the metal powders 11 and produced by fracturing a metal fracture material by means of high-velocity gas swirling flow are used as sub-materials, and molding and sintering are performed in a state of dispersing the sub-materials (10) in the main materials (11). Thus, despite being a power metallurgical product, it is possible to obtain a metal product having a dense metallographic structure and excellent in properties such as mechanical strength.

Claims

1. A method of manufacturing a metal product obtained by pressure-molding metal powders into a given configuration, and thereafter fusion-bonding particles of this molded metal powders together by sintering, comprising steps of:

producing spherical particulate metal powders,

producing random flaky metal fine powders having a smaller particle size than the spherical particulate metal powders by fracturing a metal fracture material by means of high-velocity gas swirling flow of jet mill,

producing a mixture material by dispersing the flaky metal fine powders as a sub-material in spaces among the spherical particulate metal powders as a main material, so that a mixing ratio of the sub-material to the main material does not exceed 50%,

pressure-molding the mixture material using a metal mold, wherein the spherical particulate metal powders retain a spherical shape, and

sintering the press-molded mixture material so that a framework structure having a three-dimensional network or a lattice shape is formed by fusion-bonding particles of the spherical particulate metal powders together, and air gaps in the framework structure are filled up with the random flaky metal fine powders.

2. A metal product, manufactured by sintering and fusion-bonding spherical articulate metal powders and random flaky metal fine powders having a smaller particle size than the spherical particulate metal powders, wherein

the spherical particulate metal are a main material,

the flaky metal fine powders are a sub-material,

a mixing ratio of the sub-material to the main material does not exceed 50%,

a framework structure having a three-dimensional network or a lattice shape is formed by fusion-bonding particles of the spherical particulate metal powders together,

air gaps in the framework structure are filled up with the flaky metal fine powders, and

the spherical particulate metal powders in the framework structure retain a spherical shape.