Sinterable metal powder mixture for the production of sintered components

Abstract

The present invention relates to sinterable powder compositions, sintered components produced therefrom, and methods for prepared such components. Sinterable powder compositions are composed of an aluminum-based powder, and a first metal powder comprising molybdenum and/or tungsten. The aluminum based powder is composed of aluminum and magnesium, silicon, copper, zinc, titanium, tin, manganese, nickel, or combinations thereof. In another embodiment, the sinterable powder composition includes a second metal powder comprising copper, tin, zinc, lithium, magnesium, or combination thereof. The sinterable powder compositions may be used for the production of sintered components, including composite components, having not only sufficient strength values but also with high hardness.

1 . A sinterable powder composition for the production of sintered components comprising: 
 (a) at least 60 weight percent of an aluminum-based powder, based on the weight of the sinterable powder composition, comprising:    aluminum, and    from 0.2 to 30 weight percent magnesium, from 0.2 to 40 weight percent silicon, from 0.2 to 15 weight percent copper, from 0.2 to 15 weight percent zinc, from 0.2 to 15 weight percent titanium, from 0.2 to 10 weight percent tin, from 0.2 to 5 weight percent manganese, from 0.2 to 10 weight percent nickel, or combinations thereof based on the weight of the aluminum based powder; and    (b) from 0.8 to 40 weight percent of a first metal powder comprising molybdenum, tungsten or combinations thereof, based on the weight of the sinterable powder composition.    
     
     
         2 . The sinterable powder composition of  claim 1  wherein the aluminum based powder further comprises up to 1 weight percent of arsenic, antimony, cobalt, beryllium, lead, boron, or combinations thereof, based on the weight of the aluminum-based powder.  
     
     
         3 . The sinterable powder composition of  claim 1 , wherein the aluminum based powder is composed of: 
 aluminum, and    from 0.2 to 15 weight percent magnesium, from 0.2 to 16 weight percent silicon, from 0.2 to 10 weight percent copper, from 0.2 to 15 weight percent zinc, or combinations thereof, based on the weight of the aluminum-based powder.    
     
     
         4 . The sinterable powder composition of  claim 1 , wherein the first metal powder is a prealloy.  
     
     
         5 . The sinterable powder composition of  claim 1 , further comprising a second metal powder comprising copper, tin, zinc, lithium, magnesium, or combination thereof.  
     
     
         6 . The sinterable powder composition of  claim 5 , wherein the second metal powder is a prealloy.  
     
     
         7 . The sinterable powder composition of  claim 5 , wherein the ratio of the weight percent of the first metal powder to the weight percent of the second metal powder is from 1:8 to 15:1.  
     
     
         8 . The sinterable powder composition of  claim 5 , wherein the ratio of the weight percent of the first metal powder to the weight percent of the second metal powder is from 2:1 to 6:1.  
     
     
         9 . The sinterable powder composition of  claim 5 , wherein the second metal powder is composed of copper, tin, zinc, or combination thereof.  
     
     
         10 . The sinterable powder composition according to  claim 1 , further comprising from 0.2 to 5 weight percent of at least one lubricant, based on the weight of the sinterable powder composition.  
     
     
         11 . The sinterable powder composition of  claim 10 , wherein the at least one lubricant is MoS 2 , WS 2 , BN, MnS, or carbon.  
     
     
         12 . The sinterable powder composition of  claim 1 , further comprising polyvinyl acetate, an amide wax, or combinations thereof.  
     
     
         13 . The sinterable powder composition of  claim 12 , wherein the amide wax comprises polyvinyl acetate, ethylene-bisstearoylamide, shellac, polyalkylene oxide, polyalkylene polyglycol, or combinations thereof.  
     
     
         14 . A sintered component comprising the sinterable powder composition of  claim 1 .  
     
     
         15 . The sintered component of  claim 14 , wherein the sintered component has a tensile strength of at least 140 N/mm 2 .  
     
     
         16 . Sintered component of  claim 14 , wherein the sintered component has an elasticity modulus of at least 70 kN/mm 2 .  
     
     
         17 . Sintered component of  claim 15 , wherein the sintered component has an elasticity modulus of at least 70 kN/mm 2 .  
     
     
         18 . Sintered component of  claim 14 , wherein the sintered component has a hardness of at least 100, at 2.5 mm and 62.5 kg.  
     
     
         19 . A method of preparing sintered components comprising: 
 (a) providing the sinterable powder composition of  claim 1;     (b) filling a mold with the sinterable powder composition;    (c) pressing the sinterable powder composition to form a green compact;    (d) at least partially post-compressing said green compact; and    (e) sintering the post-compressed green compact.    
     
     
         20 . The method of  claim 19 , further comprising the step of dewaxing the green compact before partially post-compressing the green compact.  
     
     
         21 . The method of  claim 19 , wherein the density of the partially post-compacted green compact is from 2% to 60% greater than the density before partial post-compaction.  
     
     
         22 . The method of claims  19 , further comprising the step of applying a lubricant to said mold.  
     
     
         23 . The method of  claim 19 , wherein said sintering is performed under nitrogen with a dew point below at least −45° C.