EP0798062A2 - Element made of foamed metal - Google Patents

Element made of foamed metal Download PDF

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Publication number
EP0798062A2
EP0798062A2 EP97105225A EP97105225A EP0798062A2 EP 0798062 A2 EP0798062 A2 EP 0798062A2 EP 97105225 A EP97105225 A EP 97105225A EP 97105225 A EP97105225 A EP 97105225A EP 0798062 A2 EP0798062 A2 EP 0798062A2
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EP
European Patent Office
Prior art keywords
component
semi
finished product
foamed
contour
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
EP97105225A
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German (de)
French (fr)
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EP0798062A3 (en
EP0798062B1 (en
Inventor
Hans-Wolfgang Seeliger
Winfried Bunsmann
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Wilhelm Karmann GmbH
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Wilhelm Karmann GmbH
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Publication date
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Publication of EP0798062A3 publication Critical patent/EP0798062A3/en
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Publication of EP0798062B1 publication Critical patent/EP0798062B1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1103—Making porous workpieces or articles with particular physical characteristics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49904—Assembling a subassembly, then assembling with a second subassembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12382—Defined configuration of both thickness and nonthickness surface or angle therebetween [e.g., rounded corners, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/1241—Nonplanar uniform thickness or nonlinear uniform diameter [e.g., L-shape]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12479—Porous [e.g., foamed, spongy, cracked, etc.]

Definitions

  • the invention relates to a component made of a metallic foam material according to the preamble of claim 1 or claim 2.
  • the invention further relates to a method for the final shaping of a component formed from a substantially flat metallic foam material according to the preamble of claim 6 and devices for carrying out the method .
  • Metallic foam materials that either contain only a foamable layer comprising metal powder and blowing agents or that contain a layer comprising foamable metal powder and blowing agents that is provided with at least one solid metal sheet as a cover layer, whereby there are metallic bonds between the solid metal sheet and the foamable layer known per se.
  • DE 41 01 630 A1 shows how a foam material is formed from a metallic powder and the addition of a gas-releasing blowing agent powder, preferably a metal hydride, which is subjected to a high pressure and high temperature after mixing, which can be done, for example, by a warm Rolling process can be achieved, and then cooled, so that a foamable semi-finished product is formed.
  • a gas-releasing blowing agent powder preferably a metal hydride
  • DE 44 26 627 A1 describes the production of a material with a foamable layer consisting of metal powder and blowing agent, which is at least delimited by a solid metallic cover layer.
  • a connection of the different layers by roll cladding is proposed, whereby a flat layer material is formed which is to be foamed after its final shaping.
  • the invention has for its object to provide metallic lightweight components for a constant dimensional production, Especially in vehicle construction, to create flat foam materials of the type mentioned.
  • the invention provides components with the features of claims 1 or 2 and a manufacturing method according to claim 6 for various starting materials.
  • the component according to the invention solves all the essential geometric requirements that are placed on flat metallic components in body and vehicle construction.
  • the formation of the transition angle between 100 ° and less than 180 ° ensures that the structure of the foamed layer in the area of the transitions is not interrupted, drawn in or thinned, so that the mechanical stability and dimensional accuracy of the component is retained over its entire area.
  • a component according to the invention has a very low mass, at the same time providing high rigidity, in particular in the case of multi-layer composites, so that such components can be used both in the load-bearing area of the body and for cladding and shielding purposes.
  • Integral foam can be used in particular as crash elements, the cellular structure of the foamed material giving it very good energy absorption capacity when the component is deformed. Due to the inventive design of the component, it is possible to deform it so far before it is foamed that it can be used, for example, as the inner layer of a bumper made of z. B. plastic can be used.
  • Components that comprise a foamed metallic layer that is provided on one side with a solid metallic cover layer are suitable for forming very light and highly rigid components, for example a vehicle roof that does not require a stiffening substructure.
  • Materials that have a foamed layer and cladding on both sides with a solid metal sheet are suitable for producing components that have a smooth-walled surface that absorbs tensile and compressive forces on both sides, for example for the rear transverse wall of a vehicle.
  • the foamed layer takes on the function of the spacer and the transmission of the thrust forces.
  • Such a component also has high rigidity and low mass, is suitable for absorbing high energies, for example in the event of an accident, and is also good soundproofing.
  • the foamed layer usually consists of an aluminum-based metal powder with added parts - for example silicon.
  • the mechanical properties of the component can be adjusted by a suitable choice of the alloy elements and proportions.
  • the use of light metal alloys is also suitable for solid metal sheets.
  • a component 1 according to the invention has a foamed layer 2 which comprises a metal powder and a blowing agent which have been homogeneously mixed with one another by a mixing process and then compressed under the action of pressure, for example by axial pressing or by extrusion, to form a compact, foamable semi-finished product 2 '' and has been solidified.
  • the foamed layer 2 is provided on the top and bottom sides with a solid metal sheet 3, 4, which is not mandatory, however, and in particular when a component 1 according to the invention is formed as a crash element. It is also possible to connect a foamed layer 2 with only one solid metal cover layer 3 or 4 or to produce composites from several different foamed layers, possibly separated by solid metal layers, for example to create impact elements in which, depending on the impact speed and thus -energy a different number of foamed layers takes part in the deformation due to the impact.
  • the connection between the layer 2 foamed at the end of the method and the solid metal sheets 3 and 4 has come about under the action of pressure in such a way that a metallic bond between the individual layers 2 ', 3 ', 4' has been reached before the forming and foaming.
  • This flat composite material 6 is first cut into pieces of a suitable size, for example using a saw.
  • the shape 8 used to form the composite material 6 to form the semi-finished product 7 has angles ⁇ transverse to the contact surface of the composite material 6 in a size between approximately 100 ° and 260 °, the edges being rounded, so that the composite material 6 is bent directly to avoid. As a result, the bond is retained even in the angular ranges, and the mechanical strength of the semi-finished product 7 achieved by the shaping has no specific weak points.
  • the shaping can be carried out by known customary shaping measures, for example by deep drawing with and without hold-down devices, as is known in body construction, or by a one-sided shaping method, such as the fluid cell method.
  • a semi-finished product 7 which contains either plane-flat or curved surface areas 7 ′′ and possibly contours 7 ′ formed therefrom and which comprises a foamable layer 2 ′ for further processing.
  • the semifinished product 7 is inserted into a foaming mold 9, one wall 12 of which supports a side 10 of the semifinished product 7 substantially so that this side 10 must already have its final contour, since further contouring by foaming the semifinished product 7 into a component 1 no longer causes deformation of this side 10.
  • the walls 12, 13 of the foaming mold 9 can be made of steel or ceramic, for example. In any case, it is important that the component 1 does not make any connection with the walls 12, 13 of the foaming mold 9, despite its internal pressure prevailing during foaming. In order to prevent any sticking together here, these walls 12, 13 can be coated.
  • the thickness of the component 1 can be preselected - and thus also its density and its mechanical strength. It is thereby achieved that the same starting material can be used for components 1 with completely different properties.
  • Its rigidity can also be adjusted in this way. For example, the different stiffness requirements of a short car roof or a long roof of a station wagon can be met via the degree of foaming.
  • the upper wall 13 of the foaming mold can be omitted if only small demands are made on the dimensional accuracy of the foaming semi-finished product 7, such as in the formation of crash elements.
  • the two opposite walls 12 and 13 of the foaming mold 9 have essentially parallel surface structures, since it is not possible to emboss further structures, for example, only into one surface 11 of the semi-finished product 7, for example through recesses in the delimiting wall 13 of the foaming mold 10th
  • components 1 are obtained as lightweight series products, which can be used, for example, as body panels, as bulkheads or partition walls opposite the engine or trunk or for crash-protecting and stiffening functions within the body.
  • Such components can be curved overall, for example for use as door outer panels, or comprise pronounced contours 1 'worked out from plane or curved areas 1'', which in the area of the transitions with respect to the curved or plane surface area have angles ⁇ of the order of magnitude between 100 ° and less have than 180 °, so that hereby the most diverse requirements for body panels or body panels can be fulfilled - with very light and torsion-resistant components 1.
  • angles ⁇ of the same order of magnitude can occur within the pronounced contours 1 ', so that here too there is maximum flexibility and adaptability to the requirements of the body builder.

Abstract

A metal foam component (1), in the form of a car body element includes a foamed porous layer made up of a metal powder and a foaming agent. The component has at least one contour (1') which is raised out of its plane (1"). The angles in the transition zones of the three-dimensionally formed component lie within the range between 100 and 180 degrees. Also claimed are a method and an apparatus for producing such a component.

Description

Die Erfindung bezieht sich auf ein Bauteil aus einem metallischen Schaumwerkstoff nach dem Oberbegriff von Anspruch 1 oder Anspruch 2. Die Erfindung betrifft ferner ein Verfahren zum Endformen eines aus im wesentlichen flächigem metallischem Schaumwerkstoff gebildeten Bauteils nach dem Oberbegriff des Anspruchs 6 sowie Vorrichtungen zur Ausführung des Verfahrens.The invention relates to a component made of a metallic foam material according to the preamble of claim 1 or claim 2. The invention further relates to a method for the final shaping of a component formed from a substantially flat metallic foam material according to the preamble of claim 6 and devices for carrying out the method .

Metallische Schaumwerkstoffe, die entweder alleinig eine Metallpulver und Treibmittel umfassende aufschäumbare Schicht enthalten oder die eine aufschäumbare Metallpulver und Treibmittel umfassende Schicht enthalten, die mit zumindest einem massivmetallischen Blech als Deckschicht versehen ist, wobei zwischen dem massivmetallischen Blech und der aufschäumbaren Schicht metallische Bindungen bestehen, sind an sich bekannt.Metallic foam materials that either contain only a foamable layer comprising metal powder and blowing agents or that contain a layer comprising foamable metal powder and blowing agents that is provided with at least one solid metal sheet as a cover layer, whereby there are metallic bonds between the solid metal sheet and the foamable layer known per se.

In der DE 41 01 630 A1 ist dargestellt, wie aus einem metallischen Pulver und einer Zugabe eines gasabspaltenden Treibmittelpulvers, vorzugsweise eines Mettallhydrides, ein Schaumwerkstoff gebildet wird, der nach der Durchmischung einem hohen Druck und hoher Temperatur ausgesetzt wird, was beispielsweise durch einen Warm-Walzvorgang erreicht werden kann, und anschließend abgekühlt wird, so daß ein aufschäumbares Halbzeug entsteht.DE 41 01 630 A1 shows how a foam material is formed from a metallic powder and the addition of a gas-releasing blowing agent powder, preferably a metal hydride, which is subjected to a high pressure and high temperature after mixing, which can be done, for example, by a warm Rolling process can be achieved, and then cooled, so that a foamable semi-finished product is formed.

In der DE 44 26 627 A1 ist die Herstellung eines Werkstoffes mit einer aufschäumbaren, aus Metallpulver und Treibmittel bestehenden Schicht, die zumindest von einer massivmetallischen Deckschicht begrenzt ist, dargestellt. Für flächige Verbundwerkstoffe dieser Art wird dabei eine Verbindung der unterschiedlichen Schichten durch Walzplattieren vorgeschlagen, wodurch ein flacher Schichtwerkstoff entsteht, der nach seiner Endformung aufgeschäumt werden soll.DE 44 26 627 A1 describes the production of a material with a foamable layer consisting of metal powder and blowing agent, which is at least delimited by a solid metallic cover layer. For flat composite materials of this type, a connection of the different layers by roll cladding is proposed, whereby a flat layer material is formed which is to be foamed after its final shaping.

Die vorgestellten Verfahren zur Herstellung eines geeigneten Schaumwerkstoffes zeigen noch keine Möglichkeit, aus den zur Verfügung gestellten Werkstoffen in reproduzierbarer Weise Serienbauteile zu bilden.The methods presented for the production of a suitable foam material do not yet show any possibility of producing series components in a reproducible manner from the materials made available.

Der Erfindung liegt die Aufgabe zugrunde, metallische Leichtbauteile für eine konstant maßhaltige Serienfertigung, insbesondere im Fahrzeugbau, aus flächigen Schaumwerkstoffen der eingangs genannten Art zu schaffen.The invention has for its object to provide metallic lightweight components for a constant dimensional production, Especially in vehicle construction, to create flat foam materials of the type mentioned.

Die Erfindung sieht zur Lösung dieser Aufgabe für verschiedene Ausgangswerkstoffe Bauteile mit den Merkmalen der Ansprüche 1 oder 2 vor sowie ein Herstellungsverfahren nach Anspruch 6.To achieve this object, the invention provides components with the features of claims 1 or 2 and a manufacturing method according to claim 6 for various starting materials.

Das erfindungsgemäße Bauteil löst alle wesentlichen geometrischen Anforderungen, die im Karosserie- und Fahrzeugbau an flächige metallische Bauteile gestellt werden. Durch die Ausbildung der Übergangswinkel zwischen 100° und weniger als 180° ist erreicht, daß die Struktur der aufgeschäumten Schicht im Bereich der Übergänge nicht unterbrochen, eingezogen oder verdünnt ist, so daß die mechanische Stabilität und Maßhaltigkeit des Bauteils über seinen gesamten Bereich erhalten bleibt.The component according to the invention solves all the essential geometric requirements that are placed on flat metallic components in body and vehicle construction. The formation of the transition angle between 100 ° and less than 180 ° ensures that the structure of the foamed layer in the area of the transitions is not interrupted, drawn in or thinned, so that the mechanical stability and dimensional accuracy of the component is retained over its entire area.

Ein erfindungsgemäßes Bauteil weist eine sehr geringe Masse auf, wobei gleichzeitig eine hohe Steifigkeit, insbesondere bei Mehrschichtverbünden, gegeben ist, so daß solche Bauteile sowohl im tragenden Bereich der Karosserie als auch zu Verkleidungs- und Abschirmzwecken eingesetzt werden können.A component according to the invention has a very low mass, at the same time providing high rigidity, in particular in the case of multi-layer composites, so that such components can be used both in the load-bearing area of the body and for cladding and shielding purposes.

Bauteile, die allein aus einer Metallpulver und Treibmittel umfassenden aufgeschäumten porösen Schicht bestehen, sog. Integralschaum, können insbesondere als Crashelemente eingesetzt werden, wobei sich durch die zellige Struktur des aufgeschäumten Werkstoffes eine sehr gute Energieabsorbtionsfähigkeit bei Verformung des Bauteiles ergibt. Durch die erfindungsgemäße Ausbildung des Bauteiles ist es möglich, dieses vor seinem Aufschäumen soweit zu verformen, daß es beispielsweise als innere Lage einer Stoßstange aus z. B. Kunststoff eingesetzt werden kann.Components that consist solely of a foamed porous layer comprising metal powder and blowing agent, so-called. Integral foam can be used in particular as crash elements, the cellular structure of the foamed material giving it very good energy absorption capacity when the component is deformed. Due to the inventive design of the component, it is possible to deform it so far before it is foamed that it can be used, for example, as the inner layer of a bumper made of z. B. plastic can be used.

Bauteile, die eine aufgeschäumte metallische Schicht umfassen, die einseitig mit einer massivmetallischen Deckschicht versehen ist, sind geeignet, sehr leichte und hochsteife Bauteile, beispielsweise ein Fahrzeugdach, das ohne eine versteifende Unterkonstruktion auskommt, zu bilden.Components that comprise a foamed metallic layer that is provided on one side with a solid metallic cover layer are suitable for forming very light and highly rigid components, for example a vehicle roof that does not require a stiffening substructure.

Werkstoffe, die eine aufgeschäumte Schicht und eine beidseitige Plattierung mit einem massivmetallischen Blech aufweisen, sind geeignet zur Herstellung von Bauteilen, die beiderseits eine glattwandige und Zug- und Druckkräfte aufnehmende Oberfläche aufweisen, beispielsweise für die hintere Querwand eines Fahrzeuges. Die aufgeschäumte Lage übernimmt dabei die Funktion des Abstandhalters sowie die Übertragung der Schubkräfte. Ein solches Bauteil weist ebenfalls eine hohe Steifigkeit bei geringer Masse auf, ist geeignet, hohe Energien - etwa bei einem Unfall - aufzunehmen und ist zudem gut schallisolierend.Materials that have a foamed layer and cladding on both sides with a solid metal sheet are suitable for producing components that have a smooth-walled surface that absorbs tensile and compressive forces on both sides, for example for the rear transverse wall of a vehicle. The foamed layer takes on the function of the spacer and the transmission of the thrust forces. Such a component also has high rigidity and low mass, is suitable for absorbing high energies, for example in the event of an accident, and is also good soundproofing.

Die aufgeschäumte Schicht besteht üblicherweise aus einem Metallpulver auf Aluminiumbasis mit zulegierten Anteilen - beispielsweise von Silizium. Durch eine geeignete Wahl der Legierungselemente und -anteile sind mechanische Eigenschaften des Bauteils einstellbar. Auch für massivmetallische Bleche bietet sich die Verwendung von Leichtmetallegierungen an.The foamed layer usually consists of an aluminum-based metal powder with added parts - for example silicon. The mechanical properties of the component can be adjusted by a suitable choice of the alloy elements and proportions. The use of light metal alloys is also suitable for solid metal sheets.

Weitere Vorteile ergeben sich aus der Zeichnung und der nachfolgenden Beschreibung des Bauteils sowie seines Herstellungsverfahrens. In der Zeichnung zeigen:

Fig. 1
in schematischer Ansicht schräg von oben eine Tiefziehform mit aufgelegtem zu verformendem Schaumwerkstoff,
Fig. 2
ein in eine Aufschäumform eingelegtes und einseitig endkonturiertes Formhalbzeug in schematischer perspektivischer Ansicht,
Fig. 3
eine ähnliche Ansicht des Bauteils am Ende des Aufschäumprozesses,
Fig. 4
das gesamte Herstellungsverfahren eines erfindungsgemäßen Bauteil im schematischen Überblick,
Fig. 5
das erfindungsgemäße Aufschäumen des Bauteils in einem schematischen Ablaufplan.
Further advantages result from the drawing and the following description of the component and its manufacturing process. The drawing shows:
Fig. 1
in a schematic view obliquely from above, a deep-drawing mold with a foam material to be deformed,
Fig. 2
a semi-finished molded product inserted into a foaming mold and contoured on one end, in a schematic perspective view,
Fig. 3
a similar view of the component at the end of the foaming process,
Fig. 4
the entire manufacturing process of a component according to the invention in a schematic overview,
Fig. 5
the foaming of the component according to the invention in a schematic flow chart.

Ein erfindungsgemäßes Bauteil 1 weist eine aufgeschäumte Schicht 2 auf, die ein Metallpulver und ein Treibmittel umfaßt, die durch einen Mischungsvorgang homogen miteinander vermengt wurden und anschließend unter Druckeinwirkung, etwa durch axiales Pressen oder durch Strangpressen, zu einem kompakten, aufschäumbaren Halbzeug 2'' verdichtet und verfestigt worden ist.A component 1 according to the invention has a foamed layer 2 which comprises a metal powder and a blowing agent which have been homogeneously mixed with one another by a mixing process and then compressed under the action of pressure, for example by axial pressing or by extrusion, to form a compact, foamable semi-finished product 2 '' and has been solidified.

Im gezeigten Ausführungsbeispiel ist die aufgeschäumte Schicht 2 ober- und unterseitig mit jeweils einem massivmetallischen Blech 3, 4 versehen, was jedoch nicht zwingend ist und insbesondere bei Ausbildung eines erfindungsgemäßen Bauteils 1 als Crashelement verzichtbar ist. Es ist weiterhin möglich, eine aufgeschäumte Schicht 2 mit nur einer massivmetallischen Deckschicht 3 bzw. 4 zu verbinden oder auch Verbünde aus mehreren unterschiedlichen aufgeschäumten Schichten, eventuell abgetrennt durch massivmetallische Schichten, herzustellen, etwa um Aufprallelemente zu schaffen, bei denen je nach Aufprallgeschwindigkeit und damit -energie eine unterschiedliche Anzahl von aufgeschäumten Schichten an der Verformung durch den Aufprall teilnimmt.In the exemplary embodiment shown, the foamed layer 2 is provided on the top and bottom sides with a solid metal sheet 3, 4, which is not mandatory, however, and in particular when a component 1 according to the invention is formed as a crash element. It is also possible to connect a foamed layer 2 with only one solid metal cover layer 3 or 4 or to produce composites from several different foamed layers, possibly separated by solid metal layers, for example to create impact elements in which, depending on the impact speed and thus -energy a different number of foamed layers takes part in the deformation due to the impact.

Im Ausführungsbeispiel einer doppelseitig mit massivmetallischen Blechen 3 und 4 versehenen aufgeschäumten Schicht 2 ist die Verbindung zwischen der am Ende des Verfahrens aufgeschäumten Schicht 2 und den massivmetallischen Blechen 3 und 4 unter Druckeinwirkung derart zustandegekommen, daß eine metallische Bindung zwischen den einzelnen Schichten 2', 3', 4' vor der Umformung und Aufschäumung erreicht worden ist. Dazu bietet sich an, ein Walzplattieren eines Verbundes aus dem aufschäumbaren Halbzeug 2'', das nach dem Strangpressen bzw. axialen Pressen entstanden ist, und den massivmetallischen Blechen 3'',4'' zwischen zwei Walzen 5 vorzunehmen, so daß ein Verbundwerkstoff 6 mit Sandwichstruktur zweier massivmetallischer Deckschichten 3' und 4' und einer noch nicht aufgeschäumten porösen Zwischenschicht 2' entsteht.In the exemplary embodiment of a foamed layer 2 provided on both sides with solid metal sheets 3 and 4, the connection between the layer 2 foamed at the end of the method and the solid metal sheets 3 and 4 has come about under the action of pressure in such a way that a metallic bond between the individual layers 2 ', 3 ', 4' has been reached before the forming and foaming. For this purpose, it is advisable to perform a roll cladding of a composite of the foamable semi-finished product 2 ″, which was created after the extrusion or axial pressing, and the solid metal sheets 3 ″, 4 ″ between two rollers 5, so that a composite material 6 with a sandwich structure of two solid metallic cover layers 3 'and 4' and a not yet foamed porous intermediate layer 2 '.

Ein solcher im wesentlichen flächiger metallischer Verbundwerkstoff 6, der in jedem Fall eine noch aufschäumbare Schicht 2' umfaßt, weist zwischen den metallischen Blechen 3' und 4' und der aufschäumbaren Schicht 2' metallische Bindungen auf und steht nun zur weiteren Bearbeitung zur Verfügung. Dieser flächige Verbundwerkstoff 6 wird zunächst in Stücke geeigneter Größe zerteilt, beispielsweise mit Hilfe einer Säge.Such an essentially flat metallic composite material 6, which in each case comprises a foamable layer 2 ', has metallic bonds between the metal sheets 3' and 4 'and the foamable layer 2' and is now available for further processing. This flat composite material 6 is first cut into pieces of a suitable size, for example using a saw.

Ein solcher auf die gewünschten Außenmaße zurechtgeschnittener Verbundwerkstoff 6 wird nun zu einem Formhalbzeug 7 umgeformt, wobei die Umformung sowohl eine kontinuierliche Krümmung des Verbundwerkstoffes 6 bewirken kann als auch die Ausprägung einzelner Bereiche 7'.Such a composite material 6, which is cut to the desired external dimensions, now becomes a semi-finished product 7 reshaped, the reshaping both being able to bring about a continuous curvature of the composite material 6 and also the shaping of individual regions 7 '.

In jedem Falle weist die zur Umformung des Verbundwerkstoffes 6 zum Formhalbzeug 7 eingesetzte Form 8 quer zur Auflagefläche des Verbundwerkstoffes 6 Winkel γ in einer Größe zwischen etwa 100° und 260° auf, wobei die Kanten abgerundet sind, um somit ein direktes Abkanten des Verbundwerkstoffes 6 zu vermeiden. Dadurch bleibt der Verbund auch in den Winkelbereichen erhalten, und die mechanische Festigkeit des durch die Umformung erreichten Formhalbzeuges 7 weist keine punktuellen Schwachstellen auf.In any case, the shape 8 used to form the composite material 6 to form the semi-finished product 7 has angles γ transverse to the contact surface of the composite material 6 in a size between approximately 100 ° and 260 °, the edges being rounded, so that the composite material 6 is bent directly to avoid. As a result, the bond is retained even in the angular ranges, and the mechanical strength of the semi-finished product 7 achieved by the shaping has no specific weak points.

Das Umformen kann durch bekannte übliche Umformmaßnahmen erfolgen, etwa durch Tiefziehen mit und ohne Niederhalter, wie es im Karosseriebau bekannt ist, oder durch ein einseitiges Umformverfahren, wie etwa das Fluidzellverfahren.The shaping can be carried out by known customary shaping measures, for example by deep drawing with and without hold-down devices, as is known in body construction, or by a one-sided shaping method, such as the fluid cell method.

In jedem Falle wird ein Formhalbzeug 7 erhalten, das entweder planebene oder gekrümmte Flächenbereiche 7'' enthält und eventuell aus diesem ausgeformte Konturen 7' und das zur weiteren Bearbeitung eine aufschäumfähige Lage 2' umfaßt.In any case, a semi-finished product 7 is obtained, which contains either plane-flat or curved surface areas 7 ″ and possibly contours 7 ′ formed therefrom and which comprises a foamable layer 2 ′ for further processing.

Das Aufschäumen des Formhalbzeuges 7 zu einem Bauteil 1 in einer definierten, reproduzierbaren und maßhaltigen Weise zu gestalten ist die eigentliche Intention der Erfindung, weil dadurch erst ermöglicht wird, Bauteile für eine Serienfertigung zur Verfügung zu stellen.The foaming of the semi-finished product 7 into a component 1 in a defined, reproducible and dimensionally stable manner The actual intention of the invention is to design it, because this is the only way to make components available for series production.

Dazu wird das Formhalbzeug 7 in eine Aufschäumform 9 eingelegt, deren eine Wandung 12 eine Seite 10 des Formhalbzeuges 7 im wesentlichen flächendeckend abstützt, so daß diese Seite 10 bereits ihre Endkontur aufweisen muß, da eine weitere Konturgebung durch das Aufschäumen des Formhalbzeuges 7 zu einem Bauteil 1 keine Verformung dieser Seite 10 mehr mit sich bringt.For this purpose, the semifinished product 7 is inserted into a foaming mold 9, one wall 12 of which supports a side 10 of the semifinished product 7 substantially so that this side 10 must already have its final contour, since further contouring by foaming the semifinished product 7 into a component 1 no longer causes deformation of this side 10.

Die Wandungen 12,13 der Aufschäumform 9 können beispielsweise aus Stahl oder auch aus Keramik bestehen. In jedem Fall ist wichtig, daß das Bauteil 1 trotz seines beim Aufschäumen herrschenden Innendruckes keine Verbindung mit den Wandungen 12,13 der Aufschäumform 9 eingeht. Um hier jegliches Aneinanderhaften zu unterbinden, können diese Wandungen 12,13 beschichtet sein.The walls 12, 13 of the foaming mold 9 can be made of steel or ceramic, for example. In any case, it is important that the component 1 does not make any connection with the walls 12, 13 of the foaming mold 9, despite its internal pressure prevailing during foaming. In order to prevent any sticking together here, these walls 12, 13 can be coated.

Durch die flächige Unterstützung einer endkonturierten Seite 10 des noch nicht aufgeschäumten Formhalbzeuges 7 wird beim Aufschäumen vermieden, daß diese bereits die Endkontur des späteren Bauteils 1 aufweisende Seite 10 während des Aufschäumens durch den Druck des gasabspaltenden Treibmittels in der aufschäumenden Schicht 2' nach außen hin verformt wird. Dabei ist es vorteilhaft und für manche Anwendungen zwingend, der gegenüberliegenden Seite 11 des Formhalbzeuges 7 eine weitere Wandung 13 der Aufschäumform 9 zuzuordnen, die mit festem Abstand zur Wandung 12 angeordnet ist, um dadurch das Maß der Ausdehnung der aufschäumenden Schicht 2' definiert zu begrenzen und somit eine Maßhaltigkeit des fertigen Bauteils 1 mit weniger als 5/10 mm Abweichung zu ermöglichen. Durch eine Einstellbarkeit des Abstandes der Wandungen 12 und 13 läßt sich die Dicke des Bauteils 1 vorwählen - und damit auch seine Dichte und seine mechanische Festigkeit. Dadurch ist erreicht, daß derselbe Ausgangswerkstoff für Bauteile 1 mit völlig verschiedenen Eigenschaften verwendet werden kann. Je größer der erlaubte Aufschäumweg in der Aufschäumform 9 gelassen wird, desto geringer ist die Dichte des fertigen Bauteils 1. Auch seine Steifigkeit läßt sich auf diese Weise einstellen. Damit können beispielsweise die unterschiedlichen Steifigkeitsanforderungen eines kurzen PKW-Daches bzw. eines langen Daches eines Kombis über den Grad der Aufschäumung erfüllt werden.Due to the extensive support of an end-contoured side 10 of the semi-finished product 7 which has not yet been foamed, it is avoided during foaming that this end 10 already having the end contour of the later component 1 is deformed outwards during foaming by the pressure of the gas-releasing blowing agent in the foaming layer 2 ' becomes. It is beneficial and for some Applications imperative to assign a further wall 13 of the foaming mold 9 to the opposite side 11 of the semifinished product 7, which is arranged at a fixed distance from the wall 12, in order thereby to define the extent of the expansion of the foaming layer 2 'in a defined manner and thus a dimensional accuracy of the finished component 1 with less than 5/10 mm deviation. By adjusting the distance between the walls 12 and 13, the thickness of the component 1 can be preselected - and thus also its density and its mechanical strength. It is thereby achieved that the same starting material can be used for components 1 with completely different properties. The larger the allowed foaming path is left in the foaming mold 9, the lower the density of the finished component 1. Its rigidity can also be adjusted in this way. For example, the different stiffness requirements of a short car roof or a long roof of a station wagon can be met via the degree of foaming.

Die obere Wandung 13 der Aufschäumform kann entfallen, wenn an die Dickenmaßhaltigkeit des aufschäumenden Formhalbzeuges 7 nur geringe Ansprüche gestellt werden, wie beispielsweise bei der Ausbildung von Crashelementen.The upper wall 13 of the foaming mold can be omitted if only small demands are made on the dimensional accuracy of the foaming semi-finished product 7, such as in the formation of crash elements.

In den meisten Fällen wird es jedoch unverzichtbar sein, durch beide Wandungen 12 und 13 den Aufschäumweg und damit das Endmaß des aufgeschäumten Bauteils 1 zu begrenzen, wodurch eine Serienfertigung immer gleicher aufgeschäumter Bauteile 1 ermöglicht ist.In most cases, however, it will be indispensable, through both walls 12 and 13, of the foaming path and thus to limit the final dimension of the foamed component 1, which enables series production of the same foamed component 1.

Die beiden gegenüberliegenden Wandungen 12 und 13 der Aufschäumform 9 weisen dabei im wesentlichen parallele Flächenstrukturen auf, da es nicht möglich ist, durch das Aufschäumen weitere Strukturen etwa nur in eine Oberfläche 11 des Formhalbzeuges 7 einzuprägen - etwa durch Aussparungen in der begrenzenden Wand 13 der Aufschäumform 10.The two opposite walls 12 and 13 of the foaming mold 9 have essentially parallel surface structures, since it is not possible to emboss further structures, for example, only into one surface 11 of the semi-finished product 7, for example through recesses in the delimiting wall 13 of the foaming mold 10th

Durch ein derart definiertes Aufschäumen werden Bauteile 1 als Leichtbauserienprodukte erhalten, die beispielsweise als Karosserieinnenbleche, als Spritzwände oder Abtrennwände gegenüber Motor- oder Kofferraum oder zur crashsichernden und aussteifenden Funktion innerhalb der Karosserie eingesetzt werden können.By means of such defined foaming, components 1 are obtained as lightweight series products, which can be used, for example, as body panels, as bulkheads or partition walls opposite the engine or trunk or for crash-protecting and stiffening functions within the body.

Solche Bauteile können insgesamt gekrümmt sein, beispielsweise zur Verwendung als Türaußenbleche, oder aus planebenen oder gekrümmten Bereichen 1'' herausgearbeitete ausgeprägte Konturen 1' umfassen, die im Bereich der Übergänge gegenüber dem gekrümmten oder planebenen Flächenbereich Winkel α in der Größenordnung zwischen 100° und weniger als 180° aufweisen, so daß hiermit die verschiedensten Anforderungen an Karosseriebleche bzw. Karosserieinnenbleche erfüllt werden können - mit sehr leichten und verwindungssteifen Bauteilen 1.Such components can be curved overall, for example for use as door outer panels, or comprise pronounced contours 1 'worked out from plane or curved areas 1'', which in the area of the transitions with respect to the curved or plane surface area have angles α of the order of magnitude between 100 ° and less have than 180 °, so that hereby the most diverse requirements for body panels or body panels can be fulfilled - with very light and torsion-resistant components 1.

Ebenso können innerhalb der ausgeprägten Konturen 1' Winkel β in der gleichen Größenordnung auftreten, so daß auch hier eine maximale Flexibilität und Anpassungsfähigkeit an die Ansprüche der Karosseriebauer gegeben ist.Likewise, angles β of the same order of magnitude can occur within the pronounced contours 1 ', so that here too there is maximum flexibility and adaptability to the requirements of the body builder.

Mit dem hier vorgestellten Verfahren und den daraus resultierenden Bauteilen ist es erstmals möglich, Werkstoffe aus metallischen Schäumen - und eventuell massivmetallischen Blechen, die mit diesen verbunden sind - zur Serienfertigung einzusetzen und in reproduzierbarer Weise durch bekannte Umformprozesse und ein anschließendes definiertes Aufschäumen der Metallpulver und Treibmittel enthaltenden Schicht 2' die Vorteile, die ein solcher Leichtbau bietet, in die Praxis umzusetzen.With the method presented here and the resulting components, it is possible for the first time to use materials made of metallic foams - and possibly solid metallic sheets that are connected to them - for series production and in a reproducible manner using known forming processes and subsequent defined foaming of the metal powder and blowing agent containing layer 2 'to implement the advantages that such a lightweight construction offers in practice.

Claims (11)

Bauteil, für insbesondere Landfahrzeuge, vorzugsweise Karosseriebauteil für Kraftfahrzeuge, bestehend aus einem metallischen Schaumwerkstoff mit einer Metallpulver und Treibmittel umfassenden aufgeschäumten porösen Schicht, dadurch gekennzeichnet, daß das Bauteil (1) zumindest eine aus seiner Fläche (1'') erhaben ausgeprägte Kontur (1') aufweist, wobei die im Bereich der Übergänge zwischen der dreidimensional ausgeformten Kontur (1') und dem Flächenbereich (1'') vorkommenden Winkel (α) in einer Größenordnung zwischen 100° und < 180° gehalten sind.Component, in particular for land vehicles, preferably body component for motor vehicles, consisting of a metallic foam material with a foamed porous layer comprising metal powder and propellant, characterized in that the component (1) has at least one contour (1 '') raised from its surface (1 '') '), the angles (α) occurring in the area of the transitions between the three-dimensionally shaped contour (1') and the surface area (1 '') being kept in a range between 100 ° and <180 °. Bauteil, für insbesondere Landfahrzeuge, vorzugsweise Karosseriebauteil für Kraftfahrzeuge, bestehend aus einem metallischen Schaumwerkstoff mit zumindest einer Metallpulver und Treibmittel umfassenden aufgeschäumten porösen Schicht und zumindest einem massivmetallischen Blech, wobei zwischen dem massivmetallischen Blech und der aufgeschäumten porösen Schicht metallische Bindungen bestehen, dadurch gekennzeichnet, daß das Bauteil (1) zumindest eine aus seiner Fläche (1'') erhaben ausgeprägte Kontur (1') aufweist, wobei die im Bereich der Übergänge zwischen der dreidimensional ausgeformten Kontur (1') und dem Flächenbereich (1'') vorkommenden Winkel (α) in einer Größenordnung zwischen 100° und < 180° gehalten sind.Component, in particular for land vehicles, preferably a body component for motor vehicles, consisting of a metallic foam material with at least one foamed porous layer comprising at least one metal powder and propellant and at least one solid metal sheet, between the solid metal sheet and the foamed sheet Porous layer metallic bonds exist, characterized in that the component (1) has at least one contour (1 ') raised from its surface (1''), the contour (1') in the area of the transitions between the three-dimensionally shaped contour the surface area (1 '') occurring angles (α) are kept in a range between 100 ° and <180 °. Bauteil nach Anspruch 1 oder 2 mit einer erhaben ausgeprägten Kontur, innerhalb der Winkel auftreten, dadurch gekennzeichnet, daß diese Winkel (β) im Bereich von 100° bis < 180° gehalten sind.Component according to Claim 1 or 2 with a raised, pronounced contour within which angles occur, characterized in that these angles (β) are kept in the range from 100 ° to <180 °. Bauteil nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß die Flächenbereiche (1'') planeben sind.Component according to one of claims 1 to 3, characterized in that the surface areas (1 '') are flat. Bauteil nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß die Flächenbereiche (1'') gekrümmt sind.Component according to one of claims 1 to 3, characterized in that the surface areas (1 '') are curved. Verfahren zum Endformen eines aus im wesentlichen flächigem metallischem Schaumwerkstoff gebildeten Bauteils, insbesondere nach einem oder mehreren der Ansprüche 1 bis 3, das zumindest eine mit einem Treibmittel vermischtes Metallpulver umfassende Schicht aufweist und ggf. mit zumindest einem massivmetallischen Blech durch z. B. Walzplattieren verbunden ist, wobei die Schichten nach Druckeinwirkung mit metallischer Bindung aneinanderhaften und wobei der flächige Schaumwerkstoff durch einseitige oder beidseitige Formgebung in ein dreidimensionales und einseitig endkonturiertes Formhalbzeug umgeformt wird, dadurch gekennzeichnet, daß das so gebildete Formhalbzeug (7) in eine mit einer Wandung (12) an dessen endkonturierte Seite (10) angepaßte Aufschäumform (9) eingebracht und darin aufgeschäumt wird.Process for the final shaping of a component formed from a substantially flat metallic foam material, in particular according to one or more of claims 1 to 3, which has at least one layer comprising metal powder mixed with a blowing agent and optionally with at least one solid metal sheet by e.g. B. roller plating is connected, the layers adhering to each other after exposure to pressure with metallic bond and the flat foam material being shaped into a three-dimensional and end-contoured semi-finished product by shaping on one or both sides, characterized in that the semi-finished product (7) thus formed is converted into a foaming mold (9) which has a wall (12) on its end-contoured side (10) introduced and foamed in it. Verfahren nach Anspruch 6, dadurch gekennzeichnet, daß durch eine Anpassung der Wandungen (12,13) der Aufschäumform an beide Seiten (10,11) des Formhalbzeuges (7) das Maß der Ausdehnung der aufschäumenden Schicht (2') durch die Wandungen (12,13) der Aufschäumform (9) definiert begrenzt wird.Method according to Claim 6, characterized in that, by adapting the walls (12, 13) of the foaming mold to both sides (10, 11) of the semi-finished product (7), the extent of expansion of the foaming layer (2 ') through the walls (12 , 13) the foaming mold (9) is limited defined. Verfahren nach einem der Ansprüche 6 bis 7, dadurch gekennzeichnet, daß durch die Umformung des Verbundwerkstoffes (6) eine Krümmung von Flächenbereichen (7'') in einem Formhalbzeug (7) bewirkt wird.Method according to one of claims 6 to 7, characterized in that the deformation of the composite material (6) causes a curvature of surface areas (7 '') in a semi-finished product (7). Verfahren nach einem der Ansprüche 6 bis 8, dadurch gekennzeichnet, daß durch die Umformung des Verbundwerkstoffes (6) eine Ausprägung von Teilbereichen (7') aus Flächenbereichen (7'') des Formhalbzeuges (7) bewirkt wird.Method according to one of claims 6 to 8, characterized in that the reshaping of the composite material (6) causes partial regions (7 ') to be formed from surface regions (7'') of the semi-finished product (7). Vorrichtung zur Ausführung des Verfahrens nach einem der Ansprüche 6 bis 9, dadurch gekennzeichnet, daß für die Umformung eine Form (8) vorgesehen ist, die den aufliegenden flächigen Verbundwerkstoff (6) einseitig abstützt und quer zu dessen Auflagefläche Winkel (γ) in einer Größe zwischen 100° und 260° aufweist.Device for carrying out the method according to one of claims 6 to 9, characterized in that for the Forming a shape (8) is provided which supports the flat composite material (6) on one side and has angles (γ) in a size between 100 ° and 260 ° transverse to its support surface. Vorrichtung zur Ausführung des Verfahrens nach Anspruch 6, dadurch gekennzeichnet, daß die gegenüberliegenden Wandungen (12,13) der Aufschäumform (9) im wesentlichen parallele Flächenstrukturen aufweisen.Device for carrying out the method according to claim 6, characterized in that the opposite walls (12, 13) of the foaming mold (9) have essentially parallel surface structures.
EP97105225A 1996-03-29 1997-03-27 Element made of foamed metal Expired - Lifetime EP0798062B1 (en)

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US6090232A (en) 2000-07-18
EP0798062A3 (en) 1998-10-07
US6094798A (en) 2000-08-01
DE59705836D1 (en) 2002-01-31
US20010023027A1 (en) 2001-09-20
EP0798062B1 (en) 2001-12-19
JPH1058575A (en) 1998-03-03
DE19612781C1 (en) 1997-08-21

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