Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D19/00—Casting in, on, or around objects which form part of the product
  • B22D19/02—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
  • B22D19/00—Casting in, on, or around objects which form part of the product
  • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
  • C04B35/111—Fine ceramics
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
  • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
  • C04B35/581—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on aluminium nitride
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
  • C04B35/584—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
• • C—CHEMISTRY; METALLURGY
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
  • C04B41/51—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal
  • C04B41/515—Other specific metals
  • C04B41/5155—Aluminium
• • C—CHEMISTRY; METALLURGY
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
  • C04B41/81—Coating or impregnation
  • C04B41/85—Coating or impregnation with inorganic materials
  • C04B41/88—Metals
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
  • C22C29/005—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides comprising a particular metallic binder
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
  • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
  • F16D69/02—Composition of linings ; Methods of manufacturing
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
  • C04B2111/00362—Friction materials, e.g. used as brake linings, anti-skid materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
  • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
  • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
  • C04B2235/3232—Titanium oxides or titanates, e.g. rutile or anatase
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/38—Non-oxide ceramic constituents or additives
  • C04B2235/3817—Carbides
  • C04B2235/3826—Silicon carbides
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/38—Non-oxide ceramic constituents or additives
  • C04B2235/3852—Nitrides, e.g. oxynitrides, carbonitrides, oxycarbonitrides, lithium nitride, magnesium nitride
  • C04B2235/3865—Aluminium nitrides
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/38—Non-oxide ceramic constituents or additives
  • C04B2235/3852—Nitrides, e.g. oxynitrides, carbonitrides, oxycarbonitrides, lithium nitride, magnesium nitride
  • C04B2235/3873—Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
  • C04B2235/52—Constituents or additives characterised by their shapes
  • C04B2235/5296—Constituents or additives characterised by their shapes with a defined aspect ratio, e.g. indicating sphericity
• • 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
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249994—Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]

Definitions

• the present invention relates to a method for producing a body from metal-ceramic composite materials according to the preamble of claim 1.
• GGG nodular cast iron
• WO 2004018718 discloses an insert made of woven, continuous Al 2 O 3 fibers, which is infiltrated by means of gas pressure with AICu 2 and provided with a Ni / Ag coating. Subsequently, the composite insert is positioned in a mold in the bridge area and cast by means of press casting (squeeze casting) of the aluminum alloy caliper.
• US Pat. No. 6,719,104 discloses the local reinforcement of lightweight brake calipers by means of inserts of continuous Al 2 O 3 fibers, steel or molybdenum.
• US 5433300 discloses the local reinforcement of lightweight brake calipers by inserts made by means of an "isost foam” process (negative molding of polyurethane foams).
• the object of the invention is therefore to provide a method for local stiffening or reinforcement of lightweight components by means of inserts, which is less expensive than the aforementioned methods and also ensures a better connection between the insert and the lightweight component. This object is achieved with the features of present claim 1.
• the subclaims indicate preferred embodiments.
• a method of making a body of metal-ceramic composite materials comprises the steps of:
• the ceramic preform thus produced with a porous structure (infiltration step).
• the molten metal is a light metal alloy, in particular an Al alloy.
• curable Al alloys such as AISi7Mg.
• the ceramic particles are preferably oxides, such as Al 2 O 3 , TiO 2 , carbides, such as SiC, or nitrides, such as Si 3 N 4 , AlN.
• Existing foreign atoms in the above sense are, for example, the Mg atoms in an AISiMg alloy.
• porosity is meant the ratio of the volume of all voids of a porous solid to its outer volume. It is therefore a measure of how much space the actual solid fills within a certain volume or which cavities it leaves behind. The pores are usually filled with air. Due to the porosity of the preform, therefore, the expected volume fractions of the ceramic and metal components of the composite material are usually already determined.
• the aspect ratio of the ceramic particles used can be in the range from 1 to 10;
• the particles can therefore have an elongated shape.
• particles of this dimension are not yet fibers.
• the aspect ratio is preferably in the range of 1-5.
• the pore diameter is particularly preferably 1-5 ⁇ m, while the porosity is preferably 25-50%.
• the metal-ceramic composite materials produced in this way have low specific weights at high moduli of elasticity and, on the other hand, can be intimately bonded to the lightweight components to be reinforced
• pore formers are added to the starting powder, which contains ceramic particles. These are usually oblong, slightly burned out - A -
• the channels produced in this way can have widths of 2 to 50 ⁇ m, preferably 5 to 30 ⁇ m.
• the pore formers have a significant influence on the setting of a specific porosity.
• pore formers can also be used, in particular, in the production of ceramic preforms, in order to produce a network of pore channels, which result in a better infiltrability of the preform; the pore channels act as infiltration channels here.
• the resulting metal channels increase the strength and toughness of the material.
• cellulose flakes or fibers having a volume fraction of 1 to 30%, preferably 2 to 20%.
• pore formers e.g. also soot particles, rice starch or organic macromolecules, e.g. Fullerenes or nanotubes conceivable.
• suitable pore formers are all those materials which burn, decompose or outgas during sintering and thus generate voids in the material.
• a body is provided from a metal-ceramic composite material produced according to one of the preceding methods.
• the use of a metal-ceramic composite body produced according to one of the previous methods is provided as an insert for stiffening lightweight components, in particular in motor vehicle construction.
• Disc brake calipers are particularly suitable as lightweight components, but also any other components which are made of light metal and which have locally high stiffness requirements, in particular in the automotive, motorcycle, aircraft and shipbuilding industries. It is preferably provided that the material used for the lightweight components and for the molten metal of the inserts are largely identical. The term "largely identical" is to be understood below that the metals or alloys for the lightweight components and the inserts consist of at least the same main components.
• AISi7Mg is used for the lightweight component and AICu4MgSi for the insert.
• AICu4MgSi for the insert.
• light alloys e.g. Al alloys.
• the choice of largely identical materials allows an intimate connection between the lightweight component and the insert.
• the invention provides a method for introducing an insert of metal-ceramic composite materials according to the invention into a lightweight component.
• the method is characterized in that a casting step for producing the lightweight component takes place with or subsequent to the infiltration step.
• the insert is inserted into the mold, and the lightweight component is then poured around the insert.
• the surface of the metal-ceramic composite insert to be cast over should be modified in such a way that an improvement in the connection of the lightweight component encapsulation results. This can be achieved by mechanical surface treatment, e.g. Roughening, or by applying a coating (e.g., Zn, AIS2, Cu, NiCrAI, NiAg).
• the coating may e.g. be applied by flame spraying, galvanic or electroless.
• the material used for the lightweight components and for the molten metal of the inserts are largely identical.
• the choice of largely identical materials allows an intimate connection between the lightweight component and the insert.
• the casting process in this case does not necessarily have to be a pressure-assisted casting process.
• the infiltration step and the casting step are combined into one process step, such that the preform is infiltrated with the casting of the lightweight component in a pressure-assisted manner.
• This process is also referred to as "integrated preform infiltration.”
• casting processes are used, which generally have to be pressure-assisted in order to be able to realize a metal infiltration of the ceramic precursor body, where pressure-assisted introduction of the molten metal into the casting mold is particularly preferred in question (“squeeze casting”). Without pressure would be in this method due to the poor wetting properties between metal and ceramic integrated Preforminfiltration in most metal-ceramic combinations hardly possible.
• the ceramic preform is positioned at the point to be reinforced in the mold.
• the insert in the shape of the lightweight component to be produced can be arranged already läge- and place correctly.
• the production cost is reduced and the production time is shortened, while allowing an exact arrangement of the insert in the lightweight component and a particularly intimate connection between lightweight component and insert.
• the metal alloy is a hardenable alloy, such in the case of lightweight brake calipers
• the following hardening step preferably follows the casting step:
• Curing the lightweight component by quenching it at a cooling rate sufficiently high to ensure metastable supersaturation of any impurities present in the alloy used, and low enough to prevent thermal shock damage to the metal-ceramic composite insert (curing step ).
• AIs cooling media come here, for example, room temperature tempered air, silicone oil or mineral oils in question.
• the ceramic content was up to 70 vol .-%.
• the ceramic component consisted of Al 2 O 3 particles with an aspect ratio of 1 to 5, while the metal component consisted of AISi7Mg.
• the experimentally determined moduli of elasticity were well above 200 GPa for these materials.
• a stiffening effect of at least 20% could be simulatively demonstrated by incorporating such stiffening elements in the bridge area.
• an E modulus of 242 GPa was determined on metal-ceramic composite materials consisting of 70% by volume Al 2 O 3 and 30% by volume AISi7Mg.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Metallurgy (AREA)
• Inorganic Chemistry (AREA)
• General Engineering & Computer Science (AREA)
• Manufacture Of Alloys Or Alloy Compounds (AREA)
• Braking Arrangements (AREA)

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• 2006
  • 2006-10-30 DE DE200610051200 patent/DE102006051200A1/de not_active Withdrawn
• 2007
  • 2007-09-11 EP EP07820123A patent/EP2086707A1/de not_active Withdrawn
  • 2007-09-11 WO PCT/EP2007/059516 patent/WO2008052834A1/de active Application Filing
  • 2007-09-11 JP JP2009535042A patent/JP2010508153A/ja not_active Withdrawn
  • 2007-09-11 RU RU2009120387/02A patent/RU2009120387A/ru not_active Application Discontinuation
  • 2007-09-11 US US12/304,662 patent/US20100009163A1/en not_active Abandoned

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