EP0605915A2 - Verfahren zur Herstellung einer ausfallsicheren verbundgegossenen Metallstruktur - Google Patents

Verfahren zur Herstellung einer ausfallsicheren verbundgegossenen Metallstruktur Download PDF

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Publication number
EP0605915A2
EP0605915A2 EP93203492A EP93203492A EP0605915A2 EP 0605915 A2 EP0605915 A2 EP 0605915A2 EP 93203492 A EP93203492 A EP 93203492A EP 93203492 A EP93203492 A EP 93203492A EP 0605915 A2 EP0605915 A2 EP 0605915A2
Authority
EP
European Patent Office
Prior art keywords
groove
rod
metal
molten metal
fibres
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP93203492A
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English (en)
French (fr)
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EP0605915B1 (de
EP0605915A3 (de
Inventor
Mark Robert Morgan
Harry Junior Couch
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Motors Liquidation Co
Original Assignee
Motors Liquidation Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Motors Liquidation Co filed Critical Motors Liquidation Co
Publication of EP0605915A2 publication Critical patent/EP0605915A2/de
Publication of EP0605915A3 publication Critical patent/EP0605915A3/de
Application granted granted Critical
Publication of EP0605915B1 publication Critical patent/EP0605915B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form

Definitions

  • the present invention relates generally to a method of die-cast moulding a metal directly onto a fibre-reinforced plastics body to form a structure as specified in the preamble of claim 1, for example as disclosed in EP-A-0 501 537.
  • a structure formed pursuant to the method of the present invention includes a pre-selected failure site to control separation of the cast metal from the plastics body when the structure is subjected to excessive tensile loads.
  • Links generally formed as elongated metallic members having eyelets on each end, are well-known in the automotive industry.
  • links are used to connect various components in a suspension system.
  • a link can be subject to compressive, tensile and shear loads.
  • Fibre-reinforced plastics typically referred to as FRP hereinafter, may find increasing usage in the automotive industry, despite its higher cost, because of its high strength-to-weight ratios.
  • FRP Fibre-reinforced plastics
  • one problem with substituting FRP for metal in any automotive component is the fact that it is difficult or impossible to form FRP into shapes that are convoluted or discontinuous.
  • FRP may serve well for use in making a drive shaft, which is an elongated tube of constant cross-section, but not for use in making a transmission case, with its labyrinthine internal passages.
  • Another limitation is that many automotive components must be attached directly to another metal component at some point, which may require that the FRP component be provided with a localised metal fastening member.
  • an FRP drive shaft must have a metal connector at each end for attachment to the remainder of the drive line. It is difficult to successfully and securely mate FRP directly to metal, especially when the attachment point will be subject to heavy loading and stress.
  • Many patents are directed just to the problem of joining metal end pieces to FRP drive shafts, most of which disclose procedures which involve the use of various adhesives, rivets, splines or combinations thereof.
  • the designer of an FRP link would face both problems noted above.
  • the main body of a link is basically a rod or beam with a fairly constant cross-section and a smooth exterior surface, presenting no particular protrusions or discontinuities. This is a basic shape that would lend itself well to FRP manufacture.
  • a matrix of full-length, reinforcing glass fibres soaked with a conventional thermosetting resin is formed in a mould with the desired beam shape, and then heat-cured.
  • each end of the beam must be connected to other structures, e.g., between a suspension support and a wheel assembly support. Die-casting a metal eyelet directly to the end of an FRP beam would be preferable, in terms of time, cost and strength, to attaching a separate connector by adhesive or mechanical means.
  • thermosetting resin that binds the glass fibres together decomposes badly at the melting temperatures of suitable metals, such as aluminium alloy.
  • suitable metals such as aluminium alloy.
  • a particular aspect of a joint between an FRP body and a metal must be addressed when the component is subject to tensile loads. Under excessive tensile loads, the metal may completely pull away from the FRP member. If the component is a link, e.g., an FRP rod connected to a metal eyelet, complete separation of the eyelet from the rod under excessive tensile loads is unsatisfactory.
  • a link e.g., an FRP rod connected to a metal eyelet
  • a method of increasing the ultimate elongation of a cast structural component according to the present invention is characterised by the features specified in the characterising portion of claim 1.
  • the present invention comprises an improved a method for making a structure in which metal is die-cast directly onto a fibre-reinforced plastics body. Thermal alteration of the binding resin results in a bonding interface between the FRP body and metal. Furthermore, the structure is formed so that, if excessive tensile loads are incurred, a pre-selected failure will occur in the metal prior to the complete separation of the metal from the FRP body. This pre-selected failure provides a safety factor in load-carrying applications such as links since the bonding interface between a portion of the metal continues to resist separation from the FRP body.
  • the present invention includes a method for manufacturing a structural component including the step of forming a groove in an outer surface of a fibre-reinforced body. Molten metal is introduced to an exposed surface of the groove and to a predetermined portion of the outer surface of the body. The metal is cooled in a controlled manner so as to thermally alter sufficient resin to create a secure interconnection of the metal with the body. The metal adjacent the groove is sized so that it will fail prior to separation of the metal from the body under excessive tensile loads. A portion of the metal remains on the body so that elongation of the component significantly exceeds ultimate elongation of the fibre-reinforced body and the cast metal.
  • a moulding apparatus for use with the present invention is illustrated as a cold-chamber, die-casting machine indicated generally at 10 in Figure 1.
  • Machine 10 is of the type that has two main halves, called die holders or master dies 12.
  • the master dies 12 are the foundation of the apparatus, supporting such features as cooling water lines 14, a sprue spreader 16, and leader pins 18.
  • a shot chamber 20 and plunger 22, illustrated best in Figure 2, which are used to send a charge of molten metal 24 into the machine 10 are supported on the master die 12 opposite the sprue spreader 16.
  • the master dies 12 support a pair of smaller unit dies, indicated generally at 26 and 28. It is the unit dies 26 and 28 that actually form the moulded shape desired, allowing machine 10 to be used to make several different components.
  • Each unit die 26 and 28 is a steel block, measuring 228.6mm by 76.2mm by 127mm (9 by 3 by 5 inches), and therefore provides a significant heat-sink mass in and of itself. Furthermore, each unit die 26 and 28 makes intimate surface-to-surface contact with the interior of the master die 12 that supports it, thereby providing additional heat-sink mass.
  • Each unit die 26 and 28 has a matching cavity 30 (see Figures 3 and 4) machined therein, the basic dimensions of which, X1 to X7 in millimetres (inches), are 31.75 (1.25), 25.4 (1.0), 50.8 (2.0), 19.05 (0.75), 107.95 (4.25), 3.175 (0.125), and 6.35 (0.25) respectively. An enlarged end is formed in each cavity 30.
  • Unit die 28 has a pair of locator pins 32 in its cavity 30 as well as a cooling water passage 34, but is identical to unit die 26 otherwise. In use, the unit dies 26 and 28 would be vertically opposed to one another, but are shown in a horizontal position in Figure 4 for ease of illustration. Whilst machine 10 as disclosed is basically conventional, it should be understood that it would normally be used simply to cast a solid part of metal only.
  • Body 36 is a short beam of constant rectangular cross-section, with a 152.4mm (6 inch) length, 25.4mm (1 inch) width, and a 6.35mm (1 ⁇ 4 inch) thickness. It is manufactured by first laying up a matrix of full-length glass reinforcing fibres 38 lengthwise within a mould that has the same shape as body 36. The content of fibres 38 in the body 36 is about 72% by weight. Then, a thermo-setting resin 40, which in this case is an amine-cured bisphenol-A epoxy resin system, is injected around the bundle of fibres 38.
  • a thermo-setting resin 40 which in this case is an amine-cured bisphenol-A epoxy resin system
  • the composite material thus obtained is then heat-cured under pressure in the mould at 121°C (250°F) for approximately ten minutes, and post-cured out of the mould at 154°C (310°F) for about fifteen minutes. Finally, a pair of holes 42 are drilled in the body 36 to match the locator pins 32 of unit die 28.
  • Metal 24 is a standard 380 aluminium alloy, which is commonly used in die-casting, and which has a melting-point of 660°C (1220°F). Whilst the glass fibres 38 can withstand such a high temperature, this temperature is substantially beyond the temperature that the resin 40 could be expected to withstand without suffering very significant decomposition, even to the point of total structural failure of the part. In fact, tests showed that a sample like body 36, when dipped into molten aluminium for a time comparable to a normal moulding cycle time, did suffer debilitating thermal decomposition. Thus, it was expected that an untreated, unprotected part like body 36 would never survive having molten aluminium die-cast to it. Nevertheless, a method for doing so was developed and is described next.
  • the interior surfaces of the enlarged ends of the mated cavities 30 are close to the exterior surface of the end of body 36, so the surrounding chamber they create is symmetrical, with a basic thickness of 3.175mm (one eighth of an inch), as measured perpendicular to the surface of body 36.
  • a charge of molten metal 24 is forcibly pushed in to the chamber from shot chamber 20 by plunger 22, and fills the chamber around the end of body 36 completely in less than a tenth of a second.
  • Non-illustrated vents and wells in the unit dies 26 and 28 are provided to accommodate the displaced air as the molten metal 24 enters the chamber around the end of body 36 under pressure.
  • an inner jacket-like envelope is established at the interface of metal 24 with the external surfaces of body 36, and a surrounding outer jacket-like envelope is established at the interface between metal 24 and the inner surfaces of the cavities 30.
  • a relatively rapid outer heat flow from molten metal 24 to the unit dies 26 and 28 is immediately established at the outer envelope, which is visually represented by the longer arrows in Figure 8.
  • the radially-outward heat flow from molten metal 24 results from the large heat-sink mass of the unit dies 26 and 28 and the master dies 12, an effect that is aided by the circulation of cooling water through water lines 14 and water passage 34. Water is pumped through at a flow rate of approximately 75.71 dm3 (20 gallons a minute).
  • Heat flow from the molten metal 24 is also kept rapid and even by the relative thinness of the filled volume around the end of body 36, and by the symmetry of the volume described above.
  • the unit dies 26 and 28 are kept closed for about ten seconds, during which time the metal 24 cools to about 260°C (500°F) and solidifies.
  • the steady-state operation temperature of the unit dies 26 and 28 has been measured to be about 177°C (350°F).
  • the end product is illustrated in Figure 9.
  • the unit dies 26 and 28 are opened and the completed part, consisting of body 36 and now-solidified metal end member 44, is ejected and water-cooled to room temperature.
  • a black substance is sometimes observed to ooze out and solidify in a small, shiny pool indicated at 46 at the joint between the surface of body 36 and metal member 44, which is further explained below.
  • the body 36 has not decomposed or burned to the point where it has been eaten through or has fallen off, but its response to heavy loading is more important as to proof of production feasibility.
  • the completed part is not used as an actual component, but as a tensile test specimen to indicate that feasibility.
  • an automotive link formed according to the die-cast moulding method described above is indicated generally at 100 in Figure 12.
  • the link 100 can be designed for compressive and tensile loading, and can be adapted for a variety of applications, including between a knuckle and spindle assembly 122 and a cradle 124 in a vehicular suspension system 120 as illustrated in Figure 15.
  • Such a suspension link 100 is a load-bearing member subjected to alternating tensile and compressive forces during operation of a vehicle.
  • Various elastomeric bushings (not illustrated) and fasteners (not illustrated) can be used to secure each end of the link 100 to a desired support.
  • the completed part i.e., the link 100, includes an elongated rod 102.
  • the rod 102 is a FRP body made with full-length glass reinforcing fibres 101 in a thermo-setting resin 103.
  • the rod 102 is preferably formed by a pultrusion process. In this process, continuous fibres 101 are pulled into a resin wet-out bath where the fibres 101 are saturated with liquid resin 103. Then the fibres 101 are drawn from the bath through a squeeze-out die, which controls the fibre/resin ratio, and into a heated final forming die where the thermo-setting resin 103 hardens and cures.
  • the solid composite material thus formed is pulled out of the final forming die by in-line pulling units which grip the composite material and work in tandem to pull the material through the entire process continuously.
  • a flying cut-off unit cuts the composite material into predetermined lengths.
  • a circumferential groove 104 is provided at a predetermined depth and width near each end portion of the rod 102.
  • the rod 102 has a smooth, continuous outer circumference and the groove 104 is a uniform channel cut in the circumference.
  • other rod cross-sections and groove configurations are within the scope of the present invention.
  • a casting is formed as an eyelet 106 in unit dies similar to unit dies 26 and 28, wherein the unit dies have suitably formed cavities.
  • Each eyelet 106 includes a neck 108 to accept a predetermined length of the rod 102.
  • Each groove 104 is cut in the rod 102 so that the neck 108 extends past the groove 104 for a predetermined distance.
  • Webs 110 can be provided on the outer surfaces of the eyelet 106 and neck 108 to strengthen the casting.
  • Molten metal 24 such as a standard 380 aluminium alloy, is introduced into unit dies supporting the rod 102 according to the die-cast moulding method disclosed above. As the molten metal 24 solidifies, an annular projection 114 is formed in the inner periphery of the neck 108 which extends radially inwardly to completely fill the groove 104. The resin 103 at the outer circumference of the rod 102 and the exposed surface of the groove 104 undergoes thermal alteration and exposes glass fibres 101. As described above, even cooling of the molten metal 24 protects the rod 102 from excessive damage.
  • the joint formed between the projection 114 and the groove 104 and between the rod 102 and the neck 108 is referred to hereinafter as the "interlocking region”.
  • Figure 13 schematically illustrates tensile loading in the link 100 during use thereof.
  • the tensile load in the eyelet 106 is indicated by arrows 116 and the tensile load in the rod is indicated by arrows 118.
  • This tensile loading produces mechanical stresses in five locations within the link 100. Bending stresses present in eyelet 106 are illustrated at 120'.
  • Tensile stresses in the neck 108 are illustrated at 122'.
  • Tensile stresses in the rod 102 are illustrated at 128.
  • Shear stresses 126 are present in the portion of the rod 102 from the annular projection 114 to the end of the rod 102.
  • Shear stresses 124' are present in the annular projection 114.
  • the location in the link 100 which does not exhibit a rapid, brittle failure during extreme tensile loading is the portion of the neck 108 located adjacent the annular groove 104.
  • tensile stress 122' and shearing stress 124' are present in the aluminium.
  • the sharp corner of the annular groove 104 creates a stress-concentration factor which amplifies stresses 122' and 124'.
  • the portion of the neck 108 adjacent the annular projection 114 is made weaker than the eyelet 106, the rod 102 in a tensile mode, and the rod in a shear mode.
  • a crack 130 develops in an inner surface of the neck 108 adjacent projection 114 and propagates to the outer surface of the neck 108, eventually causing an inner portion 108A of the neck 108 to break away from an outer portion 108B of the neck 108 as illustrated in Figure 14.
  • the fracture of the neck 108 does not result in immediate separation of the rod 102 from portion 108B.
  • tensile loading of the link 100 increases to F A , at which point the neck 108 fractures into portions 108A and 108B after an elongation of X A .
  • a varying force is required to pull the rod 102 from the outer neck portion 108B for a total elongation of X B .
  • a chamber 132 is formed.
  • a significant amount of energy is required to completely separate the eyelet 106 from the rod 102. This is due to the penetration of the aluminium alloy into the composite material as described above. Testing has shown the amount of elongation of the link 100 is much greater than the ultimate elongation of the materials it is made from. The ultimate elongation of the aluminium alloy is 3% and the ultimate elongation of the FRP is 2.5%. As shown in Figure 16, the link 100 undergoes significant elongation prior to separation. For example, the original length of a tested link was 330mm. Separation of the rod from the outer neck portion occurred at 52mm, resulting in an elongation of approximately 16%.
  • the above disclosed interlocking joint provides a controllable failure mode in the event of extreme tensile loading of the link.
  • the neck 108, groove 104, and projection 114 can be varied as desired to provide a selected load at which failure begins to occur.
  • the length of the rod 102 behind annular projection 114 can be varied to provide a selected amount of ultimate elongation of link 100.
  • the length of the rod 102 behind annular projection 114 can be varied to provide a selected amount of energy to separate the portion of the casting 106 and 108B completely from the rod 102.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Vehicle Body Suspensions (AREA)
EP19930203492 1993-01-08 1993-12-13 Verfahren zur Herstellung einer ausfallsicheren verbundgegossenen Metallstruktur und die Metallstruktur Expired - Lifetime EP0605915B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US244993A 1993-01-08 1993-01-08
US2449 1993-01-08

Publications (3)

Publication Number Publication Date
EP0605915A2 true EP0605915A2 (de) 1994-07-13
EP0605915A3 EP0605915A3 (de) 1995-02-01
EP0605915B1 EP0605915B1 (de) 1998-07-08

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EP19930203492 Expired - Lifetime EP0605915B1 (de) 1993-01-08 1993-12-13 Verfahren zur Herstellung einer ausfallsicheren verbundgegossenen Metallstruktur und die Metallstruktur

Country Status (2)

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EP (1) EP0605915B1 (de)
DE (1) DE69319568T2 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2853321A4 (de) * 2012-05-21 2015-08-05 Teijin Ltd Herstellungsverfahren für geformtes harzprodukt mit metallischem einsatz

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010050970A1 (de) * 2010-11-10 2012-05-10 Daimler Ag Kraftfahrzeugbauteil und Verfahren zu dessen Herstellung

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2129342A (en) * 1982-10-21 1984-05-16 Honda Motor Co Ltd Method for making a reinforced cast article
US4566519A (en) * 1981-12-02 1986-01-28 Honda Giken Kogyo Kabushiki Kaisha Method of making a connecting rod
WO1986004650A1 (en) * 1985-02-12 1986-08-14 The Secretary Of State For Trade And Industry In H Fibre reinforced plastic connecting rod
US4648921A (en) * 1980-10-02 1987-03-10 United Technologies Corporation Method of making fiber reinforced articles
US4990207A (en) * 1987-04-02 1991-02-05 Mitsui Toatsu Chemicals, Inc. Process for preparing fiber-reinforced thermoplastic molded articles
EP0501537A1 (de) * 1991-02-25 1992-09-02 General Motors Corporation Verfahren zum Druckgiessen von Metall auf faserverstärkten Kunststoffen

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2469605A1 (fr) * 1979-11-08 1981-05-22 Rech Meca Appliquee Bielle ou objet analogue

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4648921A (en) * 1980-10-02 1987-03-10 United Technologies Corporation Method of making fiber reinforced articles
US4566519A (en) * 1981-12-02 1986-01-28 Honda Giken Kogyo Kabushiki Kaisha Method of making a connecting rod
GB2129342A (en) * 1982-10-21 1984-05-16 Honda Motor Co Ltd Method for making a reinforced cast article
WO1986004650A1 (en) * 1985-02-12 1986-08-14 The Secretary Of State For Trade And Industry In H Fibre reinforced plastic connecting rod
US4990207A (en) * 1987-04-02 1991-02-05 Mitsui Toatsu Chemicals, Inc. Process for preparing fiber-reinforced thermoplastic molded articles
EP0501537A1 (de) * 1991-02-25 1992-09-02 General Motors Corporation Verfahren zum Druckgiessen von Metall auf faserverstärkten Kunststoffen

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2853321A4 (de) * 2012-05-21 2015-08-05 Teijin Ltd Herstellungsverfahren für geformtes harzprodukt mit metallischem einsatz

Also Published As

Publication number Publication date
DE69319568T2 (de) 1998-11-05
EP0605915B1 (de) 1998-07-08
EP0605915A3 (de) 1995-02-01
DE69319568D1 (de) 1998-08-13

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