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Process for producing sintered sialon ceramic

A manufacturing method, Sialon's technology, applied in the supporting elements of blades, nanotechnology for material and surface science, nanotechnology, etc., can solve problems such as difficulty in obtaining three-dimensional complex shapes, and achieve the effect of good dimensional accuracy

Inactive Publication Date: 2012-01-04
IHI CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, in the manufacturing method disclosed in this patent, since the binder is water, although simple spherical and sheet-shaped products such as bearing balls can be obtained, it is difficult to obtain products with turbine wheels and vane nozzles. The three-dimensional complex shape products required for automobile parts represented by nozzle) parts

Method used

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  • Process for producing sintered sialon ceramic
  • Process for producing sintered sialon ceramic
  • Process for producing sintered sialon ceramic

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0100] Sialon ceramic sintered products were produced by the method of the present invention. Molding materials, heating and kneading conditions, injection molding conditions, degreasing conditions, sintering conditions, etc. are as follows. 100 compacts of 35 mm x 35 mm x 3 mm were formed, and degreasing, presence or absence of defects after sintering, and measurement of sintered density were performed.

[0101] The average particle size of sialon powder is 0.5μm (composition formula Si 5 AlON 7 )

[0102] ·Sintering aid: yttrium oxide

[0103] Organic binder composition: PVB (molecular weight 15,000) 15 volume%, PEG (molecular weight 2,000) 45 volume%, amorphous polyolefin 5 volume%, polybutylmethacrylate 15 volume%, ethylene vinyl acetate copolymer Stearic acid 15 volume %, stearic acid 5 volume %

[0104] ・Sialon powder: 90% by weight Yttrium oxide: 10% by weight

[0105] Molding material: organic binder 48% by volume Sialon powder + sintering aid 52% by volume

[0...

Embodiment 2

[0136] Various researches and experiments were conducted on the types and amounts of sintering aids and the composition of organic binders. The molding conditions, extraction degreasing conditions, drying conditions, and heating degreasing conditions were carried out under the same conditions as in Example 1. The conditions and results used in the experiment are shown in Tables 2-4.

[0137] 【Table 2】

[0138] Compounding of powder (sialon powder and sintering aid)

[0139]

[0140] 【table 3】

[0141] Composition of organic binder (vol%)

[0142] PVB15000

PVB180000

PEG1500

PEG2000

PEG10000

EVA

APOs

PBMA

St.

a

15

-

-

45

-

5

15

15

5

b

10

-

50

-

-

5

16

16

3

c

3

-

-

50

-

10

16

16

5

d

0

-

-

50

-

15

...

Embodiment 3

[0151] It can be seen from the above examples and other experiments that in order to stably manufacture sialon sintered products with a wall thickness of 1mm or more, it is preferable to use a suitable organic binder (organic binder containing specific PVB and PEG). The extraction and degreasing process is carried out. In order to further study a suitable organic binder, various organic binders were used, except for the composition of the organic binder, in the same manner as in Example 1 to manufacture a product of 35 mm×35 mm×3 mm. The results are summarized in Table 5.

[0152] In addition, the remainder of the organic binder was mixed with EVA, PBMA, and stearic acid in the compounding ratio shown in Table 5.

[0153] 【table 5】

[0154]

[0155] As shown in Table 5, when the amount of PVB added is less than 5% by volume, the strength of the molded body tends to decrease, and when the amount of PVB added exceeds 30% by volume, it remains as carbides during thermal degr...

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Abstract

A process for producing a ceramic product having a high density and a complicated three-dimensional shape, through injection molding using a Sialon powder. The process is characterized by comprising the steps of: preparing a molding material comprising a Sialon powder (A), a sintering aid (B), and an organic binder (C), in which the Sialon powder (A) is a powder having an average particle diameter of 0.01-3.0 [mu]m, the sintering aid (B) is an oxide of an element selected from a group consisting of Y, Yb, Al, and Zr and is contained in an amount of 0.5-15 wt.% relative to the total of the Sialon powder (A) and the sintering aid (B), and the organic binder (C) comprises 5-30 vol.% polyvinyl butyral having an average molecular weight of 150,000 or lower and 35-80 vol.% polyethylene glycol having an average molecular weight of 5,000 or lower, the organic binder (C); being contained in an amount of 30-70 vol.% relative to the total of the molding material; injection-molding the molding material to obtain a molded object; heating and degreasing the molded object; and sintering the molded object.

Description

technical field [0001] The invention relates to a method for obtaining a Sialon ceramic sintered product by using Sialon (a kind of silicon aluminum oxynitride ceramic) powder. More specifically, it relates to a method of manufacturing sialon ceramic sintered products by ceramic powder injection molding (CIM method). Background technique [0002] In recent years, resource depletion has become a very big problem. In particular, the buried amount of iron ore in the earth's crust is less than 5%, and the problem of depletion in the future is worrying. [0003] Therefore, from the viewpoint of efficient use of resources, the spread of ceramic materials that effectively utilize silicon is considered to be an urgent task. In the second half of the 1970s, fine ceramics became popular, so it was considered to use lightweight and high heat-resistant ceramics using silicon nitride, silicon carbide, and sialon (SiAlON) for automotive engine parts. However, the method of synthesizing...

Claims

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Application Information

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IPC IPC(8): C04B35/599B28B1/24C04B35/632F01D5/28F02B39/00
CPCC04B35/632C04B35/63416C04B35/638B28B1/24C04B2235/3217C04B2235/3869C04B2235/5454C04B2235/3224C04B2235/5436F05D2230/22C04B2235/656C04B2235/9661C04B2235/94C04B2235/6022C04B35/63424C04B2235/3244C04B2235/5445C04B2235/3225F05D2220/40C04B2235/77F05D2300/222F01D5/048C04B35/63488C04B35/6342B82Y30/00C04B35/6455C04B2235/606C04B35/597C04B2235/6567C04B2235/6562
Inventor 寒川喜光中川胜则
Owner IHI CORP
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