EP2069707B1 - Moulded metal body and method of producing a moulded metal body - Google Patents

Moulded metal body and method of producing a moulded metal body Download PDF

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Publication number
EP2069707B1
EP2069707B1 EP07763727A EP07763727A EP2069707B1 EP 2069707 B1 EP2069707 B1 EP 2069707B1 EP 07763727 A EP07763727 A EP 07763727A EP 07763727 A EP07763727 A EP 07763727A EP 2069707 B1 EP2069707 B1 EP 2069707B1
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EP
European Patent Office
Prior art keywords
metal
mold
molded
metal foam
foam
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.)
Not-in-force
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EP07763727A
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German (de)
French (fr)
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EP2069707A1 (en
Inventor
Franz Dobesberger
Herbert J. Flankl
Dietmar Leitlmeier
Jörg WELLNITZ
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Huette Klein Reichenbach GmbH
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Huette Klein Reichenbach GmbH
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Application filed by Huette Klein Reichenbach GmbH filed Critical Huette Klein Reichenbach GmbH
Priority to SI200730322T priority Critical patent/SI2069707T1/en
Publication of EP2069707A1 publication Critical patent/EP2069707A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/06—Special casting characterised by the nature of the product by its physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
    • B22D27/13—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of gas pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0442—Layered armour containing metal
    • F41H5/0457—Metal layers in combination with additional layers made of fibres, fabrics or plastics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0492—Layered armour containing hard elements, e.g. plates, spheres, rods, separated from each other, the elements being connected to a further flexible layer or being embedded in a plastics or an elastomer matrix
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C22C1/083—Foaming process in molten metal other than by powder metallurgy
    • C22C1/086—Gas foaming process
    • 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 subject invention relates to a multilayer metal molded body with a metal foam matrix, in which a one- or multi-part insert element is embedded, wherein the metal foam matrix and the insert element are positively connected to each other, and a method for producing such a metal molding.
  • Such a metal molded body is eg from the DE 20313 655 U1 which discloses an aluminum foam bullet resistant member having a net-like reinforcement embedded in the aluminum foam, the reinforcement being formed as a mesh or woven fabric of a steel wire.
  • a mesh is a braid in which a plurality of continuous wires are connected to a braid. The contact points between the individual wires can be rigid or loose. Under bombardment, these continuous wires are subjected to high tensile stresses and strains by the projectile or projectile to be stopped, so that either a high-strength and high-tensile steel wire is required, or the steel wire must be dimensioned accordingly. Although a good shot resistance can be achieved thereby, the cost of such a metal molding can be driven upwards.
  • the object of the present invention is thus to provide a metal mold body which does not have the above disadvantages and moreover an even better strength against penetrating or impacting bodies, such as impact of a body, e.g. by an obvious explosion, or by a projectile possesses.
  • the insert element is designed as a push-soft ring mesh with loosely connected rings.
  • An inventive method for producing a multilayer metal molded article is characterized by the following steps: providing a mold for the metal molding; Arranging at least one single or multi-part insert element in the form of a push soft ring mesh with loosely connected rings in the mold; Melting a metal; Introducing gas into the molten metal to foam the molten metal to produce a flowable metal foam; Introducing the flowable metal foam into the mold; and cooling the metal in the mold, wherein the metal solidifies to form the metal mold.
  • a metal molding according to the invention thus a very lightweight component with the highest bullet class B7 can be achieved.
  • a metal molding can be used, for example, as armor for vehicles or buildings, but also as a shield for persons.
  • the effect can be further increased if in the metal foam matrix a plurality of annular braids are arranged next to or behind each other, wherein the ring braids can also be arranged offset to one another.
  • the metal foam matrix may have a substantially monomodal bubble size distribution.
  • the bubble sizes of the metal foam matrix may also gradually increase from one side surface of the metal molding to the opposite side surface, whereby the strength of the metal molding can be further increased.
  • a further increase in the strength of the metal molding is achieved by a bias of the ring mesh in the metal foam matrix.
  • a further layer of a homogeneous and / or isotropic material such as a stone foil is applied to a side surface of the metal molded body, since this breaks up the impacting projectile and changes the path of the projectile and thus its effect is reduced. For such an application, it is convenient to turn this layer to the bombardment.
  • Fig. 1 shows a rigid, sheet-like, multilayer metal shaped body 1, wherein the length, height and width ratios are advantageously selected according to the relationship 1, h >> b, with which one obtains a flat metal shaped body 1 with a large-area side surface 2.
  • the metal shaped body 1 can be designed as a plate, disc or shell with any curvature and with any cross-section.
  • the metal molded body 1 consists essentially of a metal foam matrix 4, preferably aluminum foam, in which one or more single or multi-part insert elements 3 are embedded. Metal foam 4 and insert element (s) 3 are positively connected with each other and form a composite part. Due to the nature of the production of the metal shaped body 1 (by a casting method), it can also come through the adhesion to a certain material connection, but only to about max. 30% based on the breaking strength and pullout strength.
  • the insert elements 3 can be arranged almost arbitrarily, as in the FIGS. 2 to 4 indicated. For example, only a single insert element 3 may be provided at the edge or in the middle of the metal molding 1. However, it is also possible for a plurality of insert elements 3 arranged next to one another or one behind the other to be provided. Likewise, it is conceivable not to arrange insert elements 3 substantially parallel to a side surface 2, but at a certain angle thereto. Exactly so can be provided to bias one or more insert element (s) 3 before embedding in the metal foam matrix 4 with a certain force F.
  • an additional layer 5 made of a homogeneous and / or isotropic material can be applied to a side surface 2 by a suitable method, such as eg by material bond or material closure by a surface bonding, preferably a thin stone film, for example of granite or the like.
  • This layer 5 has a positive effect in particular when used as a shot-resistant rigid molded part, since this increases the permissible firing class and the blasting effect can be reduced or even eliminated.
  • This layer 5 is to turn to the bombardment.
  • By such a layer 5 is a The impacting bullet is broken open and the trajectory of the bullet is changed (essentially by spinning it on impact), thus reducing the effect.
  • a possible inventive shaped metal body 1 could be formed from an aluminum (or other suitable metal) metal foam matrix 4, in which a ring mesh of steel, titanium, or aluminum rings is embedded.
  • the rings can have an outside diameter of 3 - 20mm (depending on the application) and the bubble size of the metal foam matrix 4 is chosen depending on the application, eg up to 30mm bubble size.
  • the ring thicknesses can be chosen between 1 and 2mm, for example.
  • the ring mesh may also be surface treated and cured.
  • the bias of a ring mesh in the metal foam matrix 4 may be for example 1 kN.
  • Such an arrangement is suitable as a shot-resistant metal molding for 1 kg TNT at 5m distance or 15kg plastic explosive at 15m distance.
  • Fig. 7 describes by way of example the production of a metal molding 1 according to the invention.
  • a two-part mold 10 In a two-part mold 10, one or more, single or multi-part insert element (s) 3 in the form of a push-soft ring mesh with loosely connected rings 6 in the desired position within a cavity 12, which dictates the outer shape of the metal molding arranged.
  • the insert element 3 can also be biased with a certain force.
  • metal eg aluminum
  • the cavity 12 of the mold 10 is connected to the furnace 14 via a filler opening 11 and a filler 13 (or similar device).
  • the filler 13 dips into the liquid metal bath 16 in the oven 14.
  • a foaming device 18, such as a nozzle arrangement or an impeller is further provided.
  • Suitable foaming devices and foaming processes are, for example, in the patents EP 1 288 320 B1 and EP 1 419 835 B1 the applicant described.
  • the foaming device 18 is supplied via a feed line 20 gas, preferably air, which exits via the foaming device 18 into the liquid metal bath 16 and forms bubbles 22 in the metal bath. These bubbles 22 rise in the metal bath 16 and in the filler 13 (indicated by the arrow in FIG Fig. 7 In this way, the foaming process is carried out until the entire cavity 12 is filled with bubbles 22 or with metal foam 4.
  • the metal foam can be pressed into the cavity 12 of the mold 10, for example by a pressure on the metal bath 16 is applied.
  • the insert part (s) 3 is surrounded, at least partially, but preferably completely, with liquid metal foam and embedded in the metal foam matrix 4.
  • liquid metal foam and embedded in the metal foam matrix 4.
  • necessary vents between mold 10 or the oven 14 and the outside world may be provided to effect a pressure equalization during filling.
  • the cavity 12 can be closed and the mold 10 can be removed for cooling.
  • metal foam can be produced in a separate device, such as a furnace 14, e.g. according to conventional known methods, and this metal foam with a suitable device, such. a creator or a trowel, are conveyed to a separate mold 10. There, the liquid metal foam can be filled in the cavity 12 of the mold 10. This can e.g. take place, in which the liquid metal foam is pressed in the cavity 12 of the mold, e.g. by means of a stamp.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Superconductors And Manufacturing Methods Therefor (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Telephone Function (AREA)
  • Forging (AREA)

Abstract

Method for manufacturing a multi-layered shaped metal body includes introducing gas into a molten metal in order to form a flowable metal foam, introducing the flowable metal foam into a mold containing therein at least one insert element comprising a freely shearing chain mail of loosely interlinked rings, and cooling the flowable metal foam in the mold to form a shaped metal body.

Description

Die gegenständliche Erfindung betrifft einen mehrschichtigen Metallformkörper mit einer Metallschaummatrix, in die ein ein- oder mehrteiliges Einlageelement eingebettet ist, wobei die Metallschaummatrix und das Einlageelement formschlüssig miteinander verbunden sind, sowie ein Verfahren zum Herstellen eines solchen Metallformkörpers.The subject invention relates to a multilayer metal molded body with a metal foam matrix, in which a one- or multi-part insert element is embedded, wherein the metal foam matrix and the insert element are positively connected to each other, and a method for producing such a metal molding.

Ein solcher Metallformkörper geht z.B. aus der DE 20313 655 U1 hervor, die ein schussfestes Element aus Aluminiumschaum mit einer in den Aluminiumschaum eingebetteten, netzartigen Armierung beschreibt, wobei die Armierung als Maschengeflecht oder -gewebe aus einem Stahldraht gebildet ist. Ein Maschengeflecht ist dabei ein Geflecht, bei dem eine Vielzahl von durchgehenden Drähten zu einem Geflecht verbunden werden. Die Kontaktstellen zwischen den einzelnen Drähten können dabei starr oder lose sein. Unter Beschuss werden diese durchgehenden Drähte durch das zu stoppende Projektil oder Geschoss aber hohen Zugspannungen und Dehnungen ausgesetzt, sodass entweder ein hochfester und hochdehnbarer Stahldraht benötigt wird, oder der Stahldraht entsprechend dimensioniert sein muss. Obwohl damit eine gute Schussfestigkeit erzielt werden kann, können dadurch die Kosten eines solchen Metallformkörpers in die Höhe getrieben werden.Such a metal molded body is eg from the DE 20313 655 U1 which discloses an aluminum foam bullet resistant member having a net-like reinforcement embedded in the aluminum foam, the reinforcement being formed as a mesh or woven fabric of a steel wire. A mesh is a braid in which a plurality of continuous wires are connected to a braid. The contact points between the individual wires can be rigid or loose. Under bombardment, these continuous wires are subjected to high tensile stresses and strains by the projectile or projectile to be stopped, so that either a high-strength and high-tensile steel wire is required, or the steel wire must be dimensioned accordingly. Although a good shot resistance can be achieved thereby, the cost of such a metal molding can be driven upwards.

Die Aufgabe der gegenständlichen Erfindung liegt somit darin, einen Metallformkörper anzugeben, der die obigen Nachteile nicht aufweist und darüber hinaus eine noch bessere Festigkeit gegen eindringende oder aufprallende Körper, wie ein Anprall eines Körpers, z.B. durch eine naheliegende Explosion, oder durch ein Geschoss, besitzt.The object of the present invention is thus to provide a metal mold body which does not have the above disadvantages and moreover an even better strength against penetrating or impacting bodies, such as impact of a body, e.g. by an obvious explosion, or by a projectile possesses.

Diese Aufgabe wird durch die Erfindung gelöst, indem das Einlageelement als schubweiches Ringgeflecht mit lose ineinander verbundenen Ringen ausgebildet ist. Ein erfindungsgemäßes Verfahren zum Herstellen eines mehrschichtigen Metallformkörpers zeichnet sich durch folgende Schritte aus: Bereitstellen einer Kokille für den Metallformkörper; Anordnen zumindest eines ein- oder mehrteiligen Einlageelements in Form eines schubweichen Ringgeflechts mit lose ineinander verbundenen Ringen in der Kokille; Aufschmelzen eines Metalls; Einleiten von Gas in das aufgeschmolzene Metall, um das aufgeschmolzene Metall aufzuschäumen, wobei ein fließfähiger Metallschaum hergestellt wird; Verbringen des fließfähigen Metallschaums in die Kokille; und Abkühlen des Metalls in der Kokille, wobei das Metall erstarrt, um den Metallformkörper zu bilden.This object is achieved by the invention by the insert element is designed as a push-soft ring mesh with loosely connected rings. An inventive method for producing a multilayer metal molded article is characterized by the following steps: providing a mold for the metal molding; Arranging at least one single or multi-part insert element in the form of a push soft ring mesh with loosely connected rings in the mold; Melting a metal; Introducing gas into the molten metal to foam the molten metal to produce a flowable metal foam; Introducing the flowable metal foam into the mold; and cooling the metal in the mold, wherein the metal solidifies to form the metal mold.

Unter Belastung (durch seitlichen Anprall oder unter Beschuss) gleiten die einzelnen Ringe des schubweichen Ringgeflechts in der Metallschaummatrix aneinander ab. Dadurch wird die Belastung auf den einzelnen Ring stark reduziert, die Festigkeit des Verbundes aber gleichzeitig erhöht, da dieser Verbund ein hohes Maß an Energie dissipieren kann. Mit einem erfindungsgemäßen Metallformteil kann somit ein sehr leichter Bauteil mit der höchsten Beschussklasse B7 erzielt werden. Ein solcher Metallformteil kann z.B. als Panzerung bei Fahrzeugen oder an Gebäuden verwendet werden, aber auch als Schild für Personen.Under load (due to lateral impact or under fire), the individual rings of the push-soft ring mesh slide together in the metal foam matrix. This will the load on the individual ring is greatly reduced, but at the same time the strength of the composite is increased, since this composite can dissipate a high level of energy. With a metal molding according to the invention thus a very lightweight component with the highest bullet class B7 can be achieved. Such a metal molding can be used, for example, as armor for vehicles or buildings, but also as a shield for persons.

Die Wirkung kann weiters erhöht werden, wenn in der Metallschaummatrix mehrere Ringeflechte neben- oder hintereinander angeordnet sind, wobei die Ringgeflechte auch zueinander versetzt angeordnet sein können.The effect can be further increased if in the metal foam matrix a plurality of annular braids are arranged next to or behind each other, wherein the ring braids can also be arranged offset to one another.

Je nach Anwendung kann die Metallschaummatrix eine im Wesentlichen monomodale Blasengrößenverteilung aufweisen. Die Blasengrößen der Metallschaummatrix können aber auch von einer Seitenfläche des Metallformkörpers zur gegenüberliegenden Seitenfläche graduell zunehmen, wodurch die Festigkeit des Metallformkörpers weiter erhöht werden kann.Depending on the application, the metal foam matrix may have a substantially monomodal bubble size distribution. However, the bubble sizes of the metal foam matrix may also gradually increase from one side surface of the metal molding to the opposite side surface, whereby the strength of the metal molding can be further increased.

Eine weitere Erhöhung der Festigkeit des Metallformkörpers erzielt man, durch eine Vorspannung des Ringgeflechts in der Metallschaummatrix.A further increase in the strength of the metal molding is achieved by a bias of the ring mesh in the metal foam matrix.

Ganz besonders für Anwendung als schussfeste Panzerung ist es vorteilhaft, wenn an einer Seitenfläche des Metallformkörpers eine weitere Schicht aus einem homogenen und/oder isotropen Material, wie eine Steinfolie, aufgebracht wird, da diese das aufprallende Geschoss aufbricht und die Bahn des Geschosses verändert und somit dessen Wirkung reduziert wird. Für eine solche Anwendung ist es günstig, diese Schicht dem Beschuss zuzuwenden.Especially for use as a shot-resistant armor, it is advantageous if a further layer of a homogeneous and / or isotropic material, such as a stone foil is applied to a side surface of the metal molded body, since this breaks up the impacting projectile and changes the path of the projectile and thus its effect is reduced. For such an application, it is convenient to turn this layer to the bombardment.

Die Erfindung wird im nachfolgenden anhand der schematischen, nicht einschränkenden Figuren 1 bis 7 beschrieben, die vorteilhafte Ausführungsbeispiele zeigen. Dabei zeigt

  • Fig. 1 eine Darstellung eines mehrschichtigen Metallformkörpers,
  • Fig. 2 bis 4 Querschnitte eines erfindungsgemäßen Metallformkörpers,
  • Fig. 5 eine Ansicht eines Ringgeflechts,
  • Fig. 6 Bespiele möglicher Ringe für ein Ringgeflecht und
  • Fig. 7 eine Vorrichtung zur Herstellung eines erfindungsgemäßen Metallformkörpers:
The invention is described below with reference to the schematic, non-limiting FIGS. 1 to 7 described, the advantageous embodiments show. It shows
  • Fig. 1 a representation of a multilayer metal molding,
  • Fig. 2 to 4 Cross sections of a metal molding according to the invention,
  • Fig. 5 a view of a ring mesh,
  • Fig. 6 Examples of possible rings for a ring braid and
  • Fig. 7 an apparatus for producing a shaped metal body according to the invention:

Fig. 1 zeigt einen starren, flächigen, mehrschichtigen Metallformkörper 1, wobei die Längen-, Höhen- und Breitenverhältnisse vorteilhaft gemäß der Beziehung 1, h >> b gewählt werden, womit man einen flächigen Metallformkörper 1 mit einer großflächigen Seitenfläche 2 erhält. Der Metallformkörper 1 kann dabei als Platte, Scheibe oder als Schale mit beliebiger Krümmung und mit einem beliebigen Querschnitt ausgeführt sein. Der Metallformkörper 1 besteht im Wesentlichen aus einer Metallschaummatrix 4, bevorzugt Aluminiumschaum, in den ein oder mehrere, ein- oder mehrteilige Einlegelemente 3 eingebettet sind. Metallschaum 4 und Einlegeelement(e) 3 sind dabei formschlüssig miteinander verbunden und bilden einen Verbundteil. Aufgrund der Art der Herstellung des Metallformkörpers 1 (durch ein Gießverfahren) kann es durch die Adhäsion auch zu einer gewissen materialschlüssigen Verbindung kommen, allerdings nur zu ca. max. 30% bezogen auf die Bruch- und Auszugsfestigkeit. Fig. 1 shows a rigid, sheet-like, multilayer metal shaped body 1, wherein the length, height and width ratios are advantageously selected according to the relationship 1, h >> b, with which one obtains a flat metal shaped body 1 with a large-area side surface 2. The metal shaped body 1 can be designed as a plate, disc or shell with any curvature and with any cross-section. The metal molded body 1 consists essentially of a metal foam matrix 4, preferably aluminum foam, in which one or more single or multi-part insert elements 3 are embedded. Metal foam 4 and insert element (s) 3 are positively connected with each other and form a composite part. Due to the nature of the production of the metal shaped body 1 (by a casting method), it can also come through the adhesion to a certain material connection, but only to about max. 30% based on the breaking strength and pullout strength.

Die Einlegeelemente 3 können dabei nahezu beliebig angeordnet sein, wie in den Figuren 2 bis 4 angedeutet. Z.B. kann nur ein einziges Einlegeelement 3 am Rand oder in der Mitte des Metallformkörpers 1 vorgesehen sein. Es können aber auch mehrere nebeneinander oder hintereinander angeordnete Einlegeelemente 3 vorgesehen sein. Ebenso ist es denkbar, Einlegeelemente 3 nicht im Wesentlichen parallel zu einer Seitenfläche 2 anzuordnen, sondern in einem bestimmten Winkel dazu. Genau so kann vorgesehen sein, ein oder mehrere Einlageelement(e) 3 vor dem Einbetten in die Metallschaummatrix 4 mit einer bestimmten Kraft F vorzuspannen.The insert elements 3 can be arranged almost arbitrarily, as in the FIGS. 2 to 4 indicated. For example, only a single insert element 3 may be provided at the edge or in the middle of the metal molding 1. However, it is also possible for a plurality of insert elements 3 arranged next to one another or one behind the other to be provided. Likewise, it is conceivable not to arrange insert elements 3 substantially parallel to a side surface 2, but at a certain angle thereto. Exactly so can be provided to bias one or more insert element (s) 3 before embedding in the metal foam matrix 4 with a certain force F.

Der Metallschaum 4 weist in einer bevorzugten Ausführung eine im Wesentlichen monomodale Verteilung auf, d.h. die Blasengrößen sind im Wesentlichen alle gleich groß und homogen verteilt. Alternativ dazu kann aber auch vorgesehen sein, die Blasengröße der Metallschaummatrix 4 von einer Seitenfläche 2 des Metallformkörpers 1 zur gegenüberliegenden Seitenfläche graduell zunehmen zu lassen, wie in Fig. 3 angedeutet, was durch eine entsprechende Steuerung des Schäumprozesses möglich ist.In a preferred embodiment, the metal foam 4 has an essentially monomodal distribution, ie the bubble sizes are essentially all the same size and homogeneously distributed. Alternatively, however, it may also be provided for the bubble size of the metal foam matrix 4 to increase gradually from one side face 2 of the metal shaped body 1 to the opposite side face, as in FIG Fig. 3 indicated what is possible by an appropriate control of the foaming process.

Selbstverständlich ist es möglich die obigen Ausgestaltungen und Anordnungen beliebig zu _ kombinieren und somit auf eine bestimmte Anwendung abzustimmen.Of course, it is possible to arbitrarily combine the above configurations and arrangements and thus to tune to a particular application.

Weiters kann an einer Seitenfläche 2 eine zusätzliche Schicht 5 aus einem homogenen und/oder isotropen Material mit einem geeigneten Verfahren, wie z.B. durch Stoffschluss oder Materialschluss durch eine flächige Verklebung, aufgebracht werden, bevorzugt eine dünne Steinfolie, z.B. aus Granit oder ähnlichem. Diese Schicht 5 wirkt sich insbesondere bei einer Anwendung als schussfestes starres Formteil positiv aus, da dadurch die zulässige Beschussklasse erhöht und die Sprengwirkung gemindert oder sogar eliminiert werden kann. Diese Schicht 5 ist dazu dem Beschuss zuzuwenden. Durch eine solche Schicht 5 wird ein aufprallendes Geschoss aufgebrochen und die Bahn des Geschosses verändert (im Wesentlichen indem es beim Aufprall ins Trudeln gebracht wird) und die Wirkung somit abgemindert.Furthermore, an additional layer 5 made of a homogeneous and / or isotropic material can be applied to a side surface 2 by a suitable method, such as eg by material bond or material closure by a surface bonding, preferably a thin stone film, for example of granite or the like. This layer 5 has a positive effect in particular when used as a shot-resistant rigid molded part, since this increases the permissible firing class and the blasting effect can be reduced or even eliminated. This layer 5 is to turn to the bombardment. By such a layer 5 is a The impacting bullet is broken open and the trajectory of the bullet is changed (essentially by spinning it on impact), thus reducing the effect.

Ein Einlegeelement 3 ist erfindungsgemäß als schubweiches Ringgeflecht ausgeführt, wie in Fig. 5 angedeutet. Ein solches Ringgeflecht besteht dabei aus einer Vielzahl von Ringen 6, die ineinander greifen, aber ansonsten lose ineinander angeordnet sind, also keinerlei feste Kontaktstellen aufweisen. Somit ist ein solches Ringgeflecht in allen Richtungen vollkommen schubweich und die Ringe 6 gleiten unter Belastung aneinander ab. Die Herstellung eines solchen Ringgeflechts ist an sich bekannt und erfolgt z.B. durch Verschweißen der einzelnen Ringe 6 zu einem Geflecht. Das Ringgeflecht kann dabei z.B. als 1:4, 1:6 oder 2:8 Geflecht, gemäß Ring in Ring Definition, ausgeführt sein. In Fig. 6 sind Beispiele möglicher Ringformen dargestellt, wobei in einem Geflecht unterschiedliche Ringformen auch kombiniert werden können.An insert element 3 is designed according to the invention as a push-soft ring mesh, as in Fig. 5 indicated. Such a ring mesh consists of a plurality of rings 6, which engage with each other, but otherwise are loosely arranged one inside the other, so have no fixed contact points. Thus, such a ring mesh in all directions completely push soft and the rings 6 slide under load from each other. The preparation of such a ring mesh is known per se and is done for example by welding the individual rings 6 to a braid. The ring mesh can be made, for example, as a 1: 4, 1: 6 or 2: 8 mesh, according to ring in ring definition. In Fig. 6 Examples of possible ring shapes are shown, wherein in a mesh different ring shapes can also be combined.

Die erfindungsgemäße Wirkung entfaltet ein solches schubweiches Ringgeflecht in der Metallschaummatrix 4. Unter Belastung (durch Anprall oder unter Beschuss) gleiten die einzelnen Ringe 6 in der Metallschaummatrix 4 aneinander ab. Dadurch wird die Belastung auf den einzelnen Ring 6 stark reduziert, die Festigkeit des Verbundes aber gleichzeitig erhöht, da dieser Verbund ein hohes Maß an Energie dissipieren kann. Zudem wird die Schockwellenausbreitung in dem Verbund deutlich reduziert und es können sich breite Rissfronten zur Energieabsorption ausbilden. Mit einem erfindungsgemäßen Metallformteil kann somit ein sehr leichter Bauteil bis zur höchsten Beschussklasse B7 erzielt werden. Ein solcher Metallformteil kann z.B. als Panzerung bei Fahrzeugen oder an Gebäuden verwendet werden, aber auch als Schild für Personen.The effect of the invention unfolds such a low-shear ring mesh in the metal foam matrix 4. Under load (by impact or under fire) slide the individual rings 6 in the metal foam matrix 4 from each other. As a result, the load on the individual ring 6 is greatly reduced, but at the same time the strength of the composite is increased, since this composite can dissipate a high degree of energy. In addition, the shock wave propagation in the composite is significantly reduced and it can form wide crack fronts for energy absorption. With a metal molding according to the invention thus a very light component up to the highest bullet class B7 can be achieved. Such a metal molding may e.g. used as armor on vehicles or buildings, but also as a shield for persons.

Ein möglicher erfinderischer Metallformkörper 1 könnte dabei aus einer Aluminium- (oder einem anderen geeigneten Metall) Metallschaummatrix 4 gebildet werden, in der ein Ringgeflecht aus Stahl, Titan, oder Aluminium-Ringen eingebettet ist. Die Ringe können dabei z.B. Außendurchmesser von 3 - 20mm aufweisen (je nach Anwendung) und auch die Blasengröße der Metallschaummatrix 4 wird je nach Anwendung gewählt, z.B. bis zu 30mm Blasengröße. Die Ringstärken können z.B. zwischen 1 und 2mm gewählt sein. Das Ringgeflecht kann auch oberflächenbehandelt und gehärtet sein. Die Vorspannung eines Ringgeflechts in der Metallschaummatrix 4 kann z.B. 1 kN betragen. Eine solche Anordnung ist geeignet als schussfester Metallformteil für 1 kg TNT bei 5m Entfernung oder 15kg Plastiksprengstoff bei 15m Entfernung.A possible inventive shaped metal body 1 could be formed from an aluminum (or other suitable metal) metal foam matrix 4, in which a ring mesh of steel, titanium, or aluminum rings is embedded. The rings can have an outside diameter of 3 - 20mm (depending on the application) and the bubble size of the metal foam matrix 4 is chosen depending on the application, eg up to 30mm bubble size. The ring thicknesses can be chosen between 1 and 2mm, for example. The ring mesh may also be surface treated and cured. The bias of a ring mesh in the metal foam matrix 4 may be for example 1 kN. Such an arrangement is suitable as a shot-resistant metal molding for 1 kg TNT at 5m distance or 15kg plastic explosive at 15m distance.

Nachfolgend wird anhand der Fig. 7 beispielhaft die Herstellung eines erfindungsgemäßen Metallformteils 1 beschrieben.The following is based on the Fig. 7 describes by way of example the production of a metal molding 1 according to the invention.

In einer zweiteiligen Kokille 10 wird ein oder mehrere, ein- oder mehrteilige Einlegeelement(e) 3 in Form eines schubweichen Ringgeflechts mit lose ineinander verbundenen Ringen 6 in der gewünschten Position innerhalb eines Hohlraums 12, der die Außenform des Metallformteils vorgibt, angeordnet. Das Einlegeelement 3 kann dabei auch mit einer bestimmten Kraft vorgespannt werden. In einem Ofen 14 wird Metall, z.B. Aluminium, erhitzt und in einen flüssigen Zustand versetzt. Der Hohlraum 12 der Kokille 10 ist über eine Einfüllöffnung 11 und einem Füllstück 13 (oder einer ähnlichen Einrichtung) mit dem Ofen 14 verbunden. Das Füllstück 13 taucht dabei in das flüssige Metallbad 16 im Ofen 14 ein. Im Ofen 14, unterhalb des Füllstücks 13, ist weiters eine Schäumeinrichtung 18, wie z.B. eine Düsenanordnung oder ein lmpeller, vorgesehen. Geeignete Schäumvorrichtungen und Schäumverfahren sind z.B. in den Patenten EP 1 288 320 B1 und EP 1 419 835 B1 der Anmelderin beschrieben. Der Schäumeinrichtung 18 wird über eine Zuleitung 20 Gas, vorzugsweise Luft, zugeführt, das über die Schäumeinrichtung 18 in das flüssige Metallbad 16 austritt und im Metallbad Blasen 22 bildet. Diese Blasen 22 steigen im Metallbad 16 und im Füllstück 13 auf (angedeutet durch den Pfeil in Fig. 7) und gelangen so in den Hohlraum 12 der Kokille 10. Der Schäumvorgang wird dabei solange durchgeführt, bis der gesamte Hohlraum 12 mit Blasen 22 bzw. mit Metallschaum 4 gefüllt ist. Der Metallschaum kann dabei in den Hohlraum 12 der Kokille 10 gedrückt werden, z.B. indem ein Druck auf das Metallbad 16 ausgeübt wird. Dadurch wird der (die) Einlegeteil(e) 3, zumindest teilweise, bevorzugt aber vollständig, mit flüssigem Metallschaum umgeben und in die Metallschaummatrix 4 eingebettet. Selbstverständlich können auch unter Umständen notwendige Entlüftungsöffnungen zwischen Kokille 10 oder dem Ofen 14 und der Außenwelt vorgesehen sein, um während des Befüllens einen Druckausgleich zu bewirken. Nach dem Schäumvorgang kann der Hohlraum 12 verschlossen und die Kokille 10 zum Abkühlen entfernt werden.In a two-part mold 10, one or more, single or multi-part insert element (s) 3 in the form of a push-soft ring mesh with loosely connected rings 6 in the desired position within a cavity 12, which dictates the outer shape of the metal molding arranged. The insert element 3 can also be biased with a certain force. In an oven 14, metal, eg aluminum, is heated and put into a liquid state. The cavity 12 of the mold 10 is connected to the furnace 14 via a filler opening 11 and a filler 13 (or similar device). The filler 13 dips into the liquid metal bath 16 in the oven 14. In the oven 14, below the filling piece 13, a foaming device 18, such as a nozzle arrangement or an impeller, is further provided. Suitable foaming devices and foaming processes are, for example, in the patents EP 1 288 320 B1 and EP 1 419 835 B1 the applicant described. The foaming device 18 is supplied via a feed line 20 gas, preferably air, which exits via the foaming device 18 into the liquid metal bath 16 and forms bubbles 22 in the metal bath. These bubbles 22 rise in the metal bath 16 and in the filler 13 (indicated by the arrow in FIG Fig. 7 In this way, the foaming process is carried out until the entire cavity 12 is filled with bubbles 22 or with metal foam 4. The metal foam can be pressed into the cavity 12 of the mold 10, for example by a pressure on the metal bath 16 is applied. As a result, the insert part (s) 3 is surrounded, at least partially, but preferably completely, with liquid metal foam and embedded in the metal foam matrix 4. Of course, under certain circumstances necessary vents between mold 10 or the oven 14 and the outside world may be provided to effect a pressure equalization during filling. After the foaming process, the cavity 12 can be closed and the mold 10 can be removed for cooling.

Nach dem Befüllen wird die Kokille 10 bzw. der darin befindliche Metallformkörper 1 abgekühlt, bis der flüssige Metallschaum verfestigt ist und die Metallschaummatrix 4 bildet. Danach kann die Kokille 10 geöffnet und der fertige Metallformkörper 1 entnommen werden.After filling, the mold 10 or the metal mold 1 located therein is cooled until the liquid metal foam has solidified and forms the metal foam matrix 4. Thereafter, the mold 10 can be opened and the finished metal moldings 1 are removed.

Grundsätzlich ist es aber möglich, den Hohlraum 12 der Kokille 12 vor dem Schäumen teilweise oder vollständig mit flüssigem Metall zu füllen, z.B. in dem auf das flüssige Metallbad 16 ein Druck ausgeübt wird, womit der Flüssigkeitsspiegel im Füllstück 13 und folglich auch im Hohlraum 12 steigt. Wird nun das flüssige Metall wie oben beschrieben aufgeschäumt, steigen die Blasen 22 wieder nach oben und verdrängen dabei das flüssige Metall im Hohlraum 12, bis dieser zur Ausbildung der Metallschaummatrix 4 vollständig mit Metallschaum gefüllt ist. Dazu kann auch ein gewisser Druckausgleich vorgesehen sein, um eine gleichmäßige Schaumbildung sicherzustellen, z.B. in dem die Kokille während des Schäumvorgangs langsam angehoben wird oder in dem der Druck auf das Metallbad 16 langsam abgesenkt wird.In principle, however, it is possible to fill the cavity 12 of the mold 12 partially or completely with liquid metal before foaming, for example, in which a pressure is exerted on the liquid metal bath 16, whereby the liquid level in the filling piece 13 and consequently also in the cavity 12 rises , Now, if the liquid metal foamed as described above, the bubbles rise 22 back up and displace the liquid metal in the cavity 12 until it is completely filled with metal foam to form the metal foam matrix 4. For this purpose, a certain pressure equalization can be provided to ensure a uniform foam formation, for example, in which the mold is slowly raised during the foaming process or in which the pressure on the metal bath 16 is lowered slowly.

Der Schäumprozess kann aber auch so gesteuert werden, dass der Metallformkörper 1 Bereiche mit Metallschaum und Bereiche aus kompaktem Metall nebeneinander liegen. Dazu können auch geeigneten Trennelemente in der Kokille 10 angeordnet werden.However, the foaming process can also be controlled so that the metal moldings 1 are areas with metal foam and areas of compact metal next to each other. For this purpose, suitable separating elements can be arranged in the mold 10.

Ebenso ist es natürlich möglich, den Schäumvorgang und den Gießvorgang zu trennen. Dazu kann in einer separaten Vorrichtung, wie ein Ofen 14, Metallschaum erzeugt werden, z.B. nach herkömmlichen bekannten Verfahren, und dieser Metallschaum mit einer geeigneten Vorrichtung, wie z.B. einem Schöpfer oder eine Kelle, zu einer separaten Kokille 10 befördert werden. Dort kann der flüssige Metallschaum in den Hohlraum 12 der Kokille 10 gefüllt werden. Das kann z.B. erfolgen, in dem der flüssige Metallschaum in dem Hohlraum 12 der Kokille gedrückt wird, z.B. mittels eines Stempels.Likewise, it is of course possible to separate the foaming process and the casting process. For this purpose metal foam can be produced in a separate device, such as a furnace 14, e.g. according to conventional known methods, and this metal foam with a suitable device, such. a creator or a trowel, are conveyed to a separate mold 10. There, the liquid metal foam can be filled in the cavity 12 of the mold 10. This can e.g. take place, in which the liquid metal foam is pressed in the cavity 12 of the mold, e.g. by means of a stamp.

Claims (16)

  1. A multi-layer molded metal part having a metal foam matrix (4) in which a single- or multi-part insert element (3) is embedded, with the metal foam matrix (4) and the insert element (3) being connected to one another in a positive fit, characterized in that the insert element (3) is designed as a non-shear resistant mesh of rings having loosely interlinked rings (6).
  2. The multi-layer molded metal part according to Claim 1, characterized in that a plurality of insert elements (3) disposed one next to the other or one behind the other are embedded in the metal foam matrix (4).
  3. The multi-layer molded metal part according to Claim 1 or 2, characterized in that the metal foam matrix (4) has an essentially monomodal bubble size distribution.
  4. The multi-layer molded metal part according to Claim 1 or 2, characterized in that the bubble sizes of the metal foam matrix (4) gradually increase from one lateral surface (2) of the molded metal part (1) to the opposite lateral surface.
  5. The multi-layer molded metal part according to one of Claims 1 to 4, characterized in that the insert element (3) is pre-tensed in the metal foam matrix (4).
  6. The multi-layer molded metal part according to one of Claims 1 to 5, characterized in that an additional layer (5) made of a homogeneous and/or isotropic material is applied to one lateral surface (2) of the molded metal part (1).
  7. The multi-layer molded metal part according to Claim 6, characterized in that the additional layer (5) is embodied as a gravel sheet.
  8. A use of the molded metal part according to one of Claims 1 to 7 as a rigid, bulletproof molded part.
  9. The use according to Claim 8, characterized in that the additional layer (5) made of a homogeneous and/or isotropic material is disposed on the lateral surface of the molded metal part (1) facing the shot.
  10. A method for the production of a multi-layer molded metal part (1) having the following steps:
    Providing a mold (10) for the molded metal part (1);
    Arranging at least one single-or multi-part insert element (3) in the form of a non-shear resistant mesh of rings having loosely interlinked rings in the mold (10);
    Melting a metal;
    Introducing gas into the melted metal (16) in order to produce a foam of the melted metal (16), with a pourable metal foam being produced;
    Placing the pourable metal foam into the mold (10); and
    Cooling the metal in the mold (10), whereupon the metal solidifies in order to form the molded metal piece (1).
  11. The method according to Claim 10, in which the pourable metal foam is pressed into or filled into the mold (10).
  12. The method according to Claim 10 or 11, characterized in that the mold (10) is disposed above the metal melt (16) with a fill opening (11), in that a hollow space (12) of the mold (10) is connected to a fill piece (13) in a liquid metal-impermeable fashion, with the fill piece (13) extending into the metal melt (16), and in that the pourable metal foam is conducted through the fill piece (13) into the hollow space (12) of the mold (10).
  13. The method according to Claim 10 or 11, characterized in that the mold (10) is disposed above the metal melt (16) with a fill opening (11), in that a hollow space (12) of the mold (10) is connected to a fill piece (13) in a liquid metalimpermeable fashion, with the fill piece (13) extending into the metal melt (16), in that the liquid metal level of the metal melt (16) is conducted upward through the fill piece (13) and the fill opening (11) into the hollow space (12) of the mold (10), and in that the metal melt (16) is displaced in the hollow space (12) by the pourable metal foam.
  14. The method according to one of Claims 10 to 13, characterized in that at least one insert element (3) is pre-tensed before the introduction of the pourable metal foam.
  15. The method according to one of Claims 10 to 14, characterized in that the foaming process is controlled in such a way that the bubble size of the metal foam gradually increases or decreases during the foaming process.
  16. The method according to one of Claims 10 to 15, characterized in that an additional layer (5) made of a homogeneous and/or isotropic material is applied to one lateral surface (2) of the hardened molded metal part (1).
EP07763727A 2006-10-05 2007-07-02 Moulded metal body and method of producing a moulded metal body Not-in-force EP2069707B1 (en)

Priority Applications (1)

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SI200730322T SI2069707T1 (en) 2006-10-05 2007-07-02 Moulded metal body and method of producing a moulded metal body

Applications Claiming Priority (2)

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AT0167006A AT504305B1 (en) 2006-10-05 2006-10-05 MULTILAYER METAL MOLDING PENCIL WITH A METAL FOAM MATRIX AND ITS USE
PCT/AT2007/000327 WO2008040035A1 (en) 2006-10-05 2007-07-02 Metal moulding and method of producing a metal moulding

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EP2069707B1 true EP2069707B1 (en) 2010-06-23

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EP (1) EP2069707B1 (en)
CN (1) CN101356416B (en)
AT (2) AT504305B1 (en)
DE (1) DE502007004210D1 (en)
ES (1) ES2347604T3 (en)
PT (1) PT2069707E (en)
RU (1) RU2375668C1 (en)
SI (1) SI2069707T1 (en)
WO (1) WO2008040035A1 (en)

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WO2014052019A1 (en) * 2012-09-28 2014-04-03 Dow Global Technologies Llc Foamed-metal components for wireless-communication towers
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CN101356416B (en) 2012-09-26
EP2069707A1 (en) 2009-06-17
ATE472081T1 (en) 2010-07-15
CN101356416A (en) 2009-01-28
PT2069707E (en) 2010-08-20
AT504305B1 (en) 2009-09-15
WO2008040035A1 (en) 2008-04-10
SI2069707T1 (en) 2010-11-30
US20100107860A1 (en) 2010-05-06
ES2347604T3 (en) 2010-11-02
AT504305A1 (en) 2008-04-15
US20160024618A1 (en) 2016-01-28
RU2375668C1 (en) 2009-12-10

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