# US 10,478,895 B2 · Porous aluminum sintered compact and method of producing porous aluminum sintered compact

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- Number: US 10,478,895 B2
- Document ID: US10478895B2
- Status: Granted
- Kind: B2
- Application number: 15/302,374
- Filed: 2015-05-18
- Published: 2017-02-02
- Granted: 2019-11-19
- Earliest claimed: 2014-05-16
- Assignees: Mitsubishi Materials Corporation
- Applicants: Mitsubishi Materials Corporation
- Inventors: Ji-Bin Yang; Koichi Kita; Toshihiko Saiwai; Koji Hoshino; Jun Katoh
- Web page: https://patentgrep.com/patent/US10478895B2

## CPC

- B22F 3/1103: {with particular physical characteristics}
- B22F 1/10: Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F 1/16: Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10)
- B22F 1/17: Metallic particles coated with metal
- B22F 3/11: Making porous workpieces or articles
- 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)
- C22C 1/08: Alloys with open or closed pores
- C22C 21/00: Alloys based on aluminium
- C22C 21/06: with magnesium as the next major constituent
- C22C 32/0089: {with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass}
- C22C 49/06: Aluminium
- B22F 1/062: Fibrous particles
- B22F 3/1118: {comprising internal reinforcements}
- B22F 2301/052: Aluminium
- B22F 2301/058: Magnesium
- B22F 2301/15: Nickel or cobalt
- B22F 2301/205: Titanium, zirconium or hafnium
- B22F 2302/45: Others, including non-metals
- B22F 2998/10: Processes characterised by the sequence of their steps
- Y10T 428/12479: Porous [e.g., foamed, spongy, cracked, etc.]
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A high-quality porous aluminum sintered compact, which can be produced efficiently at a low cost; has an excellent dimensional accuracy with a low shrinkage ratio during sintering; and has sufficient strength, and a method of producing the porous aluminum sintered compact are provided. The porous aluminum sintered compact is the porous aluminum sintered compact that includes aluminum substrates sintered each other. The junction, in which the aluminum substrates are bonded each other, includes the Ti—Al compound and the eutectic element compound capable of eutectic reaction with Al. It is preferable that the pillar-shaped protrusions projecting toward the outside are formed on outer surfaces of the aluminum substrates, and the pillar-shaped protrusions include the junction.

## Claims

### Claim 1

A porous aluminum sintered compact comprising a plurality of aluminum substrates sintered to each other,
wherein the aluminum substrates are made of aluminum fibers or both of aluminum fibers and an aluminum powder,
a fiber diameter of the aluminum fiber is in a range of 50 μm or more and 1000 μm or less,
a junction in which the plurality of aluminum substrates are bonded to each other includes a Ti—Al compound and a eutectic element compound including a eutectic element capable of eutectic reaction with Al, and
a plurality of pillar-shaped protrusions projecting toward an outside are formed on outer surfaces of the aluminum substrates, and the pillar-shaped protrusions include the junction.

### Claim 2 (depends on 1)

The porous aluminum sintered compact according to claim 1, wherein a porosity of the porous aluminum sintered compact is in a range of 30% or more and 90% or less.

### Claim 3 (depends on 2)

The porous aluminum sintered compact according to claim 2, wherein the porosity of the porous aluminum sintered compact is in a range of 65.9% or more and 90% or less.

### Claim 4 (depends on 1)

A method of producing a porous aluminum sintered compact including a plurality of aluminum substrates sintered to each other, the method comprising the steps of:
forming an aluminum raw material for sintering by adhering a titanium powder, which is made of any one of or both of a titanium metal powder and a titanium hydride powder, and a eutectic element powder made of a eutectic element capable of eutectic reaction with Al on outer surfaces of the aluminum substrates;
spreading the aluminum raw material for sintering on a holder; and
sintering the aluminum raw material held on the holder by heating, wherein
the porous aluminum sintered compact according to claim 1 is produced,
the aluminum substrates are made of aluminum fibers or both of aluminum fibers and an aluminum powder,
a fiber diameter of the aluminum fiber is in a range of 50 μm or more and 1000 μm or less, and
the plurality of the aluminum substrates are bonded through a junction including a Ti—Al compound and a eutectic element compound including the eutectic element capable of eutectic reaction with Al.

### Claim 5 (depends on 4)

The method of producing a porous aluminum sintered compact according to claim 4, wherein
a nickel powder is used as the eutectic element powder in the step of forming an aluminum raw material for sintering;
a content amount of the titanium powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 20 mass % or less; and
a content amount of the nickel powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 5 mass % or less.

### Claim 6 (depends on 4)

The method of producing a porous aluminum sintered compact according to claim 4, wherein
a magnesium powder is used as the eutectic element powder in the step of forming an aluminum raw material for sintering;
a content amount of the titanium powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 20 mass % or less; and
a content amount of the magnesium powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 5 mass % or less.

### Claim 7 (depends on 4)

The method of producing a porous aluminum sintered compact according to claim 4, wherein
a copper powder is used as the eutectic element powder in the step of forming an aluminum raw material for sintering;
a content amount of the titanium powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 20 mass % or less; and
a content amount of the copper powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 5 mass % or less.

### Claim 8 (depends on 4)

The method of producing a porous aluminum sintered compact according to claim 4, wherein
a silicon powder is used as the eutectic element powder in the step of forming an aluminum raw material for sintering;
a content amount of the titanium powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 20 mass % or less; and
a content amount of the silicon powder in the aluminum raw material for sintering is set in a range of 0.01 mass % or more and 15 mass % or less.

### Claim 9 (depends on 4)

The method of producing a porous aluminum sintered compact according to claim 4, wherein the step of forming an aluminum raw material for sintering comprises the steps of:
mixing the aluminum substrates; and the titanium powder and the eutectic element powder, in a presence of a binder; and
drying a mixture obtained in the step of mixing.