EP1196259A1 - Component comprised of a composite material containing a formable metallic material and method for producing the same - Google Patents

Component comprised of a composite material containing a formable metallic material and method for producing the same

Info

Publication number
EP1196259A1
EP1196259A1 EP00938562A EP00938562A EP1196259A1 EP 1196259 A1 EP1196259 A1 EP 1196259A1 EP 00938562 A EP00938562 A EP 00938562A EP 00938562 A EP00938562 A EP 00938562A EP 1196259 A1 EP1196259 A1 EP 1196259A1
Authority
EP
European Patent Office
Prior art keywords
foamable
layer
metallic material
component
layers
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
EP00938562A
Other languages
German (de)
French (fr)
Other versions
EP1196259B1 (en
Inventor
Joachim Baumeister
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.)
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Original Assignee
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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 Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV filed Critical Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Publication of EP1196259A1 publication Critical patent/EP1196259A1/en
Application granted granted Critical
Publication of EP1196259B1 publication Critical patent/EP1196259B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

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
    • 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
    • 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
    • B22F2003/1042—Sintering only with support for articles to be sintered
    • B22F2003/1046—Sintering only with support for articles to be sintered with separating means for articles to be sintered
    • 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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/94—Pressure bonding, e.g. explosive
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/11—Methods of delaminating, per se; i.e., separating at bonding face
    • 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
    • Y10T29/49616—Structural member making
    • 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
    • Y10T29/49616—Structural member making
    • Y10T29/49622—Vehicular structural member making
    • 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
    • Y10T29/49789—Obtaining plural product pieces from unitary workpiece

Definitions

  • the invention relates to a component made of composite material and a method for its production according to the preambles of claims 1, 10 and 11.
  • Light components e.g. Hollow bodies with two cover layers consisting of a solid metallic material and a layer of a metal foam located between them are known. These components have particularly high rigidity and strength with a low weight. From DE 41 01 630 it is known that hollow bodies are filled with foamable aluminum and that the foaming process takes place inside the hollow body, which results in a particularly light component. The presence of oxide layers on all surfaces of the hollow body and on the surface of the expanding foam can impair the rf.e connection between the foam filling and the hollow body.
  • Sandwich-like composite materials can also be produced by gluing aluminum foam bodies with cover layers made of solid metallic metal.
  • composite materials which by roll cladding foamable aluminum with cover layers made of solid metallic material, such as. B steel, aluminum or titanium, and a subsequent foaming of the foamable aluminum.
  • Hollow bodies produced in this process have a cover layer made of solid metallic material on the outside and inside.
  • the inner cover layer contributes little to the rigidity and strength of the component, but increases the weight of the entire component
  • the object of the present invention is to provide a component which has high rigidity and strength, but whose weight is low.
  • Another object of the invention is to provide a method for producing such a component.
  • a component which has a layer of solid metallic material and in which at least one surface is formed by a foamable metallic material.
  • This surface can be the outer or the inner surface.
  • the component can be designed as a flat composite sheet or a hollow body. The manufacturing process of this component ensures that the connection between the solid metallic cover layer and the foamable layer is very good and that the foamable layer adheres firmly to the cover layer.
  • the component When the component is designed as a flat composite sheet, it can be provided that it consists of a solid metallic layer and a layer of a foamable metallic material firmly adhering to it.
  • These composite sheets are particularly suitable as side impact protection beams for car doors.
  • Such a side impact protection beam therefore consists of a hollow profile, on the inner wall of which there is a firmly adhering metal foam, which contributes significantly to the rigidity and strength of the component, but only a little to the weight
  • the component consists of several layers of a solid material and the layers of a foamable metallic material arranged between them, both or only one surface of a composite sheet designed in this way being provided by a layer of a foamable metallic material Material is formed.
  • the invention provides that a composite sheet has a layer of solid metallic metal arranged between two foamable layers. This composite sheet has a particularly high rigidity and strength with a very low weight.
  • the components according to the invention with an asymmetrical layer sequence are preferably produced by packet rolling. Layers of a solid metallic material and layers of foamable metallic material are alternately arranged on top of one another. According to the invention, it is also provided that, instead of the finished foamable layers, loose powder mixtures containing blowing agent or pre-compressed (e.g. by cold isostatic pressing) powder mixtures are used. In these cases, one or more continuous, non-porous separating foils are used as the separating agent, since otherwise emulsions could mix with the loose or pre-compressed powder mixture. In these cases, the loose or pre-compacted powder mixtures are only compacted into foamable layers during the plating or coating process.
  • a connection between the foamable layers belonging to the individual composite sheets during the rolling process is provided by the arrangement of a separating agent, for. B. prevents an emulsion of graphite or boron nitride or a release film between the layers. If the foamable layer is in the form of a powder mixture containing blowing agent, a film is used as the release agent.
  • the packages assembled in this way are fed to the rolling process. After the rolling process has ended, the components separated by the separating agent arranged between the foamable layers and having foamable layers on their surfaces are obtained.
  • connection quality of the composite materials produced by the method according to the invention is so good that e.g. the flat composite sheets can be cold-profiled by known methods or further processed into longitudinally welded hollow profiles.
  • irregularly shaped hollow parts e.g. To obtain tanks or wishbones, it is possible to deform the flat composite sheets beforehand by any forming process, such as pressing, deep drawing or internal pressure forming, and then to shape the desired hollow body from them.
  • Fig. 1 shows an arrangement of the materials for the production of planes
  • FIG. 2 shows another arrangement of the materials according to FIG. 1
  • FIG. 3 shows a further arrangement of the materials according to FIG. 1
  • Fig. 4 shows a hollow body with a cover layer and a foamable
  • FIG. 5 shows the hollow body according to FIG. 4 with the foamed layer
  • FIG. 1 shows an arrangement of the materials in the production of flat composite sheets with only one solid metallic cover layer 1 a, 1 b, and one foamable layer 2a, 2b.
  • the starting materials are arranged in symmetrical plate stacks A.
  • a layer 2a made of a metallic, foamable material is placed on a cover layer 1a made of solid metallic material.
  • a release agent 3 is arranged on this layer.
  • a further layer 2b made of foamable metallic material and a further cover layer 1b made of a solid metallic material are applied to the release agent layer 3.
  • Such plate stacks A are subjected to a roll plating process.
  • the cover layer connects in each case 1 a, b with the adjacent foamable layer 2a, b.
  • a connection between the foamable layers 2a, 2b is prevented by the release agent 3.
  • two flat composite sheets are formed, each consisting of only one cover layer 1a, b and one foamable layer 2a, 2b adhering firmly to it.
  • a composite sheet produced in this way can also have a three-dimensional structure.
  • the quality of the connection between the two layers 1 and 2 is so good that they cannot separate from one another during subsequent processing by conventional methods such as pressing, deep drawing, hydroforming, etc.
  • FIG. 2 shows another arrangement for the production of composite sheets in the packet rolling process.
  • the layers are arranged as follows: a cover layer 4 made of solid metallic material is followed by a layer 5 made of foamable material.
  • This layer 5 is followed by a release agent layer 3, on which a further layer 6 made of foamable material is arranged.
  • This layer 6 is followed by a layer 7 made of solid metallic material and a layer 8 made of foamable material and a release agent layer 3.
  • This is followed by a layer made of foamable material and a cover layer 10 made of solid metallic material.
  • This package is fed to the roll plating process. After the roll plating process has ended, two composite sheets 4, 5 coated on one side with foamable material; 9, 10 and a composite sheet 6, 7, 8 provided with foamable material on both sides.
  • FIG. 3 shows a layer sequence in which a sandwich construction (foamable layer arranged between two cover layers) is additionally coated with a foamable layer on one or both surfaces.
  • a sandwich construction foamable layer arranged between two cover layers
  • foamable layer solid metallic material 19.
  • solid metallic material 11 foamable material 12, release agent 3, foamable material 13, solid metallic material 14, foamable material 15, solid metallic material 16, foamable material 17, release agent 3, foamable Material 18, solid metallic material 19.
  • this package is roll-clad, two sides are created a foamable layer provided composite sheets 1 1, 12; and 18, 19 and a Sanchwich construction with two solid cover layers 14, 16, which are provided on their surfaces with foamable material 13, 17 and wherein foamable material 15 is located between the cover layers 14, 16.
  • layers 11, 12, 3a and 13 are omitted in the arrangement according to FIG. 3, a sandwich construction 14, 15, 16 provided on one side with a foamable layer 17 and a composite sheet 18, 19 provided on one side with a foamable layer 18 are produced.
  • the composite bends described above can be formed by deep drawing into two three-dimensionally curved half-shells 20, 21. If these half-shells 20, 21 are placed on top of one another such that a cavity 23 is formed between them, the foamable layers 24 facing each other, and then the foaming is triggered by heating, the two foaming layers 24 bond to one another at the contact surfaces, so that after cooling, the two half-shells 20, 21 are inseparably connected to one another by the metal foam 25. Another possibility is to press the half-shells 20, 21 onto one another during the foaming process, for example by means of screws or tensioning devices.
  • the foaming can be carried out in such a way that the entire interior of a hollow component is filled with foam.

Abstract

Component is made of a composite material having at least one layer of solid metallic material and at least one foamable metallic material. At least one outer and/or the inner surface of the component is made of foamable metallic material. An independent claim is also included for a process for producing a component comprising arranging at least two layers of foamable metallic material separated by a separating device between at least two layers of solid metallic material, rolling and removing the composite component.

Description

BAUTEIL AUS METALLSCHAUM ENTHALTENDEN VERBUNDWERKSTOFF UND VERFAHREN ZU SEINER HERSTELLUNGCOMPONENT MADE OF COMPOSITE METAL FOAM AND METHOD FOR THE PRODUCTION THEREOF
Bauteil aus Verbundwerkstoff und Verfahren zu seiner HerstellungComposite component and process for its manufacture
BESCHREIBUNGDESCRIPTION
Die Erfindung betrifft ein Bauteil aus Verbundwerkstoff und ein Verfahren zu seiner Herstellung gemäß den Oberbegriffen der Patentansprüche 1 , 10 und 1 1.The invention relates to a component made of composite material and a method for its production according to the preambles of claims 1, 10 and 11.
Leichte Bauteile, wie z.B. Hohlkörper, mit zwei aus einem massiven metallischen Material bestehenden Deckschichten und einer dazwischen befindlichen Schicht aus einem Metallschaum sind bekannt. Diese Bauteile weisen besonders hohe Steifigkeit und Festigkeit bei einem niedrigen Gewicht auf. Aus der DE 41 01 630 ist bekannt, dass Hohlkörper mit aufschaumbarem Aluminium gefüllt werden und dass der Aufschäumvorgang im Inneren des Hohlkörpers stattfindet, wodurch ein besonders leichtes Bauteil entsteht. Durch die Anwesenheit von Oxydschichten auf allen Oberflachen des Hohlkörpers und auf der Oberflache des expandierenden Schaumes kann rf.e Verbindung zwischen der Schaumfullung und dem Hohkorper beeinträchtigt werden.Light components, e.g. Hollow bodies with two cover layers consisting of a solid metallic material and a layer of a metal foam located between them are known. These components have particularly high rigidity and strength with a low weight. From DE 41 01 630 it is known that hollow bodies are filled with foamable aluminum and that the foaming process takes place inside the hollow body, which results in a particularly light component. The presence of oxide layers on all surfaces of the hollow body and on the surface of the expanding foam can impair the rf.e connection between the foam filling and the hollow body.
Sandwichartige Verbundwerkstoffe können auch durch Bekleben von Aluminiumschaumkorpern mit Deckschichten aus massivem metallischen Meteπal hergestellt werden. Hier ist die mangelnde Festigkeit der Klebstoffe, insbesondere bei höheren Temperaturen, nachteilig. Aus der DE 44 26 627 sind Verbundwerkstoffe bekannt, die durch Walzplattieren von aufschaumbarem Aluminium mit Deckschichten aus massivem metallischen Material, wie z. B Stahl, Aluminium oder Titan, und einem nachfolgenden Aufschäumen des aufschaumbaren Aluminiums, hergestellt werden. In diesem Verfahren hergestellte Hohlkörper weisen außen und innen eine Deckschicht aus massivem metallischen Material auf Die innere Deckschicht tragt hierbei wenig zur Steifigkeit und Festigkeit des Bauteiles bei, erhöht jedoch das Gewicht des gesamten Bauteiles Aufgabe der vorliegenden Erfindung ist es, ein Bauteil anzugeben, das eine hohe Steifigkeit und Festigkeit aufweist, dessen Gewicht jedoch gering ist. Eine weitere Aufgabe der Erfindung ist es, ein Verfahren zur Herstellung eines solchen Bauteiles anzugeben.Sandwich-like composite materials can also be produced by gluing aluminum foam bodies with cover layers made of solid metallic metal. The lack of strength of the adhesives, particularly at higher temperatures, is disadvantageous here. From DE 44 26 627 composite materials are known which by roll cladding foamable aluminum with cover layers made of solid metallic material, such as. B steel, aluminum or titanium, and a subsequent foaming of the foamable aluminum. Hollow bodies produced in this process have a cover layer made of solid metallic material on the outside and inside. The inner cover layer contributes little to the rigidity and strength of the component, but increases the weight of the entire component The object of the present invention is to provide a component which has high rigidity and strength, but whose weight is low. Another object of the invention is to provide a method for producing such a component.
Diese Aufgabe wird durch die in den Patentansprüchen 1 , 7 und 8 angegebenen Merkmale gelost Unteranspruche stellen vorteilhafte Weiterbildungen dar.This object is achieved by the features specified in claims 1, 7 and 8. Subclaims represent advantageous developments.
Gemäß der Erfindung wird ein Bauteil angegeben, das eine Schicht aus massivem metallischen Material aufweist und bei dem mindestens eine Oberflache durch einen aufschaumbaren metallischen Werkstoff gebildet ist Diese Oberflache kann die äußere oder die innere Oberflache sein. Das Bauteil kann als ein ebenes Verbundblech oder ein Hohlkörper ausgebildet sein. Durch das Herstellungsverfahren dieses Bauteils ist gewährleistet, dass die Verbindung zwischen der massiven metallischen Deckschicht und der aufschaumbaren Schicht sehr gut ist und dass die aufschaumbare Schicht an der Deckschicht fest haftet.According to the invention, a component is specified which has a layer of solid metallic material and in which at least one surface is formed by a foamable metallic material. This surface can be the outer or the inner surface. The component can be designed as a flat composite sheet or a hollow body. The manufacturing process of this component ensures that the connection between the solid metallic cover layer and the foamable layer is very good and that the foamable layer adheres firmly to the cover layer.
Bei Ausgestaltung des Bauteils als ebenes Verbundblech kann vorgesehen sein, dass dieses aus einer massiv-metallischen Schicht und einer fest daran haftenden Schicht aus einem aufschaumbaren metallischen Werkstoff besteht. Diese Verbundbleche eignen sich insbesondere als Seitenaufprallschutztrager für PKW-Turen. Ein derartiger Seitenaufprallschutztrager besteht demnach aus einem Hohiprofil, an dessen Innenwandung sich ein fest anhaftender Metallschaum befindet, der deutlich zur Steifigkeit und Festigkeit des Bauteiles, aber nur wenig zum Gewicht beitragtWhen the component is designed as a flat composite sheet, it can be provided that it consists of a solid metallic layer and a layer of a foamable metallic material firmly adhering to it. These composite sheets are particularly suitable as side impact protection beams for car doors. Such a side impact protection beam therefore consists of a hollow profile, on the inner wall of which there is a firmly adhering metal foam, which contributes significantly to the rigidity and strength of the component, but only a little to the weight
Eine andere Ausgestaltung der Verbundbleche sieht vor, dass das Bauteil aus mehreren Schichten eines massiven Werkstoffes und der dazwischen angeordneten Schichten eines aufschaumbaren metallischen Werkstoffes besteht, wobei beide oder nur eine Oberflache eines derart ausgestalteten Verbundbleches durch eine Schicht aus einem aufschaumbaren metallischen Werkstoff gebildet wird. In Ausgestaltung sieht die Erfindung vor, dass ein Verbundblech eine zwischen zwei aufschaumbaren Schichten angeordnete Schicht aus massivem metallischen Meteπal aufweist. Dieses Verbundblech weist eine besonders hohe Steifigkeit und Festigkeit bei einem sehr geringen Gewicht auf.Another embodiment of the composite sheets provides that the component consists of several layers of a solid material and the layers of a foamable metallic material arranged between them, both or only one surface of a composite sheet designed in this way being provided by a layer of a foamable metallic material Material is formed. In one embodiment, the invention provides that a composite sheet has a layer of solid metallic metal arranged between two foamable layers. This composite sheet has a particularly high rigidity and strength with a very low weight.
Die erfindungsgemaßen Bauteile mit unsymmetrischer Schichtfolge werden vorzugsweise durch Paketwalzen hergestellt. Dabei werden abwechselnd Schichten aus einem massiven metallischen Werkstoff und Schichten aus aufschaumbarem metallischen Werkstoff aufeinander angeordnet. Erfindungsgemaß wird auch vorgesehen, anstelle der fertigen aufschaumbaren Schichten lose, treibmittelhaltige Pulvermischungen oder aber vorverdichtete (z.B. durch kaltisostatisches Pressen) Pulvermischungen zu verwenden. In diesen Fallen werden als Trennmittel eine oder mehrere zusammenhangende, durchgehende, nichtporose Trennfolien verwendet, da Emulsionen sich sonst mit der losen oder vorverdichteten Pulvermischung vermischen konnten. Die losen oder vorverdichteten Pulvermischungen werden in diesen Fallen erst wahrend des Plattier- oder Beschichtungsvorgangs zu aufschaumbaren Schichten verdichtet. Eine Verbindung zwischen den zu den einzelnen Verbundblechen gehörenden aufschaumbaren Schichten wahrend des Walzprozesses wird durch die Anordnung eines Trenπmittels, z. B. eine Emulsion aus Graphit oder Bornitrit oder eine Trennfolie, zwischen den Schichten verhindert. Liegt die aufschaumbare Schicht in Form einer treibmittelhaltigen Pulvermischung vor, so wird als Trennmittel eine Folie eingesetzt. Die so zusammengesetzten Pakete werden dem Walzvorgang zugeführt. Nach der Beendigung des Walzvorgangs werden die durch das zwischen den aufschaumbaren Schichten angeordnete Trennmittel getrennten Bauteile, die an ihren Oberflachen aufschaumbare Schichten aufweisen, erhalten.The components according to the invention with an asymmetrical layer sequence are preferably produced by packet rolling. Layers of a solid metallic material and layers of foamable metallic material are alternately arranged on top of one another. According to the invention, it is also provided that, instead of the finished foamable layers, loose powder mixtures containing blowing agent or pre-compressed (e.g. by cold isostatic pressing) powder mixtures are used. In these cases, one or more continuous, non-porous separating foils are used as the separating agent, since otherwise emulsions could mix with the loose or pre-compressed powder mixture. In these cases, the loose or pre-compacted powder mixtures are only compacted into foamable layers during the plating or coating process. A connection between the foamable layers belonging to the individual composite sheets during the rolling process is provided by the arrangement of a separating agent, for. B. prevents an emulsion of graphite or boron nitride or a release film between the layers. If the foamable layer is in the form of a powder mixture containing blowing agent, a film is used as the release agent. The packages assembled in this way are fed to the rolling process. After the rolling process has ended, the components separated by the separating agent arranged between the foamable layers and having foamable layers on their surfaces are obtained.
Auch andere bekannte Plattier- oder Beschichtungsverfahren können eingesetzt werden, sofern sie zu einer guten Verbindung zwischen der aufschaumbaren Metallschicht und der Deckschicht aus massivem metallischen Material fuhren Dabei kann es sich um Ziehen, thermisches Spritzen, Sprengplattieren, Koextrusion, Strangpressplattieren oder HIP-Plattieren handeln.Other known plating or coating processes can also be used, provided that they lead to a good connection between the foamable metal layer and the cover layer made of solid metallic material. This can involve drawing, thermal spraying, Explosive plating, coextrusion, extrusion plating or HIP plating.
Die Verbindungsqualität der nach dem erfindungsgemäßen Verfahren hergestellten Verbundwerkstoffe ist so gut, dass z.B. die ebenen Verbundwerkstoffbleche durch bekannte Verfahren kaltprofiliert oder zu längsnahtgeschweißten Hohlprofilen weiterverarbeitet werden können. Um unregelmäßig geformte Hohlteile, wie z.B. Tanks oder Querlenker, zu erhalten, ist es möglich, die ebenen Verbundbleche zuvor durch beliebige Umformverfahren, wie Pressen, Tiefziehen oder Innendruckumformen, zu verformen und anschließend daraus den gewünschten Hohlkörper zu formen.The connection quality of the composite materials produced by the method according to the invention is so good that e.g. the flat composite sheets can be cold-profiled by known methods or further processed into longitudinally welded hollow profiles. Around irregularly shaped hollow parts, e.g. To obtain tanks or wishbones, it is possible to deform the flat composite sheets beforehand by any forming process, such as pressing, deep drawing or internal pressure forming, and then to shape the desired hollow body from them.
Die Erfindung wird anhand der nachfolgenden Zeichnungen näher erläutert. Es zeigen :The invention is illustrated by the following drawings. Show it :
Fig. 1 eine Anordnung der Werkstoffe zur Herstellung von ebenenFig. 1 shows an arrangement of the materials for the production of planes
Verbundblechen durch WalzplattierenComposite sheets by roll cladding
Fig. 2 eine andere Anordnung der Werkstoffe gemäß Fig. 12 shows another arrangement of the materials according to FIG. 1
Fig. 3 eine weitere Anordnung der Werkstoffe gemäß Fig. 13 shows a further arrangement of the materials according to FIG. 1
Fig. 4 einen Hohlkörper mit einer Deckschicht und einer aufschäumbarenFig. 4 shows a hollow body with a cover layer and a foamable
Schichtlayer
Fig. 5 den Hohlkörper gemäß Fig. 4 mit der aufgeschäumten Schicht5 shows the hollow body according to FIG. 4 with the foamed layer
Figur 1 zeigt eine Anordnung der Werkstoffe bei der Herstellung von ebenen Verbundblechen mit nur einer massiv- metallischen Deckschicht 1 a, 1 b, und einer aufschäumbaren Schicht 2a, 2b. Um derartige Verbundbleche zu erhalten werden die Ausgangswerkstoffe zu symmetrischen Plattenstapeln A angeordnet. Auf eine Deckschicht 1 a aus massivem metallischen Werkstoff wird eine Schicht 2a aus einem metallischen, aufschäumbaren Werkstoff gebracht. Auf dieser Schicht wird ein Trennmittel 3 angeordnet. Auf die Trennmittelschicht 3wird eine weitere Schicht 2b aus aufschäumbarem metallischen Werkstoff und eine weitere Deckschicht 1 b aus einem massiven metallischen Werkstoff aufgebracht. Derartige Plattenstapel A werden einem Walzplattiervorgang unterzogen. Dabei verbindet sich jeweils die Deckschicht 1 a, b mit der benachbarten aufschäumbaren Schicht 2a, b. Eine Verbindung zwischen den aufschäumbaren Schichten 2a, 2b wird jedoch durch das Trennmittel 3 verhindert. Nach dem Walzplattieren entstehen so zwei ebene Verbundwerkstoffbleche, die jeweils nur aus einer Deckschicht 1 a, b und einer fest daran haftenden aufschäumbarenbaren Schicht 2a, 2b bestehen. Ein so hergestelltes Verbundblech kann auch dreidimensional strukturiert sein. Die Verbindungsqualität zwischen den beiden Schichten 1 und 2 ist so gut, dass diese sich bei einer nachfolgenden Weiterverarbeitung durch übliche Verfahren wie z.B. Pressen, Tiefziehen, Innenhochdruckumformen usw. nicht voneinander lösen.FIG. 1 shows an arrangement of the materials in the production of flat composite sheets with only one solid metallic cover layer 1 a, 1 b, and one foamable layer 2a, 2b. In order to obtain composite sheets of this type, the starting materials are arranged in symmetrical plate stacks A. A layer 2a made of a metallic, foamable material is placed on a cover layer 1a made of solid metallic material. A release agent 3 is arranged on this layer. A further layer 2b made of foamable metallic material and a further cover layer 1b made of a solid metallic material are applied to the release agent layer 3. Such plate stacks A are subjected to a roll plating process. The cover layer connects in each case 1 a, b with the adjacent foamable layer 2a, b. A connection between the foamable layers 2a, 2b is prevented by the release agent 3. After roll cladding, two flat composite sheets are formed, each consisting of only one cover layer 1a, b and one foamable layer 2a, 2b adhering firmly to it. A composite sheet produced in this way can also have a three-dimensional structure. The quality of the connection between the two layers 1 and 2 is so good that they cannot separate from one another during subsequent processing by conventional methods such as pressing, deep drawing, hydroforming, etc.
In Figur 2 ist eine andere Anordnung zur Herstellung von Verbundblechen im Paketwalzverfahren dargestellt. Es ist folgende Anordnung der Schichten vorgesehen: Auf eine Deckschicht 4 aus massivem metallischen Material folgt eine Schicht 5 aus aufschäumbarem Material. Auf diese Schicht 5 folgt eine Trennmittelschicht 3, auf der eine weitere Schicht 6 aus aufschäumbarem Material angeordnet ist. Auf diese Schicht 6 folgt eine Schicht 7 aus massivem metallischen Material und dem eine Schicht 8 aus aufschäumbarem Material und eine Trennmittelschicht 3. Auf diese folgt eine Schicht aus aufschäumbarem Material und eine Deckschicht 10 aus massivem metallischen Werkstoff. Dieses Paket wird dem Walzplattiervorgang zugeführt. Nach Beendigung des Walzplattierverfahrens entstehen: zwei einseitig mit aufschäumbarem Material beschichtete Verbundbleche 4, 5; 9, 10 und ein doppelseitig mit aufschäumbarem Material versehenes Verbundblech 6, 7, 8.FIG. 2 shows another arrangement for the production of composite sheets in the packet rolling process. The layers are arranged as follows: a cover layer 4 made of solid metallic material is followed by a layer 5 made of foamable material. This layer 5 is followed by a release agent layer 3, on which a further layer 6 made of foamable material is arranged. This layer 6 is followed by a layer 7 made of solid metallic material and a layer 8 made of foamable material and a release agent layer 3. This is followed by a layer made of foamable material and a cover layer 10 made of solid metallic material. This package is fed to the roll plating process. After the roll plating process has ended, two composite sheets 4, 5 coated on one side with foamable material; 9, 10 and a composite sheet 6, 7, 8 provided with foamable material on both sides.
In Figur 3 ist eine Schichtreihenfolge dargestellt, bei der eine Sandwichkonstruktion (zwischen zwei Deckschichten angeordnete aufschäumbare Schicht) zusätzlich mit einer aufschäumbaren Schicht an einer oder beiden Oberflächen beschichtet ist. Es ergibt sich folgende Anordnung der Schichten: massiv-metallisches Material 1 1 , aufschäumbares Material 12 ,Trennmittel 3, aufschäumbares Material 13, massiv-metallisches Material 14, aufschäumbares Material 15, massiv-metallisches Material 16, aufschäumbares Material 17, Trennmittel 3, aufschäumbares Material 18, massiv-metallisches Material 19. Wird dieses Paket walzplattiert, so entstehen zwei einseitig mit einer aufschäumbaren Schicht versehene Verbundbleche 1 1 , 12; und 18, 19 und eine Sanchwichkonstruktion mit zwei massiven Deckschichten 14, 16, die an ihren Oberflächen mit aufschäumbarem Werkstoff 13, 17 versehen sind und wobei sich zwischen den Deckschichten 14, 16 aufschäumbares Material 15 befindet. Werden bei der Anordnung nach Figur 3 die Schichten 1 1 , 12 , 3a und 13 weggelassen, so entsteht eine einseitig mit einer aufschäumbaren Schicht 17 versehene Sandwichkontruktion 14, 15, 16 und ein einseitig mit einer aufschäumbaren Schicht 18 versehenes Verbundblech 18, 19.FIG. 3 shows a layer sequence in which a sandwich construction (foamable layer arranged between two cover layers) is additionally coated with a foamable layer on one or both surfaces. This results in the following arrangement of the layers: solid metallic material 11, foamable material 12, release agent 3, foamable material 13, solid metallic material 14, foamable material 15, solid metallic material 16, foamable material 17, release agent 3, foamable Material 18, solid metallic material 19. If this package is roll-clad, two sides are created a foamable layer provided composite sheets 1 1, 12; and 18, 19 and a Sanchwich construction with two solid cover layers 14, 16, which are provided on their surfaces with foamable material 13, 17 and wherein foamable material 15 is located between the cover layers 14, 16. If layers 11, 12, 3a and 13 are omitted in the arrangement according to FIG. 3, a sandwich construction 14, 15, 16 provided on one side with a foamable layer 17 and a composite sheet 18, 19 provided on one side with a foamable layer 18 are produced.
Gemäß der Darstellung in den Figuren 4, und 5 können oben beschriebene Verbundbieche durch Tiefziehen zu zwei dreidimensional gewölbten Halbschalen 20, 21 umgeformt werden. Legt man diese Halbschalen 20, 21 so aufeinander, daß zwischen ihnen ein Hohlraum 23 entsteht, wobei die aufschäumbaren Schichten 24 einander zugewandt sind, und löst dann das Aufschäumen durch eine Erwärmung aus, so verbinden sich an den Berührungsflächen die beiden aufschäumenden Schichten 24 miteinander, so dass nach erfolgter Abkühlung die beiden Halbschalen 20, 21 durch den Metallschaum 25 unlösbar miteinander verbunden sind. Eine andere Möglichkeit besteht darin, die Halbschalen 20, 21 während des Schäumvorgangs aufeinander zu pressen, etwa durch Schrauben oder Spannvorrichtungen. In diesen Fällen kann an den Berührflächen der beiden Halbschalen 20, 21 infolge des Anspressdrucks kein Aufschäumen erfolgen, so dass die beiden Halbschalen 20, 21 hier durch eine massive, nichtgeschäumte Aluminiumschicht unlösbar verbunden sind, während an den übrigen Innenflächen der Schaum ungehindert expandieren konnte. Eine weitere Möglichkeit zur Herstellung des Hohlbauteils besteht darin, die beiden Halbschalen 20, 21 vor oder nach dem Aufschäumen miteinander zu verschweißen, so dass die Metallschichten aus konventionellen Materialien in der Schweißzone direkt miteinander verbunden sind, ohne dass sich Schaum oder aufschäumbares Material dazwischen befindet. Schließlich ist es möglich, regelmäßig geformte Hohlkörper (z.B. einfache Rohre) herzustellen und diese anschließend, beispielsweise durch Innenhochdruckumformen, weiterzubearbeiten. Häufig erfolgt der Aufschäumvorgang als letzter Schritt, indem der Hohlkörper auf eine Temperatur erwärmt ist, bei der die aufschäumbare Aluminiumschicht 24 zu einer Schaumschicht 25 aufschäumt. Es ist jedoch auch möglich, zunächst den Schäumvorgang durchzuführen, und anschließend die Umformung vorzunehmen.According to the illustration in FIGS. 4 and 5, the composite bends described above can be formed by deep drawing into two three-dimensionally curved half-shells 20, 21. If these half-shells 20, 21 are placed on top of one another such that a cavity 23 is formed between them, the foamable layers 24 facing each other, and then the foaming is triggered by heating, the two foaming layers 24 bond to one another at the contact surfaces, so that after cooling, the two half-shells 20, 21 are inseparably connected to one another by the metal foam 25. Another possibility is to press the half-shells 20, 21 onto one another during the foaming process, for example by means of screws or tensioning devices. In these cases, no foaming can take place on the contact surfaces of the two half-shells 20, 21 as a result of the contact pressure, so that the two half-shells 20, 21 are inseparably connected here by a solid, non-foamed aluminum layer, while the foam on the other inner surfaces could expand unhindered. Another possibility for producing the hollow component is to weld the two half-shells 20, 21 to one another before or after the foaming, so that the metal layers made of conventional materials are connected directly to one another in the welding zone, without there being foam or foamable material in between. Finally, it is possible to produce regularly shaped hollow bodies (eg simple pipes) and then to further process them, for example by means of internal high pressure forming. The foaming process is often carried out as the last step in that the hollow body is heated to a temperature at which the foamable aluminum layer 24 foams into a foam layer 25. However, it is also possible to first carry out the foaming process and then to carry out the shaping.
Vorteilhaft ist es, wenn dieser Schäumvorgang mit einer Wärmebehandlung des Deckblechwerkstoffs durchgeführt wird.It is advantageous if this foaming process is carried out with a heat treatment of the cover sheet material.
In einzelnen Fällen kann das Aufschäumen gezielt soweit getrieben werden, dass der gesamte Innenraum eines Hohlbauteils mit Schaum gefüllt ist. In individual cases, the foaming can be carried out in such a way that the entire interior of a hollow component is filled with foam.

Claims

Patentansprüche claims
1. Bauteil aus Verbundwerkstoff mit mindestens einer Schicht aus massivem metallischen Werkstoff und mindestens einer Schicht aus einem aufschäumbaren metallischen Werkstoff, wobei mindestens eine äußere und/oder die innere Oberfläche des Bauteiles aus dem aufschäumbaren metallischen Werkstoff besteht.1. Component made of composite material with at least one layer made of solid metallic material and at least one layer made of a foamable metallic material, wherein at least one outer and / or the inner surface of the component consists of the foamable metallic material.
2. Bauteil nach Anspruch 1 , dadurch gekennzeichnet, dass es eine Schicht aus massivem metallischen Metall aufweist, an der die aufschäumbare Schicht fest haftet.2. Component according to claim 1, characterized in that it has a layer of solid metallic metal to which the foamable layer adheres firmly.
3. Bauteil nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das Bauteil Verbundblech ist.3. Component according to claim 1 or 2, characterized in that the component is composite sheet.
4. Bauteil nach Anspruch 1 oder 2, dadurch gekennzeichet, dass das Bauteil ein Hohlbauteil ist.4. Component according to claim 1 or 2, characterized in that the component is a hollow component.
5. Bauteil nach Anspruch 3, dadurch gekennzeichnet, dass es im Verfahren des Walzplattierens hergestellt wurde.5. Component according to claim 3, characterized in that it was produced in the process of roll cladding.
6. Bauteil nach einem der vorangegangen Ansprüche, dadurch gekennzeichnet, dass es die Form eines Tanks oder eines Querlenkers aufweist. 6. Component according to one of the preceding claims, characterized in that it has the shape of a tank or a wishbone.
7. Bauteil nach einem der vorangegangen Ansprüche, dadurch gekennzeichnet, dass nach einer Wärmebehandlung die aufschäumbare Schicht im ausgeschäumten Zustand vorliegt.7. Component according to one of the preceding claims, characterized in that after a heat treatment, the foamable layer is in the expanded state.
8. Bauteil nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass die aufschäumbare Schicht aus Aluminium, Zink oder Blei besteht.8. Component according to one of the preceding claims, characterized in that the foamable layer consists of aluminum, zinc or lead.
9. Bauteil nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass die massive metallische Schicht aus Stahl, Aluminium, Titan oder Kupfer besteht.9. Component according to one of the preceding claims, characterized in that the solid metallic layer consists of steel, aluminum, titanium or copper.
10. Verfahren zur Herstellung eines Bauteiles nach einem der vorangegangenen Ansprüche, insbesondere nach Ansp-τ;h 1 , dadurch gekennzeichnet, dass zwischen mindestens zwei Schichten aus massivmetallischem Material mindestens zwei durch ein Trennmittel voneinander getrennte Schichten aus aufschäumbarem metallischen Werkstoff angeordnet sind und dass diese Schichten einem Walzvorgang unterzogen werden und dass nach dem Walzvorgang die durch Trennmittel voneinander getrennten Verbundwerkstoffbauteile getrennt werden.10. A method for producing a component according to one of the preceding claims, in particular according to Ansp-τ; h 1, characterized in that at least two layers of foamable metallic material separated by a separating agent are arranged between at least two layers of solid metallic material and that these Layers are subjected to a rolling process and that after the rolling process, the composite material components separated from one another by separating agents are separated.
11. Verfahren zur Herstellung eines Bauteiles nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass zwischen zwei Schichten aus massiv-metallischem Material eine Schicht aus aufschäumbarem metallischen Werkstoff angeordnet ist und dass zwischen mindestens einer Schicht aus massivem metallischen Material und mindestens einer weiteren Schicht aus massivem metallischen Material mindestens zwei durch ein Trennmittel voneinander getrennte Schichten aus aufschäumbarem Material angeordnet sind.11. A method for producing a component according to one of the preceding claims, characterized in that between two layers of solid metallic material, one layer of foamable metallic material is arranged and that at least two layers of foamable material are arranged between at least one layer of solid metallic material and at least one further layer of solid metallic material.
12. Verfahren nach Anspruch 10 oder 1 1 , dadurch gekennzeichnet, dass die Schicht aus aufschäumbarem Material durch lose oder vorverdichtete treibmittelhaltige Pulvermischung gebildet ist und dass während des Walzvorganges diese Pulvermischung zu einer festen aufschäumbaren Schicht verdichtet wird.12. The method according to claim 10 or 1 1, characterized in that the layer of foamable material is formed by loose or pre-compressed blowing agent-containing powder mixture and that during the rolling process, this powder mixture is compressed into a solid foamable layer.
13. Verfahren nach einem der vorangegangenen Ansprüche 10 oder 1 1 dadurch gekennzeichnet, dass das Trennmittel eine Emulsion aus Graphit oder Bornitrit oder eine Trennfolie ist13. The method according to any one of the preceding claims 10 or 1 1, characterized in that the release agent is an emulsion of graphite or boron nitride or a release film
14. Verfahren nach Anspruch 12, dadurch gekennzeichnet, dass das Trennmittel eine Folie ist.14. The method according to claim 12, characterized in that the release agent is a film.
15. Verfahren nach einem der Ansprüche 10 bis 14, dadurch gekennzeichnet, dass das Verfahren als Walzplattieren, Ziehverfahren, Sprengplattieren, HIP-Plattieren, Strangpressplattieren, Koextrusion oder Ziehen durchgeführt wird. 15. The method according to any one of claims 10 to 14, characterized in that the method is carried out as roll plating, drawing process, explosive plating, HIP plating, extrusion plating, coextrusion or drawing.
16. Verfahren nach einem der vorangegangenen Ansprüche 10 bis 15, dadurch gekennzeichnet, dass die Weiterverarbeitung der hergestellten Bauteile durch Pressen, Innenhochdruckumformen oder Tiefziehen erfolgt.16. The method according to any one of the preceding claims 10 to 15, characterized in that the further processing of the manufactured components is carried out by pressing, hydroforming or deep drawing.
17. Verfahren nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass die Weiterverarbeitung der hergestellten Bauteile durch Tiefziehen erfolgt. 17. The method according to any one of the preceding claims, characterized in that the further processing of the manufactured components is carried out by deep drawing.
EP00938562A 1999-05-19 2000-05-18 Component comprised of a composite material containing a formable metallic material and method for producing the same Expired - Lifetime EP1196259B1 (en)

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ATE228907T1 (en) 2002-12-15
DE50000892D1 (en) 2003-01-16
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CA2374487A1 (en) 2000-11-30

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