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摘要:
铝及铝合金具有密度低、耐腐蚀、比强度高、导热性良好等特性，常被用于轻量化、功能化零部件，广泛应用于交通运输、电子产品、医疗以及化工等领域。铝合金金属粉末注射技术能实现精细复杂结构铝合金制品的低成本高效制造，具有力学性能优良、组织均匀、尺寸精度高、原料利用率高等优点，对推动铝合金注射成形零部件的产业化进程，加速其在电子信息产品、医疗器械、新能源汽车中的应用具有重要作用。本文介绍了铝合金金属粉末注射成形的发展现状，综述了铝合金注射成形用喂料制备要求，分析了粘结剂组分设计、脱脂方式、气氛烧结制度及合金元素对烧结致密化的作用机制，并展望了铝合金粉末注射成形亟待解决的问题与发展方向。
Abstract:Aluminum and aluminum alloys have the characteristics as low density, corrosion resistance, high specific strength, and good thermal conductivity, which are widely used in transportation, electronic products, medical, and chemical industries as the lightweight and functional components. Metal powder injection (MIM) can achieve the low-cost and efficient manufacturing of the fine and complex aluminum alloy products, exhibiting the satisfactory mechanical properties, uniform microstructure, and high dimensional accuracy. Development of Al-MIM technology plays an important role in promoting the industrialization of injection molded Al alloy parts and accelerating the application in electronic information products, medical devices, and new energy vehicles. The development status of metal powder injection molding for aluminum alloys was introduced in this paper, the effects of feeding requirements, binder composition design, degreasing method, atmosphere sintering system, and action mechanism on the sintering densification were reviewed, and the problems to be solved and the development direction were prospected.
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Keywords:
- aluminum alloys /
- metal powder injection molding /
- binder /
- degreasing /
- sintering densification
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图 5 铝合金注射成形喂料粘结剂设计的影响要素及其评价方法
Figure 5. Influencing factors and evaluation methods of the feeding binder design for the aluminum alloy injection molding
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图 6 铝合金粉末注射成形三种脱脂方式及其主要特点
Figure 6. Three typical debinding methods of the Al-MIM and the corresponding characteristics
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图 9 热脱脂模型示意图：（a）初始阶段；（b）连通孔隙形成；（c）低熔点组元脱除；（d）高熔点组元脱除
Figure 9. Schematic diagram of the thermal degreasing model: (a) initial stage; (b) connected pore formation; (c) removal of low melting point components; (d) removal of the high melting-point components
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图 11 Al–Si合金在不同烧结温度（保温时间1 h）和不同保温时间（烧结温度550 ℃）条件下的力学性能[17]：（a）相对密度，1 h；（b）硬度，1 h；（c）抗拉强度，1 h；（d）相对密度，550 ℃；（e）硬度，550 ℃；（f）抗拉强度，550 ℃
Figure 11. Mechanical properties of the Al–Si alloys sintered at different sintering temperatures (1 h) for different sintering times (550 ℃)[17]: (a) relative density, 1 h; (b) hardness, 1 h; (c) tensile strength, 1 h; (d) relative density, 550 ℃; (e) hardness, 550 ℃; (f) tensile strength, 550 ℃
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图 12 Al–Cu–Mg合金及添加合金元素后烧结显微组织[62]：（a）Al–3.8Cu–1Mg；（b）Al–3.8Cu–1Mg–0.1Sn；（c）Al–3.8Cu–1Mg–0.7Si；（d）Al–3.8Cu–1Mg–0.7Si–0.1Sn
Figure 12. Microstructures of the Al–Cu–Mg alloys added with different elements after sintering[62]: (a) Al–3.8Cu–1Mg; (b) Al–3.8Cu–1Mg–0.1Sn; (c) Al–3.8Cu–1Mg–0.7Si; (d) Al–3.8Cu–1Mg–0.7Si–0.1Sn
表 1 铝合金及钛铝合金的粘结剂体系及注射成形构件的力学性能
Table 1 Binder systems of the Al and Ti–Al alloys and the mechanical properties of injection molded components
材料体系
（质量分数）粉末粒径 /
µm粘结剂 组分（质量分数） 粘结剂含量 温度 / ℃ 气氛 相对密度 / % 抗拉强度 / MPa 参考文献 7429Al 35 蜡基 PW+HDPE +SA+PJ 40%（质量分数） 720 真空 98.2 96 [16] Ti47Al 30 PW+PE+SA 32%（体积分数） 1360 氩气 — — [21] Al–Si 10 62%CW+35%HDPE+3%SA 27%（质量分数） 550 氮气 95.5 154 [17] 6061Al+2%Sn 6061Al为10
Sn为4352%CW+45%HDPE+3%SA 17%（质量分数） 620 氮气 97.0 165 [18] 6061Al+2%Sn+10%AlN 6061Al为10
Sn为43
AlN为5CW+HDPE+SA 17.5%
（质量分数）640 氮气 97.1 84 [20] Ti45Al 30 PW+LDPE+PP+SA+LPW+PEG+
Naphthalene32%（体积分数） 1480 真空 — — [23] Al — POM基 POM+Lucry G55 28%（质量分数） 665 氮气 90.0 [25] 231Al — POM+表面活性剂 30%（质量分数） 665 真空 92.0 — [25] Ti–6Al–4V 30 86%POM+5%HDPE+5%EVA+2%SA+
2%PW40%（质量分数） 1280 真空 94.8 — [23] Ti–6Al–4V 20 其他 PEG+PMMA+SA 40%（体积分数） 1330 真空 — — [24] 
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表 2 不同烧结气氛下铝合金烧结的密度、硬度与尺寸变化率[51]
Table 2 Density, hardness, and dimensional change rate of the sintered Al alloys in different sintering atmospheres[51]
烧结气氛 密度 / (g·cm−3) 相对密度 / % 硬度，HRB 尺寸变化率 / % 高纯氮气 2.66 97.1 23 −1.65 分解氨 2.45 89.4 12 3.82 高纯氢气 2.43 88.7 8 5.02 高纯氩气 2.48 90.5 6 3.07
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表 3 6061Al+Sn+AlN复合材料在不同烧结温度和热处理条件下力学性能[19]
Table 3 Mechanical properties of the 6061Al+Sn+AlN composites sintered and heat-treated in different conditions[19]
热处理条件 相对密度 / % 硬度，HRH 屈服强度 / MPa 抗拉强度 / MPa 伸长率 / % 630 ℃下烧结 94.7±0.6 75.3±1.7 80.8±3.5 134.6±23.6 1.66±0.88 635 ℃下烧结 96.4±0.4 80.2±0.9 82.0±3.6 149.7±28.3 2.33±1.88 640 ℃下烧结 97.1±0.1 80.2±0.9 84.0±3.6 184.7±9.2 6.63±3.26 645 ℃下烧结 96.9±0.1 80.0±1.4 79.5±2.4 168.3±16.7 4.65±2.48 640 ℃下烧结并T4处理 97.1±0.1 92.0±0.9 118.7±3.2 263.3±5.8 8.1±0.52 640 ℃下烧结并T6处理 97.1±0.1 96.9±0.7 — 264.3±11.1 — AA6061+2Sn烧结 97.5±0.4 68.2±2.4 75.0±7.2 157.0±11.3 9.47±3.77 AA6061+2Sn T4处理 97.5±0.4 81.8±2.8 78.2±3.4 208.8±4.2 10.41±0.69 AA6061+2Sn T6处理 97.5±0.4 96.1±0.5 278.6±13.1 303.2±19.3 — 注：T4处理，525 ℃处理1 h，水淬，自然时效250 h；T6处理，525 ℃处理1 h，水淬，175 ℃人工时效8 h。
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