DE102018213490A1 - Component and method for producing a component - Google Patents

Abstract

Component, in particular die-cast component, comprising at least two components, at least one first component being at least partially embedded in a second component, and wherein the first component has or forms a boundary layer up to which the second component infiltrates the first component, as a result of which a transition zone is formed.

Description

The present invention relates to a component and a method for producing a component or a component assembly.

In the present case, it is in particular a component or a component assembly that comprises several materials or components. From the DE 10 2006 043 852 A1 In this context, for example, a composite casting is disclosed which consists of at least one insert part and a casting material which at least partially surrounds this insert part. The object of the present invention is to create a composite casting in which a different stiffness, in particular bending stiffness, of the composite casting is realized in a simple manner over at least part of the length of the composite casting. In reality, however, the aforementioned different stiffness can lead to problems, since in the area of the transition from the insert to the surrounding casting material, “material notches” or local stiffness jumps can occur, which place a heavy strain on the component in the area of the material transition. Dynamic loads in particular can lead to component failure at an early stage. This problem is exacerbated by the fact that materials with significantly different stiffnesses are generally used, for example a steel material for the insert part and an aluminum material for the casting material.

It is therefore an object of the present invention to provide a component and a method for producing a component which eliminate the aforementioned disadvantages, creating very light components which can withstand the highest loads.

This object is achieved by a component according to claim 1 and by a method for producing a component according to claim 12. Further advantages and features emerge from the subclaims and the description and the attached figure.

According to the invention, a component, in particular a die-cast component, comprises at least two components, at least one first component being at least partially embedded in a second component, and the first component having or forming an interface up to which the second component, in particular along an infiltration direction, thereby forming a transition zone. The boundary layer is therefore advantageously formed within the first component, the term “within” meaning that, depending on the size of the first component, it is at a distance from its edge, for example in a range from approximately 0.1 to 10 mm, in particular depending on the dimensions of the first component. The transition zone is preferably a zone or layer, with a certain thickness, width or thickness, which, according to one embodiment, completely surrounds or envelops the first component. The thickness or thickness is measured along the direction of infiltration. Alternatively, it can also be designed only in regions, for example if the first component is not completely embedded in the second component. In the present case, the two components or their materials advantageously do not “directly” come into contact with one another, but first mix. The transition zone creates an area which is characterized in that both components / materials are present in the area of the transition zone, in other words there is a mixing area, as a result of which a gradual material transition is produced. The transition zone is advantageously an infiltrable, leaking structure. On the one hand, this enables a very good interlock between the two components to be achieved, which has a positive effect on the service life of the component. In addition, a mass ratio of the two components can be adapted to the local loads. According to one embodiment, the component is a body, chassis and / or structural component of a motor vehicle, such as a passenger car or a motorcycle. According to one embodiment, it is an essentially plate-shaped component which has one or more first components which are embedded in a second component. Alternatively, the component can also have or represent complex geometries. The term “embedding” means in particular that the second component surrounds or envelops the first component, as occurs, for example, during a casting. The materials of the first and second components can be metallic and / or non-metallic materials, such as plastics.

According to a preferred embodiment, the first component has a material with a higher modulus of elasticity than the second component or a material of the second component. The first component can advantageously be used in a targeted manner to reinforce or stiffen the component, which, as it were, has the second component as the main component. This has the particular advantage that a transition in stiffness between the different materials can be compensated for by the transition zone. Alternatively, a material of the first component can also have a modulus of elasticity which is below that of the second component.

According to a preferred embodiment, the transition zone is designed in such a way that a stiffness jump in the component is at least reduced. Depending on the design of the transition zone, an approximately linear or regressive decrease in stiffness, for example from the first to the second component, can be set. According to one embodiment, a volume fraction or a concentration of the one, for example the first, component decreases approximately linearly or continuously or regressively towards the other, for example the second, component.

As already indicated, the component is, according to a preferred embodiment, a die-cast component, the first component being a steel insert which is encapsulated by the second component, and the second component being an aluminum material. It is therefore expedient to use an aluminum die-cast component such as is used, for example, in the field of motor vehicle construction. The component can have an essentially “simple” geometric shape, such as a plate-like shape. Alternatively, however, the component can also be used to represent the most complicated geometries, such as that which is present, for example, in a spring dome of a motor vehicle. Basically, the die-cast component is advantageously reinforced by one or more first components, in particular steel inserts or steel inserts, whereby rigidity and strength can be selectively increased and the required installation space can be minimized, since such components can be made significantly thinner than standard cast components without reinforcement.

According to one embodiment, the first component has a pore and / or chamber structure in the transition zone, a pore and / or chamber size increasing in the direction of the second component.
The pore and / or chamber structure is advantageously designed such that infiltration of the first component by the second component is completely possible. The actual size and configuration of the pores and / or the chambers depends on the process control, for example when casting, and on the material properties, in particular the second component.

According to one embodiment, a pore and / or chamber density of the first component increases in the region of the transition zone in the direction of the second component. This advantageously makes it possible to adjust or reduce the abovementioned stiffness jump between the materials of the first component and the second component or to adapt them to the corresponding specifications. The pore and / or chamber density naturally correlates with the pore and / or chamber size or with the geometry and / or configuration of the pores and / or chambers. As a result, according to one embodiment, the pore and / or chamber density can also increase in the direction of the first component.

In general, a porosity of the pore and / or sponge structure is expediently designed or shaped in such a way that it increases or decreases from one material to the other material, as a result of which a graduated and adapted transition or course of the elasticity module is created in the transition zone.

wobei E₁₀ der Elastizitätsmodul des Einlegers bezeichnet, V₁₀ den Volumenanteil des Einlegers, E₂₀ den Elastizitätsmodul des Umgussmaterials und V₂₀ den Volumenanteil des Umgussmaterials im entsprechenden Bereich. Angenommen wird hierbei eine homogene Durchmischung der Werkstoffe.The transition zone is preferably designed in such a way that the modulus of elasticity is reduced or decreased linearly over the width of the transition zone from the first component to the second component, slopes of between 0.5 and 1.5 having proven advantageous here, a slope of 1 , 05 or approximately 1.05 as particularly advantageous (these are the absolute values of the slopes). The aforementioned modulus of elasticity E in the transition zone is calculated as follows: $$e={\mathrm{<figure-callout\; id="10"\; label="e"\; filenames="DE102018213490A1\_0002.png"\; state="\{\{state\}\}">e</figure-callout>}}_{10}*{\mathrm{<figure-callout\; id="10"\; label="V"\; filenames="DE102018213490A1\_0002.png"\; state="\{\{state\}\}">V</figure-callout>}}_{10}+{\mathrm{<figure-callout\; id="20"\; label="e"\; filenames="DE102018213490A1\_0002.png"\; state="\{\{state\}\}">e</figure-callout>}}_{20}*\left(1-V_{20}\right).$$

where E ₁₀ denotes the elastic modulus of the insert, V ₁₀ the volume fraction of the insert, E ₂₀ the elastic modulus of the encapsulation material and V ₂₀ the volume fraction of the encapsulation material in the corresponding area. A homogeneous mixing of the materials is assumed.

According to a preferred embodiment, at least the transition zone is produced by means of an additive process. The use of additive manufacturing processes allows an extremely high degree of geometry and design freedom for a gradual material transition, for example, including mechanical clamping through undercuts, etc. In addition, a wide variety of materials, be it plastics or, in particular, metallic materials, can be processed with additive manufacturing processes.

According to one embodiment, the first component comprises the transition zone, the first component being produced by means of an additive process. In other words, the first component as such is produced by means of an additive manufacturing process, the transition zone being formed in the course of this manufacturing process. Alternatively, however, it is also possible for the first component to be a sheet metal part or the like and / or for the second component to be a mechanical one Processing the first component, for example by means of drilling or eroding.

According to one embodiment, the transition zone is attached to the first component as a separate component. In other words, the transition zone is produced separately from the first component, reference being made to the aforementioned methods for the production thereof. According to one embodiment, a material of the transition zone to a material of the first component can also be designed differently. According to one embodiment, the transition zone can also be, for example, a sponge-like structure which is fastened in a suitable manner to the first component, wherein this sponge-like structure can be formed from a plastic and / or from a metal material. Further alternatively, the transition zone can contain a plurality of layers, which lie one on top of the other along a direction of infiltration, which is directed from the second component to the first component, the layers differing, for example, with regard to their structure or their geometric structure, cf. can distinguish the aforementioned pore and / or chamber structure. Due to the layer structure, the aforementioned stiffness curve can be set very precisely or the stiffness jump can be specifically reduced.

According to one embodiment, a thickness of the transition zone varies. This creates a further degree of freedom to set the stiffness between the two components or, if necessary, to allow a higher stiffness jump at non-critical points. The thickness of the transition zone means in particular the aforementioned distance between the boundary layer and the edge of the component.

According to one embodiment, the transition zone completely or at least partially encloses the first component. In other words, according to one embodiment, the transition zone is arranged or formed completely around the first component. Depending on the application, however, such a complete arrangement can also be dispensed with, for example in order to reduce the production outlay for the first component or the transition zone. An area-wise formation of the transition zone may also be necessary for casting reasons, for example if a transition zone were positioned in such a way that sufficient infiltration of the second component would not be possible, etc.

• - Bereitstellen eines Einlegers zum Umgießen mit einem Umgussmaterial;
• - Anordnen oder Einbringen einer Übergangszone in dem Einleger, welche beim Umgießen von dem Umgussmaterial bzw. mit dem Umgussmaterial infiltriert wird;
• - Umgießen des Einlegers.

Gemäß einer bevorzugten Ausführungsform handelt es sich bei dem Bauteil um ein Druckgussbauteil. Entsprechend bevorzugt handelt es sich bei dem Einleger beispielsweise um einen Stahleinleger bzw. um ein Stahlinsert, welches mit einem vom Werkstoff des Einlegers unterschiedlichen Werkstoff, beispielsweise Aluminium, umgossen wird. Daneben kann es sich bei dem Bauteil aber auch um ein Kunststoffbauteil, wie um ein Spritzgussbauteil, handeln, wobei das Umgießen mit der zweiten Komponente dann vorzugsweise in einem geeigneten Spritzgusswerkzeug erfolgt.The invention also relates to a method for producing a component, comprising the steps:

• - Providing an insert for encapsulation with a encapsulation material;
• Arranging or introducing a transition zone in the insert, which is infiltrated by the encapsulation material or with the encapsulation material during the encapsulation;
• - Pouring over the insert.

According to a preferred embodiment, the component is a die-cast component. Accordingly, the insert is preferably a steel insert or a steel insert, for example, which is cast around with a material different from the material of the insert, for example aluminum. In addition, the component can also be a plastic component, such as an injection molding component, the encapsulation with the second component then preferably taking place in a suitable injection molding tool.

• - Anpassen einer inneren Struktur der Übergangszone entlang einer Infiltrationsrichtung.

Mit Vorteil wird die Übergangszone zwischen den Werkstoffen des Einlegers bzw. des Umgussmaterials, wobei der Einleger der vorgenannten ersten Komponente entspricht und das Umgussmaterial der vorgenannten zweiten Komponente, derart ausgebildet bzw. angepasst, dass ein Steifigkeitssprung zwischen den beiden Komponenten im Übergangsbereich zumindest reduziert ist. In der Folge wird ein äußerst belastbares Bauteil geschaffen, welches sehr flexibel an die verschiedensten Anforderungen anpassbar ist. Zudem wird durch die Übergangszone nicht nur die Lebensdauer eines derartigen Bauteils erhöht, insbesondere durch den reduzierten Steifigkeitssprung, sondern auch die Verklammerung der ersten mit der zweiten Komponente, insbesondere durch den durch die Übergangszone realisierten Formschluss, was unter anderem positive Einflüsse auf die Lebensdauer hat.According to one embodiment, the method comprises the step:

• - Adapting an internal structure of the transition zone along an infiltration direction.

The transition zone between the materials of the insert or the encapsulation material, with the insert corresponding to the aforementioned first component and the encapsulation material to the aforementioned second component, is advantageously designed or adapted such that a jump in stiffness between the two components in the transition region is at least reduced. As a result, an extremely resilient component is created which can be adapted very flexibly to a wide variety of requirements. In addition, the transition zone not only increases the lifespan of such a component, in particular due to the reduced stiffness jump, but also the clinging of the first to the second component, in particular due to the positive connection realized by the transition zone, which among other things has positive effects on the lifespan.

The advantages and features mentioned in connection with the method apply analogously and correspondingly also for the method and vice versa. Further advantages and features result from the following description of a schematic view of an embodiment of a component with reference to the attached figure.

• 1: eine (teilweise) Schnittansicht einer Ausführungsform eines Bauteils in einer schematischen Darstellung.

It shows:

• 1 : a (partial) sectional view of an embodiment of a component in a schematic representation.

1 shows a component comprising a second component 20 , in which a first component 10 is embedded. The component, which has an approximately plate-like shape, is, for example, a cast component, in particular a die cast component. The first component is accordingly 10 for example a steel insert or a steel insert and the second component 20 a casting material, for example an aluminum material. As a special feature it can be seen that in the insert 10 a boundary layer 40 is trained, cf. the dashed line. This forms part of the casting material 20 towards a transition zone 42 from, the encapsulation material in the area of the transition zone 20 the depositor 10 infiltrated. So both materials are available here. As a result, material notches or local stiffness jumps are reduced or even completely compensated for. Such a component can be exposed to the highest dynamic loads and at the same time have very long lifetimes. 1 indicates that the depositor 10 essentially entirely from the transition zone 42 is encased or that the transition zone is the first component 10 completely covers or encloses. The transition zone has a thickness d which is essentially constant in the schematic view shown here. Alternatively, the transition zone can also be adapted to the component geometry or to any casting-related boundary conditions. With the reference symbol R another direction of infiltration is designated, which of the encapsulation material 20 to the depositor 10 is directed towards. For example, the transition zone has a pore and / or chamber structure (not shown here) which runs along the direction of infiltration R is designed differently. The actual design is dependent on the type of materials used and in particular also the material properties and, in the case of a die-cast component, in particular, the technical boundary conditions.

LIST OF REFERENCE NUMBERS

10

first component, insert

20

second component, molding material

40

interface

42

Transition zone

d

thickness

R

infiltration direction

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 102006043852 A1 [0002]

Claims (13)

Component, in particular die-cast component, comprising at least two components (10, 20), wherein at least a first component (10) is at least partially embedded in a second component (20), and wherein the first component (10) has or forms an interface (40) up to which the second component (20) infiltrates the first component (10), whereby a transition zone (42) is formed. Component after Claim 1 , The first component (10) being formed from a material which has a higher modulus of elasticity than a material of the second component (20). Component after Claim 1 or 2 , The transition zone (42) being designed such that a jump in stiffness in the component is at least reduced. Component according to one of the preceding claims, wherein the component is a die-cast component, and wherein the first component (10) is a steel insert, which is encapsulated by the second component (20), and wherein the second component (20) is an aluminum material. Component according to one of the preceding claims, wherein the first component (10) in the transition zone (42) has a pore and / or chamber structure, and wherein a pore and / or chamber size increases in the direction of the second component (20). Component according to one of the preceding claims, wherein the elastic modulus of the first component (10) towards the second component (20) is linearly reduced over a width of the transition zone (42). Component according to one of the preceding claims, wherein at least the transition zone (42) is produced by means of an additive method. Component according to one of the preceding claims, wherein the first component (10) comprises the transition zone (42), and wherein the first component (10) is produced by means of an additive method. Component according to one of the preceding claims, wherein the transition zone (42) is attached as a separate component to the first component (10). Component according to one of the preceding claims, wherein a thickness (d) of the transition zone (42) varies. Component according to one of the preceding claims, wherein the transition zone (42) completely or at least partially encloses the first component (10). Method for producing a component, comprising the steps: - Providing an insert (10) for encapsulation with a encapsulation material (20); - Arranging or introducing a transition zone (42) in the insert (10), which is infiltrated by the encapsulation material (20) during the encapsulation; - Pouring around the insert (10). Procedure according to Claim 12 comprising the step of: - adjusting an internal structure of the transition zone (42) along an infiltration direction (R).

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