Title of Invention

ALUMINIUM-BASED POWDER COMPOSITE MIXTURE AND METHOD FOR THE PRODUCTION THEREOF

Abstract The invention relates to powder metallurgy and may be used as a construction material for accurate engineering products including design of control devices for aircraft flight director systems with high operating features. The inventive powder composite mixture comprises components with the following component ratio: 41-41 mass % silicon, 4,1 -5,2 mass % nickel, 0,05 - 0,1 mass % phosphorus, 0.01-0.05 mass % aluminium nitride, the rest being aluminium. The inventive method for producing said powder composite mixture consists in preparing a melt containing aluminium, silicon, nickel, spraying the melt, with creation of powder and then combining the received powder with silicon powder, wherein during the melt production with additional phosphorus content, subsequently nitrogen is injected and the melt pulverization is carried out by nitrogen at a temperature and pressure which enable the aluminium nitride to be formed. Said invention allows to obtain the material with homogenious fine-dispersed structure and processing plasticity, which ensures a satisfactory deformation treatment of the product with coefficient of linear expansion, vacuum density and dimensional stability at berillium level, thereby substantially promoting the operational reliability of the products for a long service life. The inventive material in comparison with berillium is ecologically pure.
Full Text IPC C22 C21/02, 1/04
ALUMINIUM-BASED POWDER COMPOSITE MIXTURE AND METHOD
FOR THE PRODUCTION THEREOF
Technical field of the invention
The invention relates to powder metallurgy and may be used in different fields of
national economy (engineering, aircraft, rocket technology, shipyard, automobile,
textile and others) where it's necessary to combine the following product
properties: low coefficient of linear expansion, high dimensional stability, light
specific weight, satisfactory treatability and ecological purity.
Previous level of technology
It's obvious that at present one of the main construction material , for instance for
manufacturing of command devices of aircraft control systems, is berillium which
meets necessary requirements to device components: light specific weight, low
coefficient of linear expansion, high dimensional stability, vacuum-tightness and
other. (Nikitin E.A., Shestov S.A., Matveev V.A. "Gyroscopic systems. Elements
of gyroscopic devices." Moscow, High school, 1988, p.432)
The main drawback of this material is high work content of its production, high
cost and its toxicity during processing.
It's known the composite material which consists of the aluminium-based melt
with the following admixtures: 25% silicium, 5% nickel and high-melting
combination 15% silicium nitride ( RF Patent N 2016120, IPC cl.C22 C 21/14,
32/00 dated from 17.05.91)
The drawback of this material is impossibility to secure reliability and stability of
the required operating characteristics for a long service life.
It's known the powder composite material, which consists of the aluminium-based
melt with the following admixtures: silicium, nickel and high-melting component
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as powdered crystalline silicon, which has the same physico-mechanical properties
as berillium. (RF Patent N 2149201,
IPC cl.C22 C 21/14, 32/00 dated from 20.05.2000).
The drawback of this material is low manufacturing plasticity, instability of
operating characteristics due to structure inhomogeneity, presence of gas porosity ,
high specific weight and coefficient of linear expansion that reduce product
operation safety.
It's known the composite material which consists of the aluminium-based melt
with admixture of silicium, berillium, aluminium oxide and high-melting
component like crystal silicone (RF Patent N 2175682, IPC cl. C22 C 21/02, 1/04
dated from 10.11.2001). It is accepted as the most close prototype of the proposed
invention.
The deficiency of this material is availability of structure inhomogeneity, low
manufacturing plasticity, using toxic beryllium material as an alloying ingredient.
It's known the production method of the composite material, including preparing
the melt containing aluminium, copper, magnesium, addition of silicon carbide
powder (Romanova VS, Trubkina KM "Production of pressed half-finished
product from powder composite and investigation of its properties." S-Pb,
Technology of light alloys, VILS, 1993, N° 12, p.49-53)
The drawback of this method is rather high density of the material, high coefficient
of linear expansion and insufficient dimensional stability.
It's known the production method of the composite material, including preparing
the melt containing aluminium, nickel, silicon, spraying and addition of silicon
powder. (RF Patent N 2149201, IPC cl.C22 C 21/14, 32/00 dated from
20.05.2000).
The lack of this method is instability of material operating characteristics and
uncertainty of its performance during long service life due to structure
inhomogeneity, presence of gas porosity and poor dimensional stability.
It's known the production method of composite material, including preparing the
melt containig aluminium, silicon, nickel, berillium, aluminium oxide, spraying,
2

addition of silicon powder (RF Patent N 2175682, IPC cl. C22 C 21/02, 1/04 dated
from 10.11.2001), accepted as the most close prototype of the proposed invention.
The drawback of this method is impossibility to keep operational characteristics
unchanged during long service life of the product.
Brief summary of the invention.
Assigned task is settled by that the powder composition on the base of aluminium
including silicon, nickel, accordingly to invention, contains in addition
phosphorus and aluminium nitride with the following component ratio, mass %:
- Silicon 41-43%
- Nickel 4,1-5,2%
- Phosphorus 0,05-0,1%
- Aluminium nitride 0,01-0,05%
- Aluminium - remaining
Manufacturing method of the composite mixture including preparing the melt
containing aluminium, silicon, nickel, spraying, supplemented with powdered
silicon, wherein during production process accordingly to invention phosphorus
isinjected in addition, and the melt dispensing is conducted by nitrogen at a
temperature and pressure providing formation of the aluminium nitride in desired
volume.
The proposed composition of powder mixture and its production method allow:
- Firstly, to realize modification action of the original silicon crystals by
complication their growth due to adsorption phosphorus atoms on the
faces of growing crystals and also to enlarge the numbers of
crystallization centers- crystallizable clusters (Sik)
- Secondly, owing to combined interaction of the modification process and
the process of nitride phase formation (AIN) to obtain the highest
cooling rate of the soluble melt and subsequently to reduce the growing
rate and more uniform distribution of an original silicon crystals as well
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as intermetallic phase NiAL3, FeAl3, A1N, A1P in the size of the solid
solution matrix for every particle.
- Thirdly, formation of nitride phase on the juvenile surface powder
particles enables to intensification of diffused processes during the next
redivision powder to half-finished product. This turns out that the
material structure corresponds to an aluminium a-solid solution with
fine-dispersed and uniform distributed in it an extraction of silicon crystal
extraction and intermetallic phase NiAL3, FeAl3, A1N, A1P. The same
structure is characterized by sharp space reduction between silicon
crystals and intermetallic phase and subsequently significant increasing
the contact surface with aluminium matrix.
In this issue the strength of interparticle ties increases which promote to rise
physical-mechanical properties of the material as well as elastic modulus. The
material with high elastic modulus is described by the presence of the hard ties in
the structure when attraction forces effect stronger than repulsion forces.
In this connection elastic modulus is being the reciprocal quantity to the coefficient
of linear expansion, assist that receiving material is less exposed to broadening
under temperature impact.
All these facts assist to obtain the product with a-solid aluminium solution
structure with even distributed in it disperse silicon crystals and intermetallic
phase NiAL3, FeAl3, A IN, A IP, to enlarge mechanical properties, reducing
specific density and the coefficient of linear expansion, to increase a dimensional
stability, vacuum-tightness and process plasticity.
Component content (silicon, nickel, phosphorus, aluminium nitride) less than
stated doesn't make it possible to reach in the matrix of a-solid aluminium solution
the additional dispersion and uniform distribution of the original silicon crystals
and intermetallic phase (like NiAL3, FeAl3, A IN, A IP) and possibility the nitride
phase to be formed. This will result in reducing the strength as well as resistance
of interparticle ties in the whole between alluminium matrix and intermetallic
phase. As a result the strength and plasticity characteristics are reduced, including
4

elastic modulus, the coefficient of linear expansion is growing up, dimensional
stability and the process material plasticity are reduced both. The component
content (silicon, nickel, phosphorus, aluminium nitride) higher than stated due to
the melt remodification leads to increasing the size of original silicon crystals,
which impact negatively on homogeinity structure, and therefore allows to
increase the coefficient of linear expansion, reducing dimensional stability and
process plasticity both.
Realization of the invention.
Examples of production the powder composite mixture:
They took aluminium ingots the quality not lower than A7, crystal silicon grade
KRO, pure nickel N-1, red phosphorous in pressed tablets, wrapped in aluminium
foil, and loaded in smelting furnace, where the melt was produced. When the melt
temperature reached to 1300° C the nitrogen was injected and after exposure time
30 minute the melt was pulverised by nitrogen under the pressure not less than 10
atm. on the powder which then combine with powdered silicon. Powder composite
mixture was filled in process capsules, degassed in vacuum under residual
evacuation 1.10" — 1.10" mm m.c. and then was pressed on the hydraulic press by
effort 950 ton force. Compact material blank was exposed to mechanical treatment
and their physico-mechanical properties were investigated.
Variants of the component contents in powder composite mixtures matched to:
proposed, extreme (with quantity smaller or higher than stated limiting value of the
components in proposed method) and also to well-known the more closed analog
are submitted in the table 1.
The properties of material blocks for the composite materials, manufactured from
investigated powder composite mixtures are submitted in table 2.
Analysis data of physico-mechanical properties of the powder composite
materials, specified in table 2, allows to make a conclusion that the best technical
result is reached when powder composite mixture is used with proposed
component content, which make it possible to obtain the powder composite
5

material, which is superior the well-known material by all determinative features
of such class materials.
Thus using stated component content in powder composite mixture and the
proposed inventive method, we receive the material which exhibited : homogeneity
and fine-dispersion structure, high physico-mechanical properties, low coefficient
of linear expansion, high dimensional stability and the highest vacuum-density.
Thus proposed powder composite mixture makes it possible to obtain a
construction material which exhibits a high operating performance, a high
operational reliability for a long service life and also it is non-toxic and
inexpensive.
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Aluminium-based powder composite mixtures and method for the
production thereof
Table 1
No Mixture Content of the components, % mass


A1203 Be Si Ni P A1N Al
1 Proposed - - 41 4,10 0,05 0,01 the rest


- - 42 4,55 0,075 0,03 the rest


- - 43 5,20 0,10 0,05 the rest
2 Outrageous - - 40,5 3,50 0,03 0,005 the rest


- - 43,5 5,50 0,15 0,10 the rest
3 Well-known (the analog) 2,25 0,03 44,75 4,25 - - the rest
Table 2
No Material ax 10"b, K"1 6,% E,GPa Vacuum-tightness when
8 wall not less, mm Size of the initial
crystals Si, mm
1 Proposed 12,0 1,8 120 0,65"°^ 1-3


12,0 1,8 120 0,65"°^ 1-3


12,2 1,5 115 0,70"^ 1,5-3,5
2 Outrageous 13,0 1,0 102 0,90-°

13,5 0,8 98 1,10^ 5-6
3 Well-known (the analog) 12,5 1,0 105 0,80-°'02 5-6

The claim.
1 .Aluminium-based powder composite mixture containing silicon , nickel, which is
differing that it contains in addition phosphorus and aluminium nitride with the
following component ratio:
41-43 mass% silicon,
4,1 -5,2 mass % nickel
0,05 - 0,1 mass % phosphorus
0,01 - 0,05 mass % aluminium nitride
aluminium - the rest.
2.The inventive method for producing aluminium-based powder composite
mixture, including preparing a melt containing aluminium, silicon, nickel,
dispensing the melt, with creation of powder and then combining the received
powder with silicon powder, is differing that the melt is produced with additional
phosphorus content, subsequently nitrogen is injected and pulverization of the
melt is conducted by nitrogen at a temperature and pressure which enable the
aluminium nitride to be formed.


lb:

8

The invention relates to powder metallurgy and may be used as a construction
material for accurate engineering products including design of control devices for
aircraft flight director systems with high operating features.
The inventive powder composite mixture comprises components with the
following component ratio: 41-41 mass % silicon, 4,1 -5,2 mass % nickel, 0,05 -
0,1 mass % phosphorus, 0.01-0.05 mass % aluminium nitride, the rest being
aluminium.
The inventive method for producing said powder composite mixture consists in
preparing a melt containing aluminium, silicon, nickel, spraying the melt, with
creation of powder and then combining the received powder with silicon powder,
wherein during the melt production with additional phosphorus content,
subsequently nitrogen is injected and the melt pulverization is carried out by
nitrogen at a temperature and pressure which enable the aluminium nitride to be
formed.
Said invention allows to obtain the material with homogenious fine-dispersed
structure and processing plasticity, which ensures a satisfactory deformation
treatment of the product with coefficient of linear expansion, vacuum density and
dimensional stability at berillium level, thereby substantially promoting the
operational reliability of the products for a long service life. The inventive material
in comparison with berillium is ecologically pure.

Documents:

01133-kolnp-2008-abstract.pdf

01133-kolnp-2008-claims.pdf

01133-kolnp-2008-correspondence others.pdf

01133-kolnp-2008-description complete.pdf

01133-kolnp-2008-form 1.pdf

01133-kolnp-2008-form 2.pdf

01133-kolnp-2008-form 3.pdf

01133-kolnp-2008-form 5.pdf

01133-kolnp-2008-international publication.pdf

01133-kolnp-2008-international search report.pdf

01133-kolnp-2008-others.pdf

01133-kolnp-2008-pct request form.pdf

01133-kolnp-2008-translated copy of priority document.pdf

1133-KOLNP-2008-(15-12-2011)-FORM-27.pdf

1133-KOLNP-2008-CANCELLED PAGES.pdf

1133-KOLNP-2008-CORRESPONDENCE 1.1.pdf

1133-KOLNP-2008-CORRESPONDENCE 1.2.pdf

1133-KOLNP-2008-FORM 1 1.1.pdf

1133-KOLNP-2008-FORM 1 1.2.pdf

1133-KOLNP-2008-FORM 13.pdf

1133-kolnp-2008-form 18.pdf

1133-KOLNP-2008-FORM 2 1.1.pdf

1133-KOLNP-2008-FORM 3 1.1.pdf

1133-KOLNP-2008-FORM 3 1.2.pdf

1133-KOLNP-2008-FORM 5 1.1.pdf

1133-KOLNP-2008-FORM 5 1.2.pdf

1133-KOLNP-2008-INTERNATIONAL SEARCH REPORT 1.2.pdf

1133-KOLNP-2008-PA.pdf


Patent Number 247405
Indian Patent Application Number 1133/KOLNP/2008
PG Journal Number 14/2011
Publication Date 08-Apr-2011
Grant Date 05-Apr-2011
Date of Filing 17-Mar-2008
Name of Patentee FEDERALNOE GOSUDARSTVENNOE UNITARNOE PREDPRIJATIE 'NAUCHNOPROIZVODSTVENNYJ TSENTR AVTOMATIKI I PRIBOROSTROENNIJA IM. AKADEMIKA N.A. PILJUGINA'
Applicant Address UL. VVEDENSKOGO, 1, MOSCOW
Inventors:
# Inventor's Name Inventor's Address
1 SHMAKOV, JURIJ VASILIEVICH UL. KUBINKA, 3-1-20, MOSCOW, 121596
2 ZENINA, MARINA VALERIEVNA UL. TOLBUKHINA, 14-65, MOSCOW, 121596
3 ANDRIANOV, KONSTANTIN ALEKSEEVICH UL. SHABOLOVKA, 25-1-55, MOSCOW, 117049
4 VEDERNIKOVA, MARINA ILINICHNA LENINSKY PR-T, 62-205, MOSCOW, 117571
5 MEZHIRITSKIJ, EFIM LEONIDOVICH UL. ARKHITEKTORA VLASOVA, 20-94, MOSCOW, 117393
6 PETRENKO, ALEKSEJ BORISOVICH UL. ADMIRALA LAZAREVA, 47-112, MOSCOW, 117042
7 GOLOVCHANSKIJ, BORIS VLADIMIROVICH UL. 1812 GODA, 8-1-87, MOSCOW, 121170
PCT International Classification Number C22C 21/02,C22C 1/05
PCT International Application Number PCT/RU2006/000441
PCT International Filing date 2006-08-22
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2005126579 2005-08-22 Russia