JP2000042728A - Manufacture of metallic structural material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the stickiness of solder on a surface by coating the surfaces of metallic members except a joining surface with coating agent containing prescribed powdery material and blowing high pressure air or high pressure water after joining the metallic members with the solder or brazing filler metal. SOLUTION: Desirably, the surrounding of at least joining surface on the surface of each metallic member except the joining surface is coated with the coating agent containing the prescribed powdery material and the high pressure air or the high pressure water is jetted onto the metallic structural material after joining each metallic member through the solder or the brazing filler metal. Further, each metallic member is coated with the coating agent in the state of containing the joined surface and the removal of the coating agent only to each joined surface is executed to execute the joining with the solder or the brazing filler metal. Furthermore, each metallic member uses an aluminum casting and the coating agent uses the mixture of the powdery material, water and the prescribed binder, and further, the powdery material uses carbon grain or silica grain and the binder uses polyvinyl alcohol and the coating is executed by preheating at 150-250 deg.C to each metallic member.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a metal structure, and more particularly to a method for manufacturing a metal structure by joining a plurality of metal members.

[0002]

2. Description of the Related Art Conventionally, in manufacturing a metal structural material having a complicated shape and structure, a method of manufacturing a single metal structural material by joining a plurality of metal members has been used. In particular,
When manufacturing a metal structural material having a hollow part inside,
By casting each metal member separately and joining these metal members to each other via solder or the like, a metal structure having a complicated shape can be manufactured.

For example, a cylinder head 100 used in an internal combustion engine shown in FIG. 12 will be described as an example of a metal structure material. In this cylinder head 100, cooling is performed in order to radiate heat generated by combustion in the internal combustion engine. Water circulates.
Therefore, a cooling water passage (water jacket) 101 is formed in the cylinder head 100. Thus, in order to form a space inside the cylinder head 100, it is generally necessary to use a core in casting. However, the cylinder head 100 is
When the metal member 102 and the lower metal member 103 are divided, the core is not required, and it is easy to cast the metal members 102 and 103.

[0004] The actual joining of the two metal members 102 and 103 may be performed by applying solder to the joining surfaces 104 and 105 and heating the same, or by applying ultrasonic vibration to the cylinder head 100. Here, when joining the metal members 102 and 103 of the cylinder head 100 using solder, the joining surface 10 of the metal members 102 and 103 must be set in advance.
In order to apply solder to 4,105, it is necessary to immerse each metal member 102,103 in a molten solder bath.
While immersed in the molten solder bath, the joining surfaces 104, 10
5 by applying ultrasonic vibration to the joint surfaces 104,
This is because a solder alloy is formed on the substrate 105 and a strong bonding strength can be obtained.

[0005]

However, the above-mentioned prior art has the following disadvantages. That is, when each metal member 102, 103 is immersed in a molten solder bath, the bonding surface 10 of each metal member 102, 103
Solder adheres to surfaces other than 4,105.

When the solder is cooled, it adheres more firmly to the metal members 102 and 103, and is difficult to remove. In addition, the joining surface 10 of each metal member 102, 103
In the vicinity of 4,105, surplus solder protrudes to the outside, forming a so-called burr. As described above, when the unnecessary residual solder H adheres to the surfaces of the metal members 102 and 103, not only does the appearance of the cylinder head 100 deteriorate, but also when the cylinder head 100 is used for a long time, It is conceivable that H gradually drops off and clogs the cooling water passage.

[0007]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method of manufacturing a metal structural material which can solve the disadvantages of the prior art and, in particular, can prevent solder from adhering to the surface of the metal structural material. I do.

[0008]

According to the present invention, there is provided a method for manufacturing a metal structural material, wherein a first metal member and a second metal member are bonded via a mutual bonding surface to manufacture a metal structural material. The surface of each metal member is coated with a coating material containing a predetermined powdery material except for the respective joining surfaces, and after joining these metal members via solder or brazing material, high-pressure air is applied to the metal structural material. Alternatively, a configuration is adopted in which high-pressure water is sprayed.

In the above-described configuration, the coating agent is applied to the surface of each metal member except for the joint surface. Then, soldering or brazing material is adhered to the joining surface by a technique such as heating with a solder bath or brazing material interposed therebetween to perform joining. At this time, the solder and the brazing material used for the bonding adhere to places other than the bonding surface, but since the metal member is covered with the coating material, the metal member is attached via the coating material.

[0010] Since this coating material contains a powdery material, unevenness is generated on the contact surface with the remaining solder or solder, and the adhesive force is low. Therefore, the solder or brazing material adhering to places other than the joint surface is easily peeled off by blowing high-pressure air or high-pressure water and removed from the metal member. Then, thereafter, the coating agent is removed from the surface of the metal member.

It is desirable that the coating agent be releasable from the metal member after coating. Further, it is desirable that the material has a higher melting point than solder or brazing. Further, it is desirable that the metal member has a property of being easily removed from the surface of the metal member (having water-solubility, being removable with a solvent, and having low adhesion to metal).

Further, at least the periphery of the joint surface on the surface of each metal member may be covered with a coating agent except for the joint surface. This method is effective when bonding is performed after solder or brazing material is mainly attached only to the bonding surface. In this case, the solder or brazing material that protrudes when the joining surfaces of the metal members are overlapped, or the solder or brazing material that adheres to the periphery of the joining surface during the work, is applied to the metal members via the coating agent. It is in a state of attachment and is removed in the same manner as described above.

Further, the coating of the coating agent may be performed on the entire surface or the entire surface of the bonding surface, and thereafter, the coating agent may be removed only on the bonding surface. Also in this case, it is possible to remove excess solder or brazing material in the same manner as described above.

When each of the above-mentioned metal members is an aluminum casting, it is desirable that the above-mentioned coating agent is a mixture of a powdery substance, water and a predetermined binder. Further, at this time, the powdery substance is preferably carbon particles or silica particles, and the binder is more preferably polyvinyl alcohol.

It is desirable that each metal member is preheated to 150 to 250 ° C. when coating with a coating agent.

The present invention is intended to achieve the above-mentioned object by each of the above-mentioned constitutions.

[0017]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the present embodiment, FIG.
The cylinder head (metal structural material) 100 including the upper metal member (first metal member) 102 and the lower metal member (second metal member) 103 shown in FIG.
10 shows a method 10 for manufacturing a metal structural material that is manufactured by joining through 105. Specifically, the cylinder head 100
Is used for a water-cooled two-stroke engine.
Each of the metal members 102 and 103 is formed from an aluminum casting (made of an aluminum alloy) formed by a die casting method.

In the method 10 for manufacturing a metal structural material, the surfaces of the metal members 102 and 103 are
5 except that the metal members 102 and 103 are coated with a coating agent 110 containing a predetermined powdery material, and these metal members 102 and 103 are joined via solder, and then high-pressure air or high-pressure water is blown onto the cylinder head 100. take.

The method 10 for manufacturing a metal structural material will be described in detail in the order of steps with reference to FIGS. FIG. 1 is a flowchart showing steps of a method 10 for manufacturing a metal structural material.

[Coating Step of Coating Agent] First, each metal member 1
02, 103, before coating with the coating agent 110,
Preheating is performed at 200 [° C] (Step S1). The preheating temperature is desirably set within a range of 150 to 250 [° C], and here, the preheating temperature is set at 200 [° C]. This is for the purpose of baking and hardening the binder in the coating agent 110 described later. Preheating is performed by a high-temperature furnace or the like.

The preheated metal members 102 and 103 are:
A sprayer 11 using air pressure over the entire surface of each
1 sprays the coating agent 110 (step S)
2, FIG. 2). By such spraying, each metal member 10
The coating agent 110 is uniformly coated over the entire surface of the 2,103. In addition, the coating agent 11 shown in each figure
Although 0 is shown thicker to clearly show its form, it is actually covered with a thinner film.

The coating material 110 is mainly composed of powder particles, water and a binder. As the powder particles, it is preferable to use one kind or a mixture of two or more kinds of oxide, nitride, boride, fluoride, carbide or carbon powder. The size of the powder particles is preferably set so that the center average particle diameter is 5 μm or more and 500 μm or less. If it is smaller than 5 [μm], it may fall into a solder bath in the later-described bonding, and may further enter between the bonding surface 104 and the bonding surface 105 to cause a reduction in bonding strength. .

As the binder, it is preferable to use a water-soluble organic binder or an inorganic binder or a mixture thereof. The role of the binder is to have the function of attaching and maintaining the coating agent 110 on the surfaces of the metal members 102 and 103. In particular, in the present embodiment, since the preheating is performed before the coating, the baking and curing of the binder achieves more effective adhesion of the coating agent.

The coating material 110 is composed of the above-mentioned components, and is further provided that it can be disintegrated and removed with water, alcohol, an organic solvent, or the like after coating.

In the present embodiment, more specifically, the coating agent 1
Reference numeral 10 denotes 46% of carbon particles having a center average particle diameter of 45 μm, 24% of silica particles of the same diameter, 10% of water,
P. V. What contains A (polyvinyl alcohol) 5 [%] is used.

FIG. 3A shows the first metal member 102 which has been coated, and FIG. 3B shows the second metal member 103 which has been coated. Thus, the entire surface of each of the metal members 102 and 103 is almost completely coated with the coating material 110.

[Machining of bonding surface] Next, each metal member 1
The coating agent 110 is removed only from the respective bonding surfaces 104 and 105 of the layers 02 and 103 (step S3).
The removal operation of the coating agent 110 is performed by using the bonding surfaces 104 and 10.
5 is performed by light cutting such as a milling machine or a lathe. At this time, the cutting is performed by a dry method without using a cutting fluid. FIG. 4A shows a coating agent 1 on the bonding surface 104.
FIG. 4B shows the second metal member 103 from which the coating agent 110 on the bonding surface 105 has been removed. FIG.
(C) shows a state in which the coating agent 110 has been removed from the metal member 103 and the bonding surface 105 has been exposed.

[Preheating step of metal members] Next, the metal members 102 and 103 are soldered. First, preheating is performed by a high-temperature furnace or the like in a state where the metal members 102 and 103 are overlapped in advance before soldering (step S).
4). The preheating temperature at this time is 450 ° C. or higher than the melting point of solder.
[゜ C] The following range (more specifically, 350 to 400 [゜ C]
C]). By such preheating, it is possible to easily attach the solder to the joint surfaces 104 and 105 of the metal members 102 and 103 in the subsequent solder bath.

[Joining Step] The metal members 102 and 103, which have been preheated for a certain period of time and have a uniform temperature throughout, are immersed in a solder bath 112 in which molten solder is stored (step S).
5, FIG. 5). At this time, each metal member 102, 103
The clamp jigs 113 press and hold each other.

A vibrating plate 114 is provided in the solder bath 112, and the metal members 102 and 103 are placed thereon. The vibrating plate 114 has one end supported by the solder bath 112 by point contact and the other end connected to the ultrasonic vibrator 1.
It is connected to 15 horn parts. For this reason, the ultrasonic vibration oscillated from the ultrasonic vibrator 115
Is applied to each of the metal members 102 and 103.

When ultrasonic vibration is applied to each of the metal members 102 and 103 in a state of being immersed in the molten solder, the molten solder flows between the joining surfaces 104 and 105, and furthermore, Alloying with the joining surfaces 104 and 105 is performed to join the metal members 102 and 103 (step S6). The metal members 102 and 103 are joined to form the cylinder head 100.

Then, the clamp jig 113 is released from the cylinder head 100 pulled up from the solder bath 112 after the solder is condensed due to the temperature drop.

[Cleaning Step] Residual solder H adheres to the surface of the cylinder head 100 immediately after the solder bonding via the coating material 110. The residual solder H is removed by blowing high-pressure air with the air gun 116 (step S7, FIG. 6). Air gun 11
Numeral 6 has a heater inside and injects hot air having a nozzle tip temperature of about 400 ° C. This allows
The adhesive strength between the residual solder H and the coating agent is reduced, and the residual solder can be more efficiently removed.

Since the coating material 110 contains a powder such as carbon particles and silica particles, fine irregularities due to the powder reduce the adhesive strength of the residual solder H. For this reason, the residual solder H cannot maintain an attached state against the air blow, and is easily peeled off from the surface of the coating material 110. In this step S7, the residual solder H may be removed by blowing high-pressure water instead of air blow.

When the residual solder H is removed, the cylinder head 100 is cleaned by an ultrasonic cleaning tank or the like.
The removal of the coating agent 110 is performed (Step S8). Coating agent 1
The polyvinyl alcohol of the binder contained in 10,
Since the adhesive strength with the metal is not high, it is separated from the surface of the cylinder head 100 by ultrasonic cleaning.

After the removal of the coating material 110, the surface of the cylinder head 100 is finished (step S9).
In this finishing treatment, the surface is subjected to shot blasting (blasting of abrasive steel particles by compressed air).
Dust that eventually adheres to the surface of the cylinder head 100,
All of the remaining coating agent 110 and the like are removed, and all the steps of the method 10 for manufacturing a metal structural material are completed.

As described above, in the present embodiment, since the metal members 102 and 103 are previously coated with the coating material 110 except for the joint surfaces 104 and 105, the residual solder H can be easily removed. The appearance of the cylinder head 100 is not spoiled. At the same time, the cylinder head 1
It is possible to prevent the occurrence of residual solder that falls off after the 00 is incorporated in the engine, and to effectively avoid inconveniences during use of the cylinder head 100, such as pinching the cooling water passage.

Further, since the coating material 110 is configured to contain carbon particles and the like, water and a binder, excess moisture is removed by heat generated at the time of soldering, and the surface of the coating material has an uneven structure formed of a powder. Become more apparent, and the remaining solder H can be more easily peeled off.

In the step S1, each of the metal members 102 and 103 made of die-casting is
By preheating at 0 [゜ C], each metal member 102, 1
In this way, it is possible to reduce the occurrence of dimensional changes and distortions in subsequent steps. further,
The baking effect of the binder can be promoted, and the metal members 102 and 103 can be covered in a stable state. In this case, the formability of the coating material is enhanced, and the ease of the final removal and removal is not impaired.

Here, the solder bonding steps shown in steps S5 and S6 described above may be performed as follows. That is, as shown in FIG.
2 and 103 are individually immersed in the molten solder in the solder bath 112 described above. When an ultrasonic wave is applied in such a state, the oxide film is destroyed on the bonding surface 104 of the metal member 102 (the same applies to the metal member 103), and the solder adheres to form a solder film.

Then, as shown in FIG. 8, the joining surfaces 104 and 105 of the metal members 102 and 103 are overlapped, and the periphery of the joining surfaces is mainly focused on by the burner 117 at a temperature equal to or higher than the melting point of solder at 450 [° C.]. Heating is performed in the following range (more specifically, about 350 to 400 ° C.). At this time, heating may be performed by an electric furnace. Thereby, the solder films on the joining surfaces 104 and 105 are melted.

Thereafter, each metal member 102, 10
3 is applied with ultrasonic waves. At this time, as shown in FIG.
This may be performed in a state where the horn portion 118 of the ultrasonic vibrator is directly pressed from above. Thereby, each metal member 102,
The joining between 103 is performed.

At this time, the molten solder that has stained between the joint surfaces 104 and 105 and the residual solder adhered by the solder bath can be easily removed by high-pressure air or the like in the same manner as in FIG. is there.

As another solder bonding method, there is a method in which a solder sheet corresponding to the shape of the bonding surfaces is sandwiched between the bonding surfaces 104 and 105, followed by heating and application of ultrasonic waves. In the case of such solder joining, unlike the case of solder joining using a solder bath, residual solder does not occur everywhere over the entire surface of each of the metal members 102 and 103. In this case, the residual solder generated is at most only the solder that has exuded from between the joint surfaces 104 and 105. Therefore, when performing such solder joint, the entire surface of each of the metal members 102 and 103 is coated with the coating agent. It is not necessary to cover with the bonding surfaces 110 and only around the respective bonding surfaces 104 and 105 (the relevant bonding surfaces 104 and 105
) Is sufficient.

When the first metal member 102A and the second metal member 103A made of a material having a higher melting point are joined by brazing, steps S5 and S6 are shown in FIGS. 10 and 11. This is performed by the method shown below. That is, first, each metal member 102A, 103A coated with the coating agent 110 except for the bonding surfaces 104A, 105A.
A flux having an oxide film removing action is applied to the bonding surfaces 104A and 105A. And each joining surface 104A,
Brazing material (or brazing sheet) 10 between 105A
The joint surfaces 104A and 105A are aligned with the 6A interposed. Thereafter, each metal member 102A, 103A
And an electric furnace 1 with a non-oxidizing atmosphere or a vacuum inside.
Heat at 580 to 610 [° C]. Thereby, the metal members 102A and 103A are joined by brazing. Further, even when joining by brazing, steps S1 to S4 and steps S7 to S9 are performed in the same manner.

In the above-described embodiment, after covering the entire surface of each of the metal members 102 and 103 with the covering agent 110, the covering agent 11 covering the joining surfaces 104 and 105 is used.
Although a method of removing 0 is adopted, the method is not particularly limited to this. For example, each of the joining surfaces 104, 1
05 may be masked with a peelable heat-resistant pressure-sensitive adhesive sheet, and a method of preventing the adhesion of the coating material 110 from the beginning to the joint surfaces 104 and 105 may be adopted.

In this embodiment, each metal member 10
Although the case where 2,103 is an aluminum casting has been described as an example, other metal castings may be used.

[0048]

According to the present invention, since each metal member is covered in advance with a coating agent except for the joint surface, it is possible to easily remove the residual solder or the residual solder. For this reason, it is possible to reduce the labor of removing the solder and the like in the manufacturing process of the metal structural material, and to improve the workability. Further, it is possible to prevent the occurrence of residual solder or the like, thereby preventing the appearance of the metal structural material from being impaired. At the same time, it is possible to prevent the occurrence of residual solder or residual solder that falls off when the metal structural material is used.

Further, since the coating agent is configured to include a powdery substance, water and a binder, excess moisture is removed by heat generated at the time of solder bonding or the like, and an uneven structure due to the powdery substance is formed on the surface of the coating agent. It becomes more apparent, and it becomes possible to more easily peel off residual solder and the like.

In addition, by preheating at 150 to 250 ° C. before coating each metal member with the coating agent, particularly, when joining metal members made of die-cast casting, strain reduction of each metal member is performed. And the occurrence of dimensional change and distortion in subsequent steps can be reduced. Further, when the coating agent contains a binder, the baking effect of the binder can be promoted, and the metal member can be coated in a stable state.
In this case, the formability of the coating material is enhanced, and the ease of final peeling and removal is not impaired.

[Brief description of the drawings]

FIG. 1 is a flowchart showing an embodiment of the present invention.

FIG. 2 is an explanatory view showing coating of a coating agent in the method for producing a metal structural material in FIG.

FIG. 3A shows a coated first metal member, and FIG. 3B shows a coated second metal member.

FIG. 4 (A) is a view showing a first example in which a coating agent on a bonding surface is removed.
FIG. 4B shows a second metal member from which the coating agent on the joining surface has been removed, and FIG. 4C shows FIG. 4B.
FIG.

FIG. 5 is an explanatory view showing solder joining of each metal member in the method for manufacturing a metal structural material in FIG. 1;

FIG. 6 is an explanatory view showing removal of residual solder in the method of manufacturing the metal structural material of FIG. 1;

FIG. 7 is an explanatory view showing a solder joining method different from that in FIG. 5 and showing a solder bath for each metal member.

FIG. 8 is an explanatory view showing a solder bonding technique different from that of FIG. 5 and showing melting by heating of a solder film.

FIG. 9 is an explanatory view showing a solder joining method different from that in FIG. 5 and showing application of ultrasonic waves to molten solder.

FIG. 10 is an explanatory view showing a method of joining metal members by brazing, and showing a state before heating.

FIG. 11 is an explanatory diagram showing a method of joining the respective metal members by brazing and showing a state during heating.

FIG. 12A shows a state of occurrence of residual solder which has conventionally occurred, and FIG. 12B is an enlarged view of a main part in FIG. 12A.

[Explanation of symbols]

 Reference Signs List 10 Manufacturing method of metal structural material 100 Cylinder head (metal structural material) 102, 102A First metal member 103, 103A Second metal member 104, 105, 104A, 105A Joining surface 110 Coating agent

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Masahiro Takahashi 300, Takatsukacho, Hamamatsu-shi, Shizuoka Suzuki Co., Ltd. (72) Inventor Fumitaka 300, Takatsukacho, Hamamatsu-shi, Shizuoka Suzuki F-term (reference) 4E080 AA10 AB02 AB10 BA11

Claims (6)

[Claims] 1. A method of manufacturing a metal structural material by manufacturing a metal structural material by bonding a first metal member and a second metal member via mutual bonding surfaces, wherein: After covering each of the metal members with a coating agent containing a predetermined powder except for each of the joining surfaces and joining these metal members via solder or brazing material, high-pressure air or high-pressure water is blown on the metal structural material. A method of manufacturing a metal structural material characterized by attaching. 2. A method for manufacturing a metal structural material by manufacturing a metal structural material by bonding a first metal member and a second metal member via mutual bonding surfaces, wherein at least a surface of each of the metal members is formed. Except for the joint surface, the periphery of the joint surface is covered with a coating material containing a predetermined powdery material, and after joining these metal members via solder or brazing material, high-pressure air is applied to the metal structural material. Alternatively, a method for producing a metal structural material characterized by spraying high-pressure water. 3. Each of the metal members is covered with the coating material in a state including the bonding surface, and thereafter, the coating material is removed only on each of the bonding surfaces, and thereafter, the bonding is performed by the solder or the brazing material. The method for producing a metal structural material according to claim 1, wherein the method is performed. 4. The metal structure according to claim 1, wherein each of said metal members is an aluminum casting, and wherein said coating material is a mixture of a powdery material, water and a predetermined binder. The method of manufacturing the material. 5. The method according to claim 4, wherein the powdery material is carbon particles or silica particles, and the binder is polyvinyl alcohol. 6. The metal according to claim 1, wherein the coating of the coating agent is performed after the metal members are preheated in a range of 150 to 250 [° C.]. Manufacturing method of structural material.