DE102020115980A1 - Method for producing a flat fiber composite material, a flat fiber composite material, a stack arrangement and the use of a flat fiber composite material - Google Patents

Abstract

The invention relates to a method for producing a flat fiber composite material (20), characterized bya) connecting continuous fibers (1) in and / or on a matrix (2) comprising a MIM feedstock for producing a first molded part (11), wherein the first molded part (11) is formed as a flat structure during production, b) debinding of the first molded part (11) to produce a second molded part (12) and c) subsequent sintering of the second molded part (12) to produce the flat fiber composite material (20) ). The invention also relates to a flat fiber composite material, a stack arrangement of flat fiber composite materials and a use.

Description

The present disclosure relates to a method for producing a flat fiber composite material with the features of claim 1, a flat fiber composite material with the features of claim 10, a stack arrangement with flat fiber composite materials with the features of claim 11 and a use of a flat fiber composite material or a stack arrangement with the features of claim 13.

Mechanical components - for example in aircraft engines - are exposed to considerable mechanical loads, such as centrifugal forces, during operation. It is known, among other things, to manufacture these components from heavy-duty metals or metal alloys. From the U.S. 5,876,659 A1 or the DE 10 2004 008337 A1 For example, uses of fiber-reinforced composite materials for blades of turbo machines are known.

The object is to create means with which, in particular, mechanical loads in components can be counteracted in a targeted manner.

According to a first aspect, a method for producing a flat fiber composite material having the features of claim 1 is provided

The flat fiber composite material is produced in a sequence of steps.

First, continuous fibers are connected in and / or on a matrix, the matrix having a powder-binder mixture, in particular an MIM feedstock. In principle, powder-binder mixtures for the production of molded parts are also known from the field of additive manufacturing processes. A first molded part is then produced in this way, the first molded part being designed as a flat structure.

Debinding of the first molded part then takes place later in order to produce a second molded part which, after debinding, is also flat.

The second molded part is then subsequently sintered to produce the flat fiber composite material. The flat fiber composite material can be rolled up on a roll, for example, so that it can be used again later. In principle, the flat fiber composite material can then be used in connection with a component, e.g. by connecting it to the component. The flat fiber composite material can also itself - e.g. as a layer - be a component that is used e.g. in an aircraft engine.

For the material of the MIM feedstock (MIM: metal injection molding) of the matrix, iron, titanium, light metals, copper and / or nickel or an alloy of iron, titanium, light metals and / or nickel can be used. These materials offer high strength and high temperature resistance, which is particularly important for use in aircraft engines.

In one embodiment, the continuous fiber can be a silicon carbide fiber or comprise a silicon carbide fiber. SiC fibers are high-strength and temperature-resistant ceramic fibers. Additionally or alternatively, the continuous fibers can have a coating, in particular with titanium carbide, titanium nitride, boron nitride, SCS and / or metal coatings.

Continuous fibers can be unrolled from a tape, for example, but have a length of at least 50 mm.

In one embodiment, the flat fiber composite material can be designed as a plate, film or strip, the ratio of cross-sectional width to cross-sectional height being between 3 and 80, in particular between 5 and 60. With a ratio of cross-section width to cross-section height of 80, a type of film is present. With a ratio of cross-sectional width to cross-sectional height of 3, the flat fiber composite material could be referred to as a tape. For practical applications, in particular in the area of an aircraft engine, the band can have a cross-sectional width of 10 to 30 mm, in particular 15 to 20 mm, and a cross-sectional height of 0.5 to 2 mm.

In a further embodiment of the method, a tape or the film can be wound onto a roll after sintering. This enables good storage options and efficient further processing.

In a further embodiment, the first molded part can be produced by extrusion, calendering, injection molding or pressing, the continuous fibers being mixed with the material of the matrix prior to processing and / or the continuous fibers being separately connected to the material of the matrix during processing. In any case, the continuous fibers are sheathed by the matrix material (i.e. the powder-binder mixture, in particular the MIM feedstock).

The object is also achieved by a flat fiber composite material with the features of claim 10. The flat fiber composite material can also be used in multiple layers in the form of a stack arrangement with the features of claim 11. It is particularly possible that the at least two layers of the flat fiber composite material are welded to one another by means of a laser.

In a further embodiment, the flat fiber composite material or the stacked arrangement can serve for the targeted reinforcement of a component, the reinforcement being in particular in an area of particular mechanical stress. The component can, for example, be a metallic component, a ceramic component or a component made of composite materials, in particular in an aircraft engine.

• 1 schematisch eine erste Ausführungsform eines Verfahrens zur Herstellung eines flächigen Faserverbundmaterials;
• 2 schematisch eine zweite Ausführungsform eines Verfahrens zur Herstellung eines flächigen Faserverbundmaterials;
• 3A eine schematische Querschnittansicht eines ersten Formteils, bei dem die Endlosfasern im Inneren der Matrix des ersten Formteils angeordnet sind;
• 3B eine schematische Querschnittansicht eines ersten Formteils, bei dem die Endlosfasern an der Außenseite der Matrix des ersten Formteils angeordnet sind;
• 4 eine schematische Darstellung einer Extrusion zur Herstellung des ersten Formteils;
• 5 eine schematische Darstellung einer Kalandriervorrichtung zur Herstellung des ersten Formteils;
• 6 eine schematische Darstellung einer Pressenvorrichtung zur Herstellung des ersten Formteils;
• 7 eine schematische Darstellung einer Stapelanordung von flächigen Faserverbundmaterialien;
• 8 eine schematische Darstellung einer Anwendung am Umfang einer Turbinenscheibe.

Embodiments are described below by way of example with the aid of figures. It shows

• 1 schematically a first embodiment of a method for producing a flat fiber composite material;
• 2 schematically a second embodiment of a method for producing a flat fiber composite material;
• 3A a schematic cross-sectional view of a first molded part, in which the continuous fibers are arranged in the interior of the matrix of the first molded part;
• 3B a schematic cross-sectional view of a first molded part, in which the continuous fibers are arranged on the outside of the matrix of the first molded part;
• 4th a schematic representation of an extrusion for the production of the first molded part;
• 5 a schematic representation of a calendering device for producing the first molded part;
• 6th a schematic representation of a press device for producing the first molded part;
• 7th a schematic representation of a stack arrangement of flat fiber composite materials;
• 8th a schematic representation of an application on the periphery of a turbine disk.

The following is based on the 1 the production of a flat fiber composite material 20th shown schematically with a first embodiment of the method.

Flat is understood here to mean a fiber composite material whose cross section is in the width direction B. is much greater than in height H (please refer 3A , 3B) , wherein the cross section of the fiber composite material is essentially constant in the longitudinal direction.

Typical configurations of a flat fiber composite material 20th are plates, tapes or foils. All of these configurations are flat and have a constant cross section in the longitudinal direction. This differs from components made from composite materials, which are three-dimensionally complex in shape.

In one embodiment of the flat fiber composite material 20th continuous fibers in and / or on a matrix with a powder-binder mixture, in particular MIM feedstock 7th (MIM: metal injection molding) connected. The MIM feedstock 7th basically corresponds to the feedstock known from powder metallurgical injection molding processes. In the following we mainly use MIM feedstock 7th used as an example of a powder-binder mixture.

MIM feedstock 7th is a mixture of a powder 5 (especially metal powder) and a thermoplastic binder 6th . These starting materials are subjected to a mixing (or plasticization, granulation) 100, so that finally MIM feedstock 7th is present. This is then one of the starting materials for the embodiments of the method.

In a first process step, endless bevels are made 1 with a matrix 2 (including the MIM feedstock 7th ) for the production of a first molded part 11 used, the first molding 11 is formed as a flat structure during manufacture. For shaping 101 of the first molding 11 In principle, various processes are possible (e.g. extrusion, calendering, etc.), which will be discussed below.

In the 1 is shown that the connection of the continuous fibers 1 and the MIM feedstock 7th before shaping 101 he follows. This can be done, for example, by mixing the continuous fibers 1 with the granules of the MIM feedstock 7th respectively. In connection with the 2 an alternative embodiment of the method is shown.

After shaping 101 So there is a kind of green part from the MIM feedstock 7th and filaments 1 before, which has a flat design, for example in the form of an extruded tape.

In a next step, this is the first molded part 11 a debinding 102 subjected so that a second molded part 12th is produced, which would correspond to a brown part in the known injection molding process. The second molding 12th is naturally also formed flat.

Finally the second molding 12th subjected to sintering 103 so that finally the flat fiber composite material 20th is present. In the embodiment shown, the flat fiber composite material is 20th a tape that is rolled up into a roll from which it can be easily unrolled in use, as will be described below.

In the 2 a modification of this first embodiment is shown so that reference can be made to the above description.

In the second embodiment, the filaments are continuous 1 - unlike in the first embodiment - to be added during processing, ie during manufacture 101 of the first molding 11 .

Otherwise, the sequence of the method steps corresponds to the first embodiment according to FIG 1 .

In addition, the embodiments can also be combined with one another, so that continuous fibers 1 before and during manufacture 101 of the first molding 11 with the matrix 2 can be connected.

As a manufacturing process for the first molded part 11 For example, extrusion can be used with continuous fibers 1 continuously into the extrusion path inside an extrusion tool during extrusion 201 be introduced (see 4th ). Thereby the continuous fibers 1 continuously from the extrusion mass (here MIM feedstock 7th ) enveloped. A first molded part obtained therewith 11 is in 3A shown in a sectional view.

However, it is additionally or alternatively possible that the continuous fibers 1 - similar to a coextrusion - when exiting the extrusion tool 201 outside on the first molding 11 be applied. 3B shows in cross section the variant in which the continuous fibers 1 are applied outside.

Based on the representations of the 3A and 3B can also be shown what is meant by a flat fiber composite material in connection with the method presented here 20th is understood. The flat fiber composite material 20th can be designed, for example, as a plate, film or tape, with the ratio of the cross-sectional width B. to cross-section height H is between 3 and 80, in particular between 5 and 60.

In any case it is possible to use the continuous filaments 1 continuously fed into the extrusion process via rollers, as shown schematically in FIG 4th is shown. The extruder 200 becomes MIM feedstock 7th continuously fed. This plastically deformable mass is then passed through the extrusion tool 201 pressed, with continuous fibers 1 continuously from a role 204 in extrusion tool 201 to be introduced.

Alternatively, the production of the first molded part 11 also take place by means of a calendering system. The MIM feedstock 7th by a sequence of calender rolls 202 that led to the MIM feedstock 7th and the filaments 1 bring it into a flat shape.

The continuous fibers would be introduced in a similar manner 1 take place in the context of an injection molding machine.

In 5 shows a schematic representation of a calendering system in which continuous filaments 1 be introduced into the process by a role (not shown here). This is where the MIM feedstock 7th from above between two counter-rotating calender rolls 202 introduced, with continuous fibers 1 are fed into the material flow from above. Two more calender rolls 202 then ensure that a flat molding 11 will be produced.

In a further embodiment, the flat first molded part 11 by a pressing system according to 6th getting produced. The MIM feedstock 7th in the direction of the arrow on a press roller 203 moved past. In front of the press roller 203 are of a role 204 Continuous fibers 1 into the matrix 2 of the MIM feedstock 7th then introduced by the press roller 203 be pressed. For example, a sandwich method can be used, ie a MIM feedstock layer, a continuous fiber layer, a MIM feedstock layer.

In all cases there is a flat fiber composite material at the end 20th before, which can be wound up on a roll, for example.

As a MIM feedstock 7th iron, titanium, cobalt, light metals, copper and / or nickel or an alloy of iron, titanium, cobalt, light metals and / or nickel can be used.

The continuous fiber 1 can for example be a silicon carbide fiber or have a silicon carbide fiber. The continuous fibers can 1 have a coating, in particular with titanium carbide and / or titanium nitride

In 7th is the use of flat fiber composite materials 20th described by way of example in connection with a component (not shown here).

A stack arrangement with four layers lying on top of one another is shown in cross section 21 flat fiber composite materials 20th , for example with With the help of a laser as part of a laser induction roll cladding process.

The connection between the individual layers 21 can for example after shaping 101 of the first molding 11 take place, ie before debinding 102 , after debinding 102 or even after sintering. Basically 2, 3 or more than four layers can be used 21 in a stacked arrangement of flat fiber composite materials 20th be used.

In 8th is a detail of a component 30th , here the outer circumference of a turbine disk, shown. The flat fiber composite material is on the outer circumference 20th arranged, either as a layer or as a multi-layer stacked arrangement. The continuous fibers 1 are inside the flat fiber composite material 20th arranged along the circumferential direction and thus reinforce the turbine disk and the blades arranged thereon (not shown here), in particular against the effects of centrifugal force.

In principle, it is also possible to use the flat fiber composite material 20th in the form of a band around a component 30th wrapping around to reinforce it mechanically. This can be done during the manufacture of the component 30th or as part of a repair of the component 30th respectively.

It should be understood that the invention is not limited to the embodiments described above and various modifications and improvements can be made without departing from the concepts described herein. Any of the features can be used separately or in combination with any other features, provided that they are not mutually exclusive, and the disclosure extends to and includes all combinations and subcombinations of one or more features described herein.

List of reference symbols

1

Continuous fiber

2

matrix

5

Metal powder

6th

thermoplastic binder

7th

Powder-binder mixture, MIM feedstock

11th

first molding

12th

second molding

20th

flat fiber composite material

21

Layer in a stack arrangement made of flat fiber composite materials

30th

Component

100

mixer

101

Shaping for the first molded part

102

Debinding

200

Extruder

201

Extrusion tool

202

Calender rolls

203

Press roll

204

Roll for flat fiber composite material

B.

Width of the cross section of a flat fiber composite material

E.

Direction of extrusion

H

Height of the cross section of a flat fiber composite material

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely 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

• US 5876659 A1 [0002]
• DE 102004008337 A1 [0002]

Claims (14)

A method for producing a flat fiber composite material (20), characterized by a) connecting continuous fibers (1) in and / or on a matrix (2) comprising a powder-binder mixture, in particular MIM feedstock for producing a first molded part (11 ), the first molded part (11) being formed as a flat structure during production, b) debinding of the first molded part (11) to produce a second molded part (12) and c) subsequent sintering of the second molded part (12) for production the flat fiber composite material (20). Procedure according to Claim 1 , characterized in that the material of the MIM feedstock (7) of the matrix (2) comprises iron, titanium, cobalt, light metals, copper and / or nickel or an alloy of iron, titanium, cobalt, light metals and / or nickel. Procedure according to Claim 1 or 2 , characterized in that the continuous fiber (1) is a silicon carbide fiber or has a silicon carbide fiber. Method according to at least one of the preceding claims, characterized in that the continuous fibers (1) have a coating, in particular with titanium carbide, titanium nitride, boron nitride, SCS and / or a metal coating. Method according to at least one of the preceding claims, characterized in that the continuous fibers (1) have an average length of more than 50 mm. Method according to at least one of the preceding claims, characterized in that the flat fiber composite material (20) is designed as a plate, film or tape, the ratio of cross-sectional width to cross-sectional height being between 3 and 80, in particular between 5 and 60. Procedure according to Claim 6 , characterized in that the band (20) has a cross-sectional width of 10 to 30 mm, in particular 15 to 20 mm, and a cross-sectional height of 0.5 to 2 mm. Procedure according to Claim 6 or 7th , characterized in that the tape (20) or the film (20) is wound onto a roll after sintering. Method according to at least one of the preceding claims, characterized in that the first molded part (11) is produced by extrusion, calendering, injection molding or pressing, the continuous fibers (1) being mixed with the material of the matrix (2) before processing and / or the continuous fibers (1) are connected separately to the material of the matrix (2) during processing. Flat fiber composite material (20), in particular producible with one of the methods according to at least one of the Claims 1 until 9 , characterized in that continuous fibers (1) are arranged in a metal-containing matrix (2) of a flat fiber composite material (20). Stack arrangement of at least two superimposed flat fiber composite materials according to Claim 10 . Stack arrangement according to Claim 11 , characterized in that the at least two layers of the flat fiber composite material (20) are welded to one another by means of a laser. Use of a flat fiber composite material (20) after Claim 10 or a stacking arrangement Claim 11 or 12th , characterized in that the flat fiber composite material 20 the stack arrangement is used for the targeted reinforcement of a component (30) in an area of particular mechanical stress. Use after Claim 13 , characterized in that the component (30) is a metallic component, a ceramic component or a component made of composite materials, in particular in an aircraft engine.

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