シリコンアルミニウム合金のプロセスと分類

Basic Process of Silicon Aluminum Alloy

1. Melting and Casting Method
   The melting and casting method is the most common and cost-effective way to prepare alloy materials, often used in large-scale industrial production of steel sheet and aluminized sheet. This method is beneficial due to its simple equipment and low cost. しかし, it has limitations, such as uneven silicon distribution in high-silicon aluminum alloys, cracking during skinning and processing, and component segregation. These issues become more prominent as silicon content increases, making high-silicon aluminum alloys difficult to prepare using conventional casting methods, especially when considering applications involving aluminized sheet.

2. Infiltration Method
   The infiltration method includes pressure infiltration and pressureless infiltration techniques. In pressure infiltration, mechanical or gas pressure helps the base metal melt infiltrate the gaps of the reinforcement, overcoming the non-wetting issue of reinforcement material and metal liquid. しかし, this method’s complexity limits its application and development, especially when working with steel sheet or aluminized materials in industrial processes.

3. Powder Metallurgy
   Powder metallurgy involves mixing aluminum powder, silicon powder, and a binder in specific proportions. The mixture is formed through dry pressing, injection, or other methods and then sintered under a protective atmosphere to create a dense material. This process improves silicon particle wettability and reduces the difficulty of adding silicon particles to the melt. It also enables one-time forming and minimizes material cutting. こうしたメリットがあるにもかかわらず、, powder metallurgy is complex, difficult to control, and costly, particularly for industries sourcing steel sheet or aluminized sheet from suppliers.

4. Vacuum Hot Pressing Method
   Vacuum hot pressing combines pressurized molding and sintering. The powder is placed in a mold cavity, pressurized, and heated under vacuum conditions to form a dense material quickly. This process offers short sintering times and high-density materials, which can be advantageous in the creation of aluminized sheet products. しかし, the complex process and limited operability restrict its use in high-silicon aluminum alloy preparation.

5. Rapid Cooling/Spray Deposition
   Rapid cooling or spray deposition technology addresses the challenges of complex processes and oxidation. It is a form of rapid solidification technology and has gained popularity in recent years for creating high-quality steel sheet and aluminized sheet products. This method prevents macrosegregation, produces fine and uniform crystals, and offers better hot working performance. It also maintains low oxygen content and produces high-quality materials suitable for various applications.

Classification of Silicon Aluminum Alloys:

• Hypoeutectic Silicon Aluminum Alloy: Silicon content ranges from 9% に 12%.
• Eutectic Silicon Aluminum Alloy: Silicon content ranges from 11% に 13%.
• Hypereutectic Silicon Aluminum Alloy: Silicon content exceeds 12%, typically between 15% そして 20%.
• High Silicon Aluminum Alloy: Silicon content exceeds 22%, with common values between 25% そして 70%. The highest known silicon content reaches up to 80%. Aluminized suppliers often focus on these higher silicon contents for better material properties.