Method of producing aluminum composite material

Abstract

A manufacturing method of an aluminum composite material having excellent abrasion resistant and vibration damping properties is disclosed. The aluminum composite material is manufactured by impregnating a perform with an aluminum alloy the perform is formed by mixing an alumina fiber and graphite or activated charcoal and an inorganic binder in water and sintering the resultant mixed product at a predetermined sintering temperature under vacuum, in an inert gas, or in a reducing gas.

1 . A method of manufacturing an aluminum composite material comprising the steps of: 
 mixing alumina fibers, graphite, and an inorganic binder in water;    dehydrating the mixture;    forming a preform from the dehydrated mixture by sintering at a predetermined sintering temperature under vacuum, in an inert gas, or in a reducing gas; and    processing to impregnate said preform with an aluminum alloy by pressure casting.    
   
   
       2 . A method of manufacturing an aluminum composite material comprising the steps of: 
 mixing alumina fibers, activated charcoal, and an inorganic binder in water;    dehydrating the mixture;    processing to form a preform from the dehydrated mixture by sintering at a predetermined sintering temperature under vacuum, in an inert gas, or in a reducing gas; and    processing to impregnate said perform with an aluminum alloy by pressure casting.    
   
   
       3 . A method of manufacturing an aluminum composite material according to  claim 1;   wherein particle diameters of said graphite are in the range of 0.1 μm to 100 μm.    
   
   
       4 . A method of manufacturing the aluminum composite material according to  claim 2;   wherein particle diameters of said activated charcoal are in a range of 0.1 μm to 100 μm.    
   
   
       5 . A method of manufacturing the aluminum composite material according to  claim 2;   wherein said activated charcoal comprises a porous structure.    
   
   
       6 . A method of manufacturing the aluminum composite material according to  claim 1;   wherein an average diameter of said alumina fiber is in a range of 1 μm to 10 μm, and;    an average length of said alumina fiber is in a range of 10 cc/5 gf to 100 cc/5 gf.    
   
   
       7 . A method of manufacturing the aluminum composite material according to  claim 1;   wherein said sintering temperature is in a range of 600° C. to 1600° C.    
   
   
       8 . A method of manufacturing the aluminum composite material according to  claim 1;   wherein said aluminum impregnating process is adapted to form a layered structural material which comprises an aluminum alloy layer and a composite material layer in which the aluminum alloy is impregnated in the preform.    
   
   
       9 . A method of manufacturing an aluminum composite material comprising the steps of: 
 mixing alumina fibers, graphite, and an inorganic binder in water;    dehydrating the mixture;    forming a preform from the dehydrated mixture by sintering at a predetermined sintering temperature under vacuum, in an inert gas, or in a reducing gas and under conditions to prevent a reaction between the graphite and the alumina fibers, while permitting the mixture to coagulate due to the presence of the inorganic binder; and    processing to impregnate said preform with an aluminum alloy by pressure casting.