DE102018126796A1 - Metal material and method for the production of a component or semi-finished product, and semi-finished product and component, in particular for the aerospace industry - Google Patents

Abstract

A metal material is produced by a spraying process, in which metal or a metal alloy is applied to a surface or into a cavity (10b) of a base body (10), which can be detached from the base body (10) by means of water. In a method for producing a component (50), a base body (10) is provided and a metallic material (20) is applied to a surface or into a cavity (10b) of the base body (10) using a spraying method. The metallic material (20) is coated with a cover layer (30). The metallic material (20) is then dissolved or removed using water, the cover layer (30) remaining. A semifinished product and a component with cavities (10b), in particular for aerospace, are made with the metallic material (20).

Description

The invention relates to a metal material for use in the production of a component or semi-finished product, in particular for aerospace, a method for producing a component or semi-finished product, a semi-finished product for producing a component and a component. The invention is particularly suitable for the aerospace industry.

The invention can be used in any field of technology, but is described below with regard to components and their manufacture in the field of aerospace, in particular components for aircraft and spacecraft.

In the case of aircraft and spacecraft but also in many other areas, such as for example in the manufacture of vehicles or motor vehicles, but also in the case of industrially manufactured components in other areas, the aim is generally to keep the weight as low as possible. There should be no loss of mechanical properties, such as the resilience and rigidity of the components and structures.

The components or structural components to be manufactured often have complex shapes or geometries. For example, they can be curved in three spatial dimensions or have cavities. Cavities are generally understood to mean cavities, recesses, channels, grooves, slots, etc.

In the production of components of this type, the cavities or channels are filled, for example, with a wide variety of pulverized material, the material also being stirred into a liquid matrix, for example. The problem here is that the cavities cannot be emptied or can only be emptied to a limited extent. Chemicals often have to be used to trigger them. The process for the production of components with channels or cavities also requires a lot of time and money. In many cases, expensive production and operating resources are also consumed. In addition, the known materials or material mixtures, for example, cannot be coated with a high-strength metallic coating in order to form bridges.

The object of the invention is to save time and costs in the production of components with channels or cavities, to enable the formation of stable bridges and to reduce the environmental impact.

To achieve the object, the invention provides a metal material for use in the manufacture of a component or semi-finished product, in particular for the aerospace industry, the metal material being produced by an injection molding process in which the metal or a metal alloy is applied to a surface of a base body and / or is applied into a cavity of the base body, and the metal material can be removed from the base body by means of water or a liquid containing water.

The water-containing liquid includes, for example, water-based solutions or emulsions.

The metal material can advantageously be removed by rinsing and / or dissolving by means of water or a liquid containing water.

Metals or metal alloys from the group Al, Sn, Zn are preferably used as spraying agents in the spraying process.

SnZn and Al are advantageously used as spraying agents in the spraying process.

The relative proportions of SnZn / Al are preferably in the range from 20/80 to 70/30.

These are also preferably the percentages of the total weight of the metallic material. For example, the proportion of SnZn is 20% and the proportion of Al 80% of the weight of the metallic material or the spray. The proportion of SnZn can, for example, also be 70% and the proportion of Al 30% of the weight of the spraying agent or the metallic material. Fractions or ratios of SnZn and Al that lie between these limits are preferred. The proportions by weight of SnZn and Al in the metallic material are preferably essentially the same size or in each case in the range of approximately 50% of the weight of the metallic material.
In particular, a relatively small proportion of Mg can additionally be added to the spraying process. For example, this is in the range of 1 to 5%.

Of course, the metallic material, in particular the alloy, can also contain portions of other elements. In particular, small amounts of other elements can be included. More particularly, traces of other elements or impurities can be included. For example, a percentage by weight of other elements is in the range of approximately 5%, 2%, 1% or less.

In particular, the metal material is produced by a thermal spraying process.

The metal material is preferably produced by arc spraying. But he can also by another spraying method such as flame spraying.

1. A - Bereitstellen eines Grundkörpers zum Tragen einer Beschichtung;
2. B - Applizieren eines metallischen Werkstoffs auf eine Oberfläche des Grundkörpers und/oder in eine Kavität des Grundkörpers;
3. C - zumindest teilweises Beschichten des metallischen Werkstoffs mit einer Deckschicht;
4. D - Entfernen des metallischen Werkstoffs vom Grundkörper mittels Wasser oder einer Wasser enthaltenden Flüssigkeit, wobei die Deckschicht bestehen bleibt.

Furthermore, the invention provides a method for producing a component or semi-finished product, in particular for aircraft and spacecraft, comprising the method steps:

1. A - Providing a base body for wearing a coating;
2. B - applying a metallic material to a surface of the base body and / or into a cavity of the base body;
3. C - at least partial coating of the metallic material with a cover layer;
4. D - Removal of the metallic material from the base body by means of water or a liquid containing water, the cover layer remaining.

The metallic material is preferably applied to the surface of the base body by a spraying process and / or introduced into the cavity of the base body.

The metallic material is advantageously processed after application to the base body and before coating with the cover layer.

For example, the metallic material is removed by rinsing or rinsing or dissolving or dissolving with water.

The cover layer preferably comprises metallic material, ceramic material or thermoplastic material, or a combination thereof.

The metallic material advantageously comprises one or more metals or metal alloys from the group Sn, Zn, Al.

The metallic material preferably comprises SnZn and AL.

The relative proportions of SnZn to Al are preferably in the range from 20/80 to 70/30.

These are also preferably the percentages of the total weight of the metallic material. For example, the proportion of SnZn is 20% and the proportion of AI is 80% of the weight of the metallic material. The proportion of SnZn can, for example, also be 70% and the proportion of AI 30% of the weight of the metallic material. Fractions or ratios of SnZn and Al that lie between these limits are preferred. The proportions by weight of SnZn and Al in the metallic material are preferably essentially the same size or in each case in the range of approximately 50% of the weight of the metallic material.

However, other, preferably relatively small amounts of other materials can also be added, in particular Mg. The addition is, for example, one to five%.

In particular, the metallic material is a metal material according to the invention, as generally described above and explained in more detail below.

For example, the metallic material is applied by thermal spraying.

The metallic material is preferably applied by arc spraying.

The metallic material is advantageously applied by a spraying process in which metals or metal alloys from the group Sn, Zn, Al are used as the spraying agent.

In particular, the metallic material is applied by a spraying process in which SnZn and Al are used as spraying agents.

• - in Schritt A werden eine oder mehrere Kavitäten in dem Grundkörper ausgebildet;
• - in Schritt B werden eine oder mehrere Kavitäten mit dem metallischen Werkstoff befüllt;
• - in Schritt C werden eine oder mehrere der mit dem metallischen Werkstoff befüllten Kavitäten beschichtet;
• - in Schritt D werden eine oder mehrere der Kavitäten mit Wasser ausgespült, um den metallischen Werkstoff zu entfernen.

The method advantageously comprises one or more of the following steps:

• - in step A one or more cavities are formed in the base body;
• - in step B one or more cavities are filled with the metallic material;
• - in step C. one or more of the cavities filled with the metallic material are coated;
• - In step D, one or more of the cavities are rinsed out with water in order to remove the metallic material.

• - in Schritt A wird als Grundkörper ein Kern bereitgestellt;
• - in Schritt B wird der metallische Werkstoff auf die Oberfläche des Kerns appliziert;
• - in Schritt C wird der an der Oberfläche des Kerns befindliche metallische Werkstoff an seiner Oberfläche beschichtet oder ummantelt;
• - in Schritt D wird der auf der Oberfläche des Kerns befindliche metallische Werkstoff mit Wasser entfernt, um die als Deckmantel ausgebildete Deckschicht frei entkernt zu erhalten.

The method preferably comprises one or more of the following steps:

• - in step A a core is provided as the base body;
• - in step B the metallic material is applied to the surface of the core;
• - in step C. the metallic material located on the surface of the core is coated or coated on its surface;
• - In step D, the metallic material located on the surface of the core is removed with water in order to keep the outer layer, which is designed as a cover, free of cores.

In one aspect, the invention provides a semi-finished product for producing a component, in particular for aircraft and spacecraft, comprising: a base body for carrying a coating; a metal material which is formed on a surface and / or in a cavity of the base body and is provided with a cover layer; the metal material being removable from the base body and the cover layer by the action of water.

The metal material according to the invention, as described above and described in detail below, is preferably formed. In particular, the metal material is formed by an injection molding process.

It is advantageously used in a method according to the invention.

It is achieved by the invention that time and costs are saved in the manufacture of channels or cavities and thus in the manufacture of the components, and therefore the economy is increased. The invention and in particular the application process according to the invention lead to a very economical and environmentally friendly production of components with cavities or bridges.

In addition, no chemical use is required in the dissolution process of the metal material.

The invention also leads to reusability of the expensive production and operating resources lost in the conventional methods. The invention also enables new process developments and procedures to be implemented.

In particular, the metal material or metallic material can be coated with a high-strength metallic coating, such as, for example, Inconel, stainless steel, etc., in order to form bridges, for example. The invention also offers the advantage that it can be used to produce metallizable, water-soluble coatings with thicknesses of, for example, several millimeters.

• 1 eine schematische Schnittansicht eines Halbzeugs als ein Ausführungsbeispiel der Erfindung, das befüllte Kavitäten aufweist;
• 2a-d verschiedenen Stufen der Herstellung eines Bauteils oder Halbzeugs gemäß einer bevorzugten Ausführungsform der Erfindung, jeweils als schematische Schnittansicht;
• 3a-d verschiedenen Stufen der Herstellung eines Bauteils oder Halbzeugs gemäß einer weiteren bevorzugten Ausführungsform der Erfindung, jeweils als schematische Schnittansicht;
• 4 eine schematische Darstellung einer Anordnung zum Lichtbogenspritzen.

The invention is explained below using the figures as an example. Show:

• 1 a schematic sectional view of a semi-finished product as an embodiment of the invention, which has filled cavities;
• 2a-d different stages of the production of a component or semi-finished product according to a preferred embodiment of the invention, each as a schematic sectional view;
• 3a-d different stages of the production of a component or semi-finished product according to a further preferred embodiment of the invention, each as a schematic sectional view;
• 4th is a schematic representation of an arrangement for arc spraying.

1 shows a semi-finished product as an embodiment of the invention 40 with a basic body 10th that has multiple cavities 10b has that with a metallic material 20th are filled. The cavities 10b are with a top layer 30th that are on the main body 10th is covered. The metallic material 20th is in the cavities by a spraying process 10b trained and by means of water or a liquid containing water from the base body 10th and the top layer 30th removable.

Based on 2a to 2d A first example of the method according to the invention for producing a component or a semi-finished product for a component is explained below.

As in 2a is shown in a first process step A a basic body 10th provided. In this example there are or will be on one side of the body 10th on its surface 10a several cavities 10b in the form of channels or grooves that extend in a direction perpendicular to the plane of the drawing 2a to 2d extend.

The basic body 10th is made of metal, ceramic, plastic, wood, fabric, or fibers, for example. In principle, all materials can be used that can be coated with the spraying method used, in particular arc spraying.

The cavities 10b can be shaped as desired or have a geometry according to the specification of the component or semi-finished product to be manufactured. The basic body 10th can only such a cavity 10b or have recess, or as in this example, an arrangement of several cavities 10b or recesses.

In a second step B , the result of which in 2 B is shown is a metallic material 20th into the cavities 10b applied. The cavities 10b with the metallic material 20th , which is also referred to as a metal material. For this purpose, a known spraying process is used in this example, which may be adapted to the special requirements.

Coating is carried out here with arc spraying. SnZn and AI are used as spray material. The ratio of the proportions of SnZn to Al is preferably in the range from 20% to 80% to 70% to 30%, depending on the desired dissolution behavior. There may also be small proportions of Mg, for example in the range of 1-5%.

The one with the metal material 20th filled body 10th forms a semi-finished product 40 for further processing.

Depending on the requirement, the material 20th or the applied material is now first reworked, or immediately overmolded or coated with a coating process. The same or any other coating process can be carried out.

2c shows the state of the semi-finished product after coating with a top layer 30th (Procedural step C. ). The cavities are used for coating 20th overmolded. In the example shown here is the metallic material 20th now completely with the top layer 30th coated. But it is also possible that the metallic material 20th only partially with the top layer 30th is coated.

Now the overmoulded material 20th removed again with water or rinsed or dissolved, but with the top layer 30th remains present.

2d shows the state after process step D, in which the metallic material 20th from the main body 10th is removed by means of water or a liquid containing water. This is done by rinsing out the cavities 10b . The top layer remains 30th consist.

Depending on the application, the top layer can 30th for example, form protrusions or are present on ridges. The basic body 10th now forms together with the top layer 30th a component 50 which, depending on requirements, can also be used as a corresponding semi-finished product for further processing.

The 3a to 3e show a further preferred embodiment of the method according to the invention in different process stages.

As in 3a shown, a basic body is also shown here first 11 provided, which forms a core for subsequent coating or for carrying a coating (process step A ).

The basic body or core 11 has a curved, for example spherical or cylindrical surface in this example 11a . The core 11 but can also have different and more complex surface geometries.

The basic body 11 is made of metal, ceramic, plastic, wood, fabric, or fibers, for example. In principle, all materials can be used that can be coated with the spraying method used, in particular arc spraying.

Now the metallic material 20th by spraying on the surface 11a of the core 11 applied (process step B ), and then by spraying with a top coat 31 provided (procedural step C. ). This state is in 3b shown. The one with the metallic material 20th coated core 11 forms alone or together with the top layer 31 a semi-finished product 41 .

Coating is carried out here with arc spraying. SnZn and AI are used as spray material. The ratio of the proportions of SnZn to Al is preferably in the range from 20% to 80% to 70% to 30%, depending on the desired dissolution behavior. There may also be small amounts of Mg, for example in the range of 1-5%.

Before applying the top coat 31 can the applied metallic material or the material 20th revised if necessary.

The top layer 31 now forms a spray layer. The one on the surface 11a of the core 11 located metallic material 20th is now on its surface 20a coated or with the top or spray layer 31 encased.

Then the metallic material 20th from the core 11 dissolved or removed by means of water or a liquid containing water. This is done, for example, by rinsing with water. This creates between the core 11 and the cover layer formed as a cover 31 a cavity 25th , as in 3c shown.

This allows the core 11 of the top layer present as a cover 31 can be easily separated so that it is freely cored.

3d shows the core 11 separated or separate cover layer 31 , which now exists as an independent body and a component 51 forms, but can also be used as a semi-finished product for further processing.

The cover layers described in the two exemplary embodiments described above 30th , 31 are made of metallic, ceramic or thermoplastic material, for example.

In 4th an example of a possible arrangement for carrying out the spraying process is shown schematically. In this case, the spraying is carried out by arc spraying. An arc is created between two differently polarized wires 61 , 62 generated.

The first wire 61 in the example shown here is made of SnZn and the second wire 62 is made of AI. The wire ends melt due to the resulting heat. The resulting melt 65 or the molten particles are applied to the base body with an atomizing gas, for example compressed air 10th respectively. 11 hurled.

That is, the melt 65 as described above, on the surface 11a of the basic body or core 11 or in one or more cavities of the base body 10th applied and forms the metallic material or metal material there 20th which can be removed by means of water or a liquid containing water, for example by rinsing or dissolving.

By changing the feeding speed of one or both wires 61 , 62 the amount of the respective metal or metal alloy can be varied. This allows the mixing ratio to be set to the desired value.

If, for example, the feed speed of the first wire in the case described here 61 is the same as the feed speed of the second wire 62 , there is a mixing ratio of SnZn to Al, which is approximately 50/50, that is, the proportions of SnZn and Al in the metallic melt 65 and thus in the metal material 20th are 50% each.

For the formation of the metal material 20th , which is used as a metallic material in the manufacturing process for components or semi-finished products described here, other spraying processes can also be used in addition to arc spraying, such as flame spraying.

When removing or loosening the metal material 20th the originally solid material or the metal alloy is decomposed exothermically by water and pulverized in the process, forming a kind of sludge which remains after drying as a fine powder.

The water for removing or dissolving the metallic material or metal material is preferably free of chemicals, in particular environmentally harmful or aggressive chemicals. This means that, for example, naturally occurring water, drinking water or water from the general water supply or water can be used for industrial purposes.

With the metal material and the method described here, in particular components with cooling channels or other cavities can be manufactured. Reusable cores can be used, for example in mold or tool making. This saves costs for the usually very expensive cores.

One area of application is, for example, in the area of future combustion chamber developments.

In particular, protective layers for sensitive components or devices can also be produced, which are then simply removed again with water.

For example, the material can also be used as an intermediate layer on substrates, which is removed again after metallization. There are also many other possible uses.

Reference list

10th

Basic body

10a

surface

10b

Cavity, recess

11

Basic body, core

11a

surface

20th

Metallic material / metal material

20a

surface

25th

cavity

30, 31

Top layer or spray layer

40, 41

Workpiece

50, 51

Component

61, 62

first and second wire

65

melt

Claims (15)

Metal material (20) for use in the manufacture of a component (50, 51) or semi-finished product (40, 41), in particular for the aerospace industry, characterized in that it is produced by a spraying process in which metal or a metal alloy a surface (10a) and / or in a cavity (10b) of a base body (10, 11) is applied, the metal material being removable from the base body (10, 11) by means of water or a liquid containing water. Metal material after Claim 1 , characterized in that it can be removed by loosening and / or rinsing. Metal material after Claim 1 or 2nd , characterized , 3.1. that metals or metal alloys from the group Al, Sn, Zn are used as spraying agents in the spraying process, and / or 3.2. that SnZn and AI are used as spraying agents in the spraying process, and / or 3.3. that the proportions of SnZn to AI in the spraying process are in the range from 20/80 to 70/30; and / or 3.4. that a relatively small proportion of Mg is additionally added to the spraying process; and / or 3.5. that it is produced by a thermal spraying process, and / or 3.6. that it's made by arc spraying. Method for producing a component (50, 51), in particular for the aerospace industry, comprising the method steps: A - providing a base body (10, 11) for wearing a coating; B - applying a metallic material (20) to a surface (10a) of the base body (10, 11) and / or into a cavity (10b) of the base body (10, 11); C - at least partially coating the metallic material (20) with a cover layer (30, 31); D - Removing the metallic material (20) from the base body (10, 11) by means of water or a liquid containing water, the cover layer (30, 31) remaining. Procedure according to Claim 4 , characterized in that the metallic material (20) is applied to the surface (10a, 11a) of the base body (10, 11) by a spraying process and / or is introduced into the cavity (11b) of the base body (10, 11). Procedure according to Claim 4 or 5 , characterized in that the metallic material (20) is processed after application to the base body (10, 11) and before coating with the cover layer (30, 31). Procedure according to one of the Claims 4 to 6 , characterized in that the removal of the metallic material (20) is carried out by rinsing or dissolving with water. Procedure according to one of the Claims 4 to 7 , characterized in that the cover layer (30, 31) 8.1. includes metallic material, and / or 8.2. includes ceramic material, and / or 8.3. thermoplastic material includes. Procedure according to one of the Claims 4 to 8th , characterized in that the metallic material (20) 9.1. comprises one or more metals or metal alloys from the group Sn, Zn, Al, and / or 9.2. Includes SnZn and AI, and / or 9.3. Includes SnZn and AI, the proportions of which are in the range from 20/80 to 70/30. 9.4. a metal material according to one of the Claims 1 to 4th is. Procedure according to one of the Claims 4 to 9 , characterized in that the application of the metallic material 10.1. done by thermal spraying, and / or 10.2. by arc spraying, and / or 10.3. is carried out by a spraying process in which metals or metal alloys from the group Sn, Zn, Al are used as the spraying agent, and / or 10.4. by a spraying process in which SnZn and AI are used as spraying agents. Procedure according to one of the Claims 4 to 10th , characterized by one or more of the following steps: 11.1. in step A, one or more cavities (10b) are formed in the base body (10); 11.2. in step B one or more cavities (10b) are filled with the metallic material (20); 11.3. in step C one or more of the cavities (10b) filled with the metallic material (20) are coated; 11.4. in step D, one or more of the cavities (10b) are rinsed out with water in order to remove the metallic material (20). Procedure according to one of the Claims 4 to 11 , characterized by one or more of the following steps: 12.1. in step A, a core is provided as the base body (11); 12.2. in step B the metallic material (20) is applied to the surface (11a) of the core (11); 12.3. in step C, the metallic material (20) located on the surface of the core (11) is coated or coated on its surface (20a); 12.4. In step D, the metallic material (20) located on the surface (11a) of the core (11) is removed with water or a liquid containing water in order to keep the cover layer (31) designed as a cover coat free of cores. Semifinished product (40, 41) for producing a component (50, 51), in particular for aerospace, comprising: a base body (10, 11) for carrying a coating; a metal material (20) which on a surface (10a) and / or in a cavity (11b) of the Basic body (10, 11) is formed and provided with a cover layer (30, 31); wherein the metal material (20) can be removed from the base body (10, 11) and the cover layer (30, 31) by the action of water or a liquid containing water. Semi-finished product Claim 13 , characterized in that the metal material according to one of the Claims 1 to 3rd is formed and / or in a method according to one of the Claims 4 to 12th is used. Component (50, 51), in particular for the aerospace industry, characterized in that it is made using a metal material according to one of the Claims 1 to 3rd and / or with a method according to one of the Claims 4 to 12th and / or with a semi-finished product Claim 13 or 14 is made.

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