Powder metal polymer composites

Abstract

A composite part including: a compacted powder composition; and a polymer composite comprising nanometer-sized and/or micrometer-sized reinforcement structures, wherein the composite part has an interpenetrating network between the compacted powder composition and the polymer composite and wherein the reinforcement structures comprise one or more of: particles, platelets, fibers, whiskers, and tubes. A composite part formed by a method including compacting a powder composition including a lubricant into a compacted body; heating the compacted body to a temperature above the vaporization temperature of the lubricant such that the lubricant is substantially removed from the compacted body; subjecting the obtained heat treated compacted body to a liquid polymer composite including nanometer-sized and/or micrometer-sized reinforcement structures; and solidifying the heat treated compacted body comprising liquid polymer composite by drying and/or by at least one curing treatment.

1 . A composite part comprising:
 a compacted powder composition; and   a polymer composite comprising nanometer-sized and/or micrometer-sized reinforcement structures,   wherein the composite part has an interpenetrating network between the compacted powder composition and the polymer composite and wherein the reinforcement structures comprise one or more of:
 particles, 
 platelets, 
 fibers, 
 whiskers, and 
 tubes. 
   
     
     
         2 . The composite part according to  claim 1 , wherein at least two dimensions of the reinforcement structures are below 5 μm. 
     
     
         3 . The composite part according to  claim 1 , wherein the reinforcement structures comprise carbon nanotubes. 
     
     
         4 . The composite part according to  claim 1 , wherein the powder composition comprises a soft magnetic powder. 
     
     
         5 . The composite part according to  claim 3 , wherein the powder composition comprises a soft magnetic powder. 
     
     
         6 . The composite part according to  claim 1 , wherein the powder composition comprises an iron-based powder. 
     
     
         7 . The composite part according to  claim 3 , wherein the powder composition comprises an iron-based powder. 
     
     
         8 . The composite part according to  claim 1 , wherein the composite part shows a mechanical strength more than 100 MPa at above 150° C. 
     
     
         9 . The composite part according to  claim 5 , wherein the composite part shows a mechanical strength more than 100 MPa at above 150° C. 
     
     
         10 . The composite part according to  claim 7 , wherein the composite part shows a mechanical strength more than 100 MPa at above 150° C. 
     
     
         11 . The composite part according to  claim 1 , wherein the composite part has a density above 7.0 g/cm 3  and a TRS above 100 MPa at 150° C. 
     
     
         12 . The composite part according to  claim 5 , wherein the composite part has a density above 7.0 g/cm 3  and a TRS above 100 MPa at 150° C. 
     
     
         13 . The composite part according to  claim 7 , wherein the composite part has a density above 7.0 g/cm 3  and a TRS above 100 MPa at 150° C. 
     
     
         14 . A composite part produced according to a method for producing a composite part, the method comprising:
 compacting a soft magnetic powder composition comprising a lubricant into a compacted body;   heating the compacted body to a temperature above the vaporization temperature of the lubricant such that the lubricant substantially is removed from the compacted body;   subjecting the obtained heat treated compacted body to a liquid polymer composite comprising carbon nanotubes; and   solidifying the heat treated compacted body comprising liquid polymer composite by drying and/or by at least one curing treatment,   wherein the composite part has a density above 7.0 g/cm 3  and a TRS above 100 MPa at 150° C.   
     
     
         15 . The composite part according to  claim 14 , wherein the soft magnetic powder composition comprises an iron-based powder.