JP2001047164A - Production of metal honeycomb - Google Patents

Abstract

PROBLEM TO BE SOLVED: To constitute a metal honeycomb so that a releasing agent is not dried in coating, is hardened/dried in a short time by ultra violet rays and does not have harmful volatilization/evaporation, a coating thickness of the releasing agent is thinned, generation of skipping is avoided, pressing at diffusion welding is performed with low load, further carburizing is suppressed, evaporation of a binder of the releasing agent is performed at a slow speed, interruption of diffusion jointing treatment is avoided and generation of carbide, oxide, etc., is avoided. SOLUTION: A first example of a releasing agent contains releasing powder made of ceramic powder, a binder made of an ultraviolet ray hardening resin pre-polymer and a solvent made of water. A second example releasing agent contains releasing powder made of ceramic powder, a binder made of ultraviolet ray hardening resin having different thermal decomposition/evaporation temp. and a diluting agent made of an ester group ultraviolet ray hardening resin monomer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a metal honeycomb. That is, the present invention relates to a method for manufacturing a metal honeycomb formed of a planar assembly of hollow columnar cells using stainless steel or an aluminum alloy as a base material.

[0002]

2. Description of the Related Art First, the technical background will be described in detail. Honeycomb cores, which consist of planar aggregates of hollow columnar cells defined by cell walls, have various excellent characteristics, including excellent strength by weight, and are widely used as various structural materials. I have. As the base material of the cell wall of the honeycomb core, metal, plastic, paper, or the like is used depending on the application. As the metal, stainless steel or an aluminum alloy is typical. As is well known, stainless steel has heat resistance,
It has the basic performance of being excellent in high-temperature strength, oxidation resistance, corrosion resistance, workability, and the like. An aluminum alloy containing magnesium Mg has also obtained basic performance such as excellent heat resistance, high-temperature strength, corrosion resistance, workability, and the like.
The 0 type alloy and the non-heat treatment type 5000 type alloy are particularly excellent in strength. Therefore, in view of such excellent basic performance of the base material as well as the characteristics as the honeycomb core, the honeycomb core made of the foil-shaped stainless steel or aluminum alloy as a base material is, for example, a structural material or a structure for an aircraft or a railway vehicle. It is used as a part and in many other fields for a wide variety of applications.

[0003] Next, as a method of manufacturing a honeycomb core,
The spreading method and the corrugating method are common. First, in the stretching method, after applying an adhesive or brazing material to the foil-shaped base material in the form of striations, a large number of sheets are stacked in a positional relationship shifted by half a pitch,
Next, a honeycomb core is manufactured by applying pressure and heating to bond or braze the base materials in a strip shape, and then applying a tensile force in the direction of stacking to expand. On the other hand, in the corrugation method, after corrugating a foil-like base material into a corrugated sheet, a large number of formed corrugated sheets are shifted by a half pitch at a time, and the valleys and the tops are piled up in a positional relationship of matching, Honeycomb cores have been manufactured by bonding and brazing in a linear manner between each other with an adhesive or brazing material (including spot welding).

[0004] In the method for manufacturing a honeycomb core, an adhesive or brazing material is generally used for joining a strip-shaped joining target portion (node portion) in both the stretching method and the corrugating method. Brazing was being performed. However, first, the following difficulties were pointed out in the case of bonding. That is, the adhesive has a low heat resistance temperature (generally, 3
00 ° C. or less), and the bonding strength is weak. Therefore, in the case of manufacturing a honeycomb core using the above-described stainless steel or aluminum alloy as a base material, if the bonding is performed using an adhesive, the excellent basic performance of the base material is not utilized in the manufactured honeycomb core, and the heat resistance is improved. , Disadvantages arise in high-temperature strength and the like, and the use is greatly limited.

On the other hand, the following difficulties have been pointed out by brazing. That is, a brazing material such as a nickel-based brazing material is used for brazing stainless steel, and a brazing material such as an aluminum-based brazing material is used for brazing an aluminum alloy. When a brazing material such as a nickel-based brazing material or an aluminum-based brazing material is used in the manufacture of a honeycomb core made of stainless steel or an aluminum alloy as a base material, for example, in the case of a nickel-based brazing material, about 1000 ° C. Since brazing is performed at a predetermined temperature,
Although a certain degree of heat resistance and high-temperature strength can be expected, melting occurs at such a predetermined temperature or higher. Thus, in the manufactured honeycomb core, the excellent basic performance of the base material often cannot be utilized (for example, 1
(The brazing material melts at a temperature of 000 ° C. or more), and heat resistance and high-temperature strength are limited, and the use thereof is limited. In addition, the honeycomb core manufactured by brazing has oxidation resistance, corrosion resistance, etc., due to the intervening dissimilar metal brazing material having a different composition from the base material stainless steel or aluminum alloy. In this case, the excellent basic performance of the base material was not utilized, and the application was limited. Furthermore, the brazing material used for manufacturing a honeycomb core using an aluminum alloy as a base material is often used not in the form of powder or paste, but in the form of a brazing sheet that has been made into a plate in advance. It is difficult to obtain a thick (foil thickness) brazing sheet by rolling, and in practice, a brazing sheet having a thickness of 100 μm or more has been used. However, when such a thick brazing sheet is used, the weight increases by the thickness of the brazing sheet, and the characteristic that the honeycomb core manufactured by using the sheet has excellent strength by weight cannot be utilized. It was sometimes limited.

When a honeycomb core is manufactured using stainless steel or an aluminum alloy as a base material and an adhesive or a brazing material, the characteristics of the honeycomb core, the basic performance of the base material, and the like are not exploited, and the application is not suitable. It was often limited. In conclusion, the conventional method for manufacturing a metal honeycomb by the stretching method or the corrugation method has such limitations due to bonding and brazing. The technical background is as described above.

[0007] Under such technical background, a method for manufacturing a metal honeycomb using diffusion bonding instead of adhesion or brazing is being developed. In other words, when joining the strip-shaped joining target portion (node portion) of a base material using stainless steel or an aluminum alloy, it is directly joined by diffusion joining without using any adhesive or brazing material, Recently, a method for manufacturing a metal honeycomb, which manufactures a honeycomb core, is being developed. According to the method for manufacturing a metal honeycomb by diffusion bonding, the base materials are directly bonded to each other with the same composition, and no adhesive or brazing material is interposed. Therefore, the manufactured honeycomb core has the same properties as the base material of stainless steel and aluminum alloy as it is, and is excellent in heat resistance, high-temperature strength, oxidation resistance, corrosion resistance, etc., and also excellent in strength by weight. Will also be utilized.

The method of manufacturing a metal honeycomb by diffusion bonding, which has been recently developed, is applied to a stretching method and is not applied to a corrugated method. That is, in order to perform diffusion bonding, it is essential that the base material be heated and pressurized at a high pressure. In the stretching method, a stacked flat plate, that is, a foil-shaped base material is pressed from above and below, so that the base material can easily withstand the pressing force. On the other hand, in the corrugated method, a foil-shaped base material is corrugated into a corrugated sheet and then stacked, and such a corrugated sheet is pressed from above and below for diffusion bonding.
In this case, the base material as a corrugated sheet cannot withstand this pressing force. In general, it is known that the expanding method is easier to manufacture a honeycomb core having a larger overall size than the corrugating method, and is superior in manufacturing cost.

[0009] When a honeycomb core is manufactured by a stretching method using stainless steel or an aluminum alloy as a base material by the recently developed manufacturing method using diffusion bonding, a mold release agent is indispensably used. That is, in this method for manufacturing a metal honeycomb, first, the release agent is applied to the foil-shaped base material while leaving the background in the form of striations. In other words, prior to the direct diffusion bonding of stainless steel or aluminum alloy, which is a foil-shaped base material, between the bases in a striped manner, a non-bonded portion other than the target portion of the diffusion bonding is preliminarily used as a release agent. Must be applied and covered to prevent diffusion bonding. The release agent is applied by a printing method or a coating method, and the applied release agent is immediately dried. Thereafter, the base material coated with the release agent is stacked while being shifted by a half pitch, and then pressurized and heated in a vacuum furnace, thereby exposing and contacting the diffusion bonding target portion. In between, diffusion bonding is performed in the form of a stripe. Then, by applying a tensile force in the stacking direction and expanding the non-joined portion covered with the release agent, a honeycomb core having the base material as a cell wall is manufactured. The honeycomb core manufactured in this manner is washed afterwards to remove the remaining release powder of the release agent and the like.

[0010] In the method for manufacturing a metal honeycomb by an expansion method utilizing diffusion bonding, a release agent is essentially used as described above. The release agent of this type of conventional example usually includes a release powder exhibiting a release effect, a resinous binder capable of applying the release powder and fixing to the base material, and dissolving, diluting and dissolving the binder. And a solvent for adjusting the viscosity. That is, in the release agent of this type of conventional example, a solvent-based binder that is used by being dissolved in a resinous solvent is generally used as the binder. (Release agent = Release powder + Binder + Solvent) Ceramic powder is used as the release powder of the release agent, and organic binders, paints, and inks are generally used widely as organic binders. As the solvent, aliphatic solvents such as acetone, ketones such as isophorone, aromatic solvents such as xylene, and alcohols such as ethanol have been used. The solvent contained in the release agent has been volatilized, evaporated, and eliminated in a drying step performed after the step of coating the base material. Further, the binder contained in the release agent has been thermally decomposed, evaporated, disappeared, or ashed during the bonding step of diffusion bonding the stacked base materials. The release powder contained in the release agent, together with the remaining binder ash, is used in a subsequent cleaning step.
Had been removed.

[0011]

In the recently developed method for manufacturing a metal honeycomb, the following problems have been pointed out with respect to the release agent used conventionally.
First, when the release agent is applied to the base material in the application process, that is, during the application operation by the printing method or the coating method,
The organic solvent contained in the release agent is dried, volatilized,
It has been pointed out that it has evaporated and the workability is poor. That is, many of the organic solvents used in this type of release agent have a low boiling point of less than 100 ° C., and often dry, volatilize, and evaporate simultaneously with use. However, there has been a problem that it is difficult to use the entire release agent. The boiling point is 100
When using a high boiling point solvent of about 300 ° C.
Although such a problem is considerably solved, it has been pointed out that a post-drying step is indispensable, and workability is poor in this respect. That is, not only when a high-boiling solvent is used, in this type of conventional example, a drying step is performed after the coating step, and the base material coated with the release agent is
The organic solvent contained in the applied release agent is volatilized, evaporated, and dried by hot air drying and the like.
Had disappeared. And such a drying process needs to be performed for a long time, and from this aspect, there was a problem in workability. As described above, first, a problem has been pointed out in workability.

Second, as described above, in the drying step, the solvent in the release agent is volatilized and evaporated, and the solvent thus volatilized and evaporated is often harmful to the human body. That is, when an organic solvent is volatilized and evaporated and is sucked into a human body, there is a risk of adversely affecting the human body, and a problem in safety has been pointed out. Therefore, in this type of conventional example, a local exhaust device is often attached to the drying furnace in the drying step, but this causes a problem in cost. As described above, second, problems have been pointed out in terms of safety and cost.

Third, there has been an attempt to use an ultraviolet (UV) curable resin as a binder. That is, instead of this kind of conventional example described above, a binder using a prepolymer of an ultraviolet-curable resin, a diluent using a monomer of the ultraviolet-curable resin, a photoinitiator, and the like are mixed with the release powder. Conventionally, it has been attempted to use such a material as a release agent. As described above, the release agent using the ultraviolet curable resin as the binder of the release powder is the above-described release agent (release powder + general organic binder + aliphatic / ketone type) , Aromatic and alcoholic solvents), it is excellent in workability and safety. That is, the ultraviolet curable resin is basically hard to volatilize and evaporate, so that firstly, it does not dry, volatilize and evaporate during the coating operation, the time for applying ultraviolet rays is short, and secondly, there is little danger to the human body. .

However, with respect to the release agent using the ultraviolet curable resin as a binder, first,
It has been pointed out that the coating thickness is increased. That is, in this method for manufacturing a metal honeycomb, the release agent needs to be applied in a coating process with a coating thickness as small as possible. As described above, the gap between the strips of the base material to which the release agent of the base material has not been applied is exposed, contacted, and diffusion-bonded as a diffusion bonding target portion in the bonding process. The agent must be applied as thinly as possible (see also FIG. 3 described below). If the coating thickness of the release agent at the time of diffusion bonding is too large, the degree of contact and adhesion between the base materials will be insufficient, and the base material will not be diffusion-bonded reliably in the form of striations, and the bonding strength will be insufficient. Or unjoined parts occur. When a tensile force is applied and stretched between such base materials, in the manufactured honeycomb core, so-called skipped spots where the cells are not reliably partitioned by the cell walls occur, and the quality of the honeycomb core increases. Significant defects will result.

[0015] In the conventional method of manufacturing a metal honeycomb using an ultraviolet curable resin of this type, occurrence of such skipping has been pointed out. In other words, this release agent contains a release powder having a large particle size so as to exhibit a release effect, and the ultraviolet curable resin used as a binder is less likely to volatilize and evaporate after coating, and furthermore, it is difficult to remove the solvent. Conventionally, it was difficult to apply a thin coating having a coating thickness of less than 30 μm because the coating was used without being dissolved. Therefore, in the case of a honeycomb core having a large cell size, the occurrence of skipping is relatively small, but in the case of a honeycomb core having a small cell size of, for example, 10 mm or less,
The occurrence of stuttering was remarkable. As described above, the third problem is that skipping occurs.

Fourth, in this kind of conventional method for manufacturing a metal honeycomb using an ultraviolet curable resin, an extremely high pressure and a high load are required in order to avoid such skipping. . That is, when manufacturing a honeycomb core having a small cell size, when the coating thickness of the release agent is as thick as about 30 μm or more, the pressure in the vacuum furnace for diffusion bonding in the bonding process is set to be extremely high. Then, for example, 1
If the base material is pressed from above and below with a high load of Kg / mm ² or more, skipping is avoided. That is, shortages can be avoided by compensating for the lack of contact and adhesion between the base materials by applying a high pressure, thereby improving the joining strength and eliminating unjoined portions. However, in a general vacuum furnace, it is difficult to apply such a high pressure and a high load, and it is necessary to incorporate a very expensive flat press or a hydrostatic press (HIP), and it is difficult to increase the size. It becomes difficult to manufacture a honeycomb core having a large overall size. Fourth, in terms of cost and overall size,
The problem was pointed out.

Fifth, the binder contained in the release agent applied in the application step is thermally decomposed or incinerated by heating at the beginning of diffusion bonding in the bonding step. And the binder made of the ultraviolet curing resin is hard to be thermally decomposed, and partly,
Most of the remainder is incinerated as ash, though it decomposes, evaporates and disappears. Since the remaining ash was composed of an ultraviolet-curable resin, that is, an organic component, it was mainly composed of carbon C. When the base material was stainless steel, the temperature was about 1000 ° C. at the time of diffusion bonding or in a high-temperature environment after the fact. When heated at a temperature, it reacts with the stainless steel base material to cause carburization. As is well known, carburization increases the carbon C content of the stainless steel surface of the base material, thereby increasing the hardness and strength, but changes the mechanical strength. Then, in a high-temperature environment or a corrosive environment, chromium Cr in the stainless steel of the base material reacts with the carbon C to form, precipitate and coarsen chromium carbides, thereby embrittlement, high-temperature oxidation, and granulation of the base material. It may cause interfacial corrosion and the like.

A honeycomb core manufactured using stainless steel as a base material, that is, a cell wall, is often used in such a high-temperature environment or a corrosive environment, and causes embrittlement, high-temperature oxidation, intergranular corrosion, and the like. Was considered highly undesirable. Fifth, when the base material is stainless steel, problems such as embrittlement, high-temperature oxidation, and intergranular corrosion due to the incineration and carburization of the binder in the release agent, that is, the ultraviolet curable resin, have been problems. .

Sixth, when the base material is made of stainless steel or an aluminum alloy, the binder in the applied release agent, that is, the ultraviolet curable resin, is used for the diffusion bonding between the base materials in the vacuum furnace in the bonding step. However, it was pointed out that thermal decomposition and evaporation occurred at once, and the treatment was interrupted. In other words, the inside of the vacuum furnace is maintained at a constant vacuum atmosphere. However, if the degree of vacuum drops significantly during the diffusion bonding process by pressurization and heating and the temperature deteriorates extremely, a stable The device is activated to interrupt the diffusion bonding process. In addition, during diffusion bonding between base materials in a vacuum furnace, since the binder contained in the release agent is made of an ultraviolet-curable resin, a considerable portion is incinerated by pressurization and heating as described above, and becomes ash. But remains
Some parts decompose, evaporate and disappear. Such thermal decomposition and evaporation are performed at once at a time due to the use of one type of ultraviolet curable resin.
In many cases, the degree of vacuum in the vacuum furnace suddenly deteriorates greatly. Therefore, it has been pointed out that the safety device is activated and the diffusion bonding process is often interrupted, which causes a problem in production efficiency. As described above, the sixth problem has been pointed out that the diffusion bonding process is often interrupted.

Seventh, by the way, in order to avoid such interruption of the diffusion bonding process, the safety device is turned off so as not to operate, so that the diffusion bonding process can be continued without interruption. A lot had been done. For example, in such a situation, when thermal decomposition and evaporation of a binder made of an ultraviolet curable resin are performed at a stretch, oxygen O and the like are released and diffusion bonding is performed in a bad atmosphere in which the degree of vacuum is greatly reduced. Will be heated. Further, as described above, ash mainly composed of carbon C remains. Due to these, non-reducible film-like carbides, oxides, and other compounds are likely to react, generate, bend out, and coarsen on the surface of the stainless steel or aluminum alloy base material. .

When the base material is stainless steel, for example, the above-described carburization and chromium carbides are generated, which causes embrittlement, high-temperature oxidation, intergranular corrosion and the like of the base material. Further, when the base material is an aluminum alloy, for example, the evaporation of the contained magnesium Mg is inhibited, so that the alumina Al ₂ O ₃
The oxide film formed is no longer broken, dispersed, or re-formed, causing a problem in diffusion bonding itself. In any case, products such as carbides, oxides, and other compounds on the surface of the base material cause embrittlement, high-temperature oxidation, and intergranular corrosion of the base material. Honeycomb cores manufactured using stainless steel or an aluminum alloy as a base material for cell walls are often used in such high-temperature environments or corrosive environments, and may cause embrittlement, high-temperature oxidation, intergranular corrosion, etc. Was considered highly undesirable. As described above, seventhly, problems such as embrittlement, high-temperature oxidation, and intergranular corrosion have been pointed out from this aspect.

In view of such circumstances, the present invention has been made in order to solve the problems of this type of conventional example in the recently developed method of manufacturing an expansion-type metal honeycomb by diffusion bonding. Item 1 employs a release agent containing a release powder composed of a ceramic powder, a binder composed of a prepolymer of an ultraviolet curable resin, and a solvent composed of water. According to the present invention, a mold release powder comprising a ceramic powder, a binder comprising a prepolymer of an ultraviolet curing resin having different thermal decomposition and evaporation temperatures, and a diluent comprising a monomer of an ester ultraviolet curing resin are contained. The mold release agent is adopted.

[0023] By employing such a release agent, both of the first and second aspects of the present invention first cure in a short time with ultraviolet rays without drying during the application of the release agent. Secondly, the workability is improved, and secondly, there is no volatilization and evaporation which is harmful to the human body. Thirdly, the coating thickness of the release agent can be reduced, and skipping can be prevented. It is an object of the present invention to propose a method for manufacturing a metal honeycomb which can perform pressurization under a low pressure and a low load. A fifth object of the present invention, in addition to the above, is to propose a method of manufacturing a metal honeycomb in which carburization is suppressed when the base material is stainless steel. According to the second aspect of the present invention, in addition to the above, sixthly, the thermal decomposition and evaporation of the binder and the diluent are performed at a slow speed, so that the interruption of the diffusion bonding process is avoided. It is an object of the present invention to propose a method for manufacturing a metal honeycomb, in which heating for diffusion bonding is not performed and generation of carbides and oxides is avoided.

[0024]

The technical means of the present invention for solving such a problem is as follows. First, claim 1 is as follows. That is, in this method for manufacturing a metal honeycomb, first, a foil-like stainless steel or a foil-like aluminum alloy containing magnesium is used as a base material, and a release agent is added to the base material, while leaving the background in a stripe shape. Apply and cure by applying ultraviolet light. Next, a plurality of the base materials are stacked in a positional relationship in which the exposed background that is left in a line shape between the release agents is shifted by a half pitch, and then pressurized and heated. Then, the base materials are bonded in a striped manner between the contacted backgrounds. Then, a honeycomb core, which is a planar aggregate of a large number of hollow columnar cells partitioned by the cell walls, is obtained by applying the tensile force in the stacking direction and expanding the cells to form the base material as cell walls. .

In such a method for producing a metal honeycomb, in claim 1, a release powder comprising a ceramic powder having a particle size of not less than 5% by weight and not more than 60% by weight and having a particle diameter of not more than 5 μm is used as the release agent. And a binder comprising a prepolymer of a water-soluble UV-curable resin and a solvent comprising 30% by weight or more of water. According to a second aspect of the present invention, the release agent comprises a release powder composed of a ceramic powder having a particle size of 5% by weight or more and 60% by weight or less and a particle size of 5 μm or less; It is characterized in that a binder containing a binder composed of a prepolymer of a curable resin and a diluent composed of a monomer of an ester-based ultraviolet curable resin is used.

The method for manufacturing a metal honeycomb according to the present invention is as described above. First, the foil-shaped base material, stainless steel or aluminum alloy, is coated with a release agent and cured by ultraviolet rays, leaving the background in a striped shape, then stacked by shifting by half a pitch, pressurized and heated. , Thereby forming a striped diffusion bond. In the case where the base material is an aluminum alloy, first, the contained magnesium evaporates to destroy and disperse the oxide film on the background surface, so that the aluminum is exposed on the background surface and diffusion bonding is enabled. Thereafter, the matrix material, which has been stacked and diffusion-bonded, is stretched to manufacture a honeycomb core, which is a planar aggregate of cells partitioned by the cell wall, using the matrix as a cell wall.

The release agent used in this production method does not dry during the coating operation, and is easily cured afterwards. That is, the UV-curable resin prepolymer or monomer used as a binder or a diluent for the release agent is cured by irradiation with ultraviolet light to become a polymer. Next, as the release agent, first, a ceramic powder having a small particle size of 5 μm or less and a content of 60% by weight or less is used as the release powder. The UV-curable resin used as a binder is partially thermally decomposed, evaporated and disappears by pressurization and heating at the beginning of diffusion bonding, and the remainder is ashed. Is done. Water used as a solvent evaporates and disappears. When an ester-based UV-curable resin monomer is used as the diluent, the viscosity decreases. Thus, the release agent can be applied with a small application thickness at the time of application, and the application thickness can be made smaller at the time of diffusion bonding. Therefore, the stacked base materials are surely contacted, abutted, and adhered between the strips exposed between the release agents in the form of striations, and are diffusion-bonded.

Further, in the first aspect, since the release agent contains water as a solvent in an amount of 30% by weight or more, the content of the ultraviolet-curable resin as a binder is correspondingly low and thus remains as ash. The amount is small and carburization is reduced when the base material is stainless steel. In claim 2, two types of ultraviolet-curable resins having different thermal decomposition and evaporation temperatures are used, and an ester-based ultraviolet-curable resin is used.
Therefore, in the diffusion bonding, the release agent is subjected to thermal decomposition and evaporation at different temperatures for each of these components at a gradually slow speed, and does not cause interruption of the diffusion bonding process.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail based on embodiments of the invention shown in the drawings. FIG. 1, FIG. 2,
3 and 4 are provided for explaining the embodiment of the present invention. 1 is a perspective explanatory view, (1) FIG. 1 shows a prepared base material, (2) FIG. 1 shows a state where a release agent is applied, (3) FIG. The figure shows the state of diffusion bonding.
(5) The figure shows the state of slicing, respectively. FIG. 2 is an explanatory perspective view. FIG.
The figure shows the trimmed state, and the figure (3) shows the main part of the obtained honeycomb core. 3 is an enlarged front view. FIG. 3A shows a state where a release agent is applied, and FIG. 3B shows a state at the time of diffusion bonding. FIG. 4 is an explanatory front view of a main part, in which (1) shows a state before diffusion bonding between stainless steel base materials, and (2) shows a state after diffusion bonding between the same base materials. FIG. 3C shows a state before diffusion bonding between base materials made of aluminum alloy, FIG. 4D shows a state immediately before diffusion bonding between base materials made of aluminum alloy, and FIG. The figure shows the state after diffusion bonding between the base materials.

First, the release agent 1 will be described. In the method for manufacturing a metal honeycomb according to the present invention, the following release agent 1 is employed. The release agent 1 is applied and used in advance to set the non-joined portion 3 when diffusion-bonding a foil-like stainless steel as the base material 2 or a foil-like aluminum alloy containing magnesium Mg. (See FIG. 1). The release agent 1 essentially contains a release powder and a binder, and further contains a diluent, a solvent, a dispersant, a defoamer,
Others are appropriately contained. (Release agent 1 = release powder + binder + other)

First, the release powder of the release agent 1 will be described.
You. Ceramic powder is used as the release powder.
Low reactivity with material 2 stainless steel and aluminum alloy
In addition, those with excellent release effect between the base materials 2 are selected and used.
You. In other words, between the base metal 2 stainless steel and aluminum
It is used to prevent diffusion bonding between alloys. example
For example, iron Fe, chromium Cr,
Among compounds of elements such as nickel Ni and carbon C,
Oxide Cr₂O₃Is thermodynamically stable,
The mix is more thermodynamically stable. example
For example, a temperature of about 800 ° C to 1200 ° C for diffusion bonding
Due to the heat, the oxygen O of the oxide reacts with the chromium Cr.
And chromium oxide Cr₂O₃There is no such thing as.
When the base material 2 is made of an aluminum alloy,
Lamix is thermodynamically stable, but especially aluminum
Diffusion bonding in the case where a base material 2 is made of
Is performed by heating at a relatively low temperature of
And become more stable. Such ceramics
Specifically, boron nitride BN, yttria
Stabilized zirconia Y₂O₃-ZrO₂, Magnesia stabilized
Luconia MgO-ZrO ₂, Alumina Al₂O₃, Magneshi
A MgO, calcia CaO, silica SiO₂, Ceria Ce₂
O₃, Yttria Y₂O₃, Tria ThO₂Etc., as appropriate
Select used.

And among these ceramics,
An oxide of a Group 3A element of the periodic table (long period table) and an oxide of a rare earth element are typically used. That is, among the elements, Group 3A elements such as scandium Se, yttrium Y, lanthanoid elements La to Lu, and actinoid element A
c to Lr have low standard free energy of formation and are thermodynamically stable. Also, among compounds of the elements, for example, nitrides, oxides, sulfides, chlorides, carbides, etc., oxides are
Its standard free energy of formation is low and thermodynamically stable. Accordingly, oxides of Group 3A elements, for example, ceria Ce
₂ O ₃ , yttria Y ₂ O ₃ , tria ThO _{2 and the} like are suitable, and in particular, yttria Y ₂ O ₃ is most suitable in terms of cost. That is, the oxide of the 3A group element such as yttria Y ₂ O ₃ is reduced by heating and is reduced by heating during diffusion bonding of the base material 2 made of stainless steel or an aluminum alloy.
Not to react with the base material 2 in a high temperature environment of, for example, 1300 ° C. or higher.
Yttria Y ₂ O ₃ is widely used for various purposes.

In the release agent 1, as the release powder,
Ceramic powder obtained by powdering such ceramics is used. And this ceramic powder is 5
Weight% or more and 60 weight% or less and a particle size of 5 μm.
m or less are used. First, the particle size of the ceramic powder is 5 μm or less, and if it exceeds 5 μm, the size of the particle size hinders the application of the release agent 1 thinly. The ceramic powder is a mold release agent 1
If the content is less than 5% by weight, the release effect of the release agent 1 is insufficient. Further, the ceramic powder is contained in the release agent 1 at a ratio of up to 60% by weight or less. If the content exceeds 60% by weight, the ceramic powder is too much, and the liquefaction as the release agent 1 occurs. As a result, it becomes difficult to form a paste, and the release agent 1 cannot be applied thinly. The release agent 1 essentially contains such a ceramic powder as a release powder.

Next, a first example of the present invention will be described. The release agent 1 of the first example contains, together with the release powder composed of the ceramic powder described above, a binder composed of a prepolymer of a water-soluble ultraviolet-curable resin, a solvent composed of 30% by weight or more of water, and others. It becomes. (Release agent 1 of the first example = release powder + binder + solvent + other)

The release agent 1 of the first example will be described in more detail. First, the binder is used to make it possible to apply the ceramic powder, which is a release powder, as the release agent 1 and to adhere and fix the ceramic powder after being applied as the release agent 1 so that the ceramic powder does not peel off or fall off from the base material 2. Used as glue. As such a binder, a prepolymer of a water-soluble ultraviolet (UV) curable resin (when applied)
Is used. For example, a photopolymerizable and water-soluble urethane acrylate prepolymer (oligomer) is used. When irradiated with light, that is, ultraviolet light, a prepolymer is used, which undergoes a polymerization reaction, cures and dries to form a polymer (including oligomer). Also, this binder is contained in the release agent 1,
It is contained at a ratio of 5% by weight or more and 30% by weight or less. In other words, in order to exhibit the function as a binder / paste, the content is essential at least 5% by weight or more and at most 30% by weight or less. In the case of a high concentration exceeding 30% by weight, there is a problem that the amount of ash of the polymer becomes excessive when heated at the time of the subsequent diffusion bonding.

Further, the release agent 1 contains 30% by weight or more of water as a solvent. That is, for the release agent 1 using an ultraviolet curable resin as a binder, water is used as a solvent for the first time. The water serving as the solvent is used for dissolving and liquefying the above-mentioned binder to make it thinner, thereby adjusting the viscosity so that the release agent 1 can be applied (decreasing the viscosity to a low level), and at the same time, the coating thickness T of the release agent 1 (see FIG. Used for ultra-thin purposes. Therefore, at least 30% by weight
If the content is less than 30% by weight, the viscosity required for the release agent 1 cannot be obtained, and it is difficult to achieve the purpose of making the release agent 1 extremely thin.

The release agent 1 contains 5% by weight or more of 20%.
1% by weight or less of a monomer of an ether-based UV-curable resin as a photopolymerizable diluent, 1% by weight or more and 10% by weight or less of a photoreaction initiator, if necessary, 0% by weight or more and 30% by weight
It contains the following urethane acrylate emulsions (emulsions). The ether-based monomer as a diluent is used for adjusting the viscosity of the release agent 1, and is contained in an amount suitable for a coating method described later. The binder is mainly composed of a photopolymerizable and water-soluble urethane acrylate prepolymer, and if necessary, an emulsion of urethane acrylate is added. Further, in the release agent 1, the total content of the release powder and the binder (including the above emulsion) is set to less than 70% by weight (corresponding to 30% by weight or more of water as a solvent).

It is to be noted that a dispersant and an antifoaming agent are added and contained in the release agent 1 as needed. The dispersant is mixed so that the ceramic powder as the release powder in the release agent 1 does not agglomerate, bond, or solidify with each other.
The antifoaming agent is mixed in to prevent foaming when the release agent 1 is applied. As such a dispersant or defoaming agent, for example, an organic solvent such as methanol is typical. The dispersant and the defoamer are contained in the release agent 1 at a ratio of 0% by weight or more and 10% by weight or less. The release agent 1 of the first example of the present invention comprises:
As described above, 5 to 60% by weight of a ceramic powder as a release powder, 5 to 30% by weight of a binder, 30% or more of water as a solvent, 5% by weight
The above composition contains 20% by weight or less of a diluent, 1% by weight or more and 10% by weight or less of a photoinitiator, and 0% by weight or more and 10% by weight or less of a dispersant or an antifoaming agent. First of the present invention
The release agent 1 of the example is thus configured.

Next, a second embodiment of the present invention will be described. In the release agent 1 of the second example, a binder composed of a prepolymer of two types of ultraviolet curable resins having different evaporation temperatures due to thermal decomposition, together with a release powder composed of a ceramic powder,
It contains a diluent composed of a monomer of an ester-based UV-curable resin and others. (Release agent 1 of second example = release powder + two kinds of binders +
Diluent + other)

The release agent 1 of the second example will be described in more detail. In the release agent 1 of the second example, first, two kinds of binders having different thermal decomposition and evaporation temperatures are used as the binder of the ceramic powder as the release powder (the function of the binder is the same as that described in the first example). A prepolymer of ultraviolet curable resin (when applied) is used. For example, a photopolymerizable amino-based prepolymer (oligomer) is contained in the release agent 1 at a ratio of 5% by weight or more and 20% by weight or less, and a photopolymerizable epoxy-based prepolymer (oligomer) is contained. ) Is 35% or more in the release agent 1 at 10% by weight or more.
% By weight or less. When light, that is, ultraviolet light, is applied, a prepolymer that undergoes a polymerization reaction, cures and dries to become a polymer (including oligomer) is used.
These two types of UV-curable resins are contained in amounts that are substantially matched as described above. For each content, the minimum content is set to exhibit the function as a binder and glue, and the maximum content is determined by taking into account the content of the diluent described below and heating during the subsequent diffusion bonding. The amount is set so that the amount of ash of the polymer when the heating is performed is not excessive.

Further, the two types of ultraviolet curable resins (polymers) have different evaporation temperatures due to thermal decomposition. That is, due to the subsequent heating at the beginning of the diffusion bonding, a part of the two types of ultraviolet curable resins (polymers) is thermally decomposed and evaporated, and the remaining is ashed. Then, two types of ultraviolet curable resins having different thermal decomposition and evaporation temperatures are used. For example, the photopolymerizable amino-based polymer and the photopolymerizable epoxy-based polymer described above have significantly different thermal decomposition and evaporation temperatures.

Further, in this release agent 1, no solvent is used as in the above-mentioned conventional example of this type. In the release agent 1, a monomer of an ester-based ultraviolet curable resin is used as a diluent. That is, for the first time in the release agent 1 using an ultraviolet curable resin as a binder, an ester monomer is employed as a diluent. That is, the release agent 1 contains an ester monomer as a photopolymerizable diluent in a ratio of 15% by weight or more and 45% by weight or less. When light, that is, ultraviolet light, is applied, a monomer that is polymerized and cured to become a polymer is used. Then, this diluent adjusts the viscosity of the release agent 1 to a level at which the release agent 1 can be applied (decreases the viscosity to a low level), and thereby enables the release agent 1 to be applied with a thin coating thickness T (see FIG. 3). To be used. Therefore, the content is required to be at least 15% by weight or more, and the maximum content is 45% by weight or less from the relationship with the content of other release powders and binders.

Further, the release agent 1 contains 1% by weight or more of 1% by weight.
In addition to containing 0% by weight or less of a photoreaction initiator, a dispersant or an antifoaming agent may be added or contained up to 10% by weight as needed (for these, the first
Same as described above in the examples). Thus, the release agent 1 of the second example of the present invention contains 60% by weight or more at 5% by weight or more.
A ceramic powder as a mold release powder, a binder of not less than 5 wt% and not more than 20 wt%, a binder of not less than 10 wt% and not more than 35 wt%, a diluent of not less than 15 wt% and not more than 45 wt%, 10% by weight at 1% or more
It contains the following photoreaction initiator, 0% by weight or more and 10% by weight or less of a dispersant and an antifoaming agent. The release agent 1 of the second example of the present invention is as described above.

As described above, the release agent 1 includes a ceramic powder as a release powder, an ultraviolet-curable resin as a binder, water as a solvent, an ultraviolet-curable resin as a diluent, a photoreaction initiator, a dispersant, An antifoaming agent or the like is appropriately compounded and blended based on the above-mentioned predetermined content. (Release agent 1 of the first example = release powder + binder + solvent + other) (Release agent 1 of the second example = release powder + two kinds of binders +
(Diluent + Others) That is, the release agent 1 is blended and prepared by mixing and dispersing the release powder in a binder dissolved and diluted with a solvent or a diluent. At that time, in order to obtain the optimum viscosity for the coating method according to the coating method described below, the contents of the release powder, the solvent, the diluent, and the like are adjusted, and thus the viscosity of the release agent 1 is adjusted. In any case, the release agent 1
It is in the form of liquid or paste with some viscosity,
It may be emulsified.

Here, the method of applying the release agent 1 will be described. The release agent 1 is applied to the base material 2 by a coating method or a printing method. The coating method is such that, after masking the striation-shaped diffusion bonding target portions 4 in advance, the release agent 1 is applied to the non-bonding portions 3 by spraying, dipping, dipping or the like, and then the masking is performed. Is carried out. As a printing method, stencil printing such as screen printing, intaglio printing such as transfer roll printing, letterpress printing, or the like is used. Screen printing is suitable to be performed after cutting the base material 2 to a predetermined length.
It is also possible to perform two-roll printing (printing while flowing the strip-shaped base material 2 before cutting between rolls), and transfer roll printing is suitable for roll-to-roll printing. The release agent 1 is applied to the base material 2 while leaving the background 5 in the form of striations by an application method such as a coating method or a printing method ((2) of FIG. 1 or FIG. 3). (1) Refer to the figure). The coating thickness T (see FIG. 3) of the release agent 1 on the base material 2 is conventionally set to a limit value that can be generally controlled to about 30 μm in practice by any of the coating methods. However, in theory, at least about 0.5 μm is necessary from the viewpoint of the release effect at the time of diffusion bonding. The application of the release agent 1 is performed in this manner. Release agent 1
Has been described above.

In the method for manufacturing a metal honeycomb according to the present invention, such a release agent 1 is employed. The release agent 1 contains a release powder composed of a predetermined ceramic powder, a binder composed of an ultraviolet-curable resin, a solvent composed of water, a diluent composed of an ultraviolet-curable resin, and others. It is applied by a method. Next, a method for manufacturing a metal honeycomb using such a release agent 1 will be described in the order of the manufacturing steps. That is, in this method for manufacturing a metal honeycomb, the preparation step, the coating step, the UV
The honeycomb core H is manufactured by a stretching method that sequentially follows a process, a stacking process, a joining process, a spreading process, a washing process, and the like.

First, the preparation process will be described. In this manufacturing method, first, as shown in FIG. 1A, a base material 2 is prepared. This base material 2 is made of a thin foil-shaped stainless steel having a thickness of 200 μm or less or an aluminum alloy containing magnesium Mg in view of being used for manufacturing the honeycomb core H. As is well known, stainless steel is obtained by adding chromium (Cr) of 10% or more to iron (Fe), and in many cases, adding nickel (Ni), carbon (C), and the like. ,
Excellent workability, etc. Aluminum alloys containing magnesium Mg are also excellent in heat resistance, high temperature strength, corrosion resistance, workability, etc.
It is known that a 00 series alloy and a 5000 series alloy are particularly excellent in strength. Then, the foil-shaped base material 2 made of such stainless steel or aluminum alloy is rolled into a belt shape, and then, if necessary, cleaned by degreasing or the like, and then cut into a predetermined width or a predetermined length. Cutting into a fixed length is performed by the following coating process or UV
It may be performed after the step. In addition, the surface of the base material 5 of the aluminum alloy as the base material 2 usually has an oxide film 6
4 (see FIG. 4 (3)), it is oxidized immediately after washing to form an oxide film 6, and this oxide film 6 is made of alumina Al ₂ O ₃ . In the preparation process,
Such a base material 2 is prepared.

Next, the coating step will be described. In this manufacturing method, as shown in FIG. 1 (2) and FIG. 3 (1), the release agent 1 is applied next. That is, the release agent 1 is added to the base material 2 prepared in the above-described preparation step.
It is applied while leaving the background 5 in a line shape. The release agent 1 has a configuration described in detail above, and is applied with a predetermined application thickness T by various application methods. Then, the mold release agent 1 causes the base material 2 to form
While leaving an interval so as to leave a constant width and pitch line,
For example, the non-bonded portion 3 of the base material 2 is applied at a constant width and pitch along the width direction, for example. In the illustrated example, the release agent 1 is applied at a constant width and pitch only to one surface (front surface) of the base material 2, and only such a base material 2 is stacked, joined, and spread as described below. Will be done. In addition, regardless of such an illustration example,
The release agent 1 may be applied to both surfaces (front and back surfaces) of the base material 2 at a constant width and pitch. In this case, the base material having the release agent 1 applied to both surfaces 2 and release agent 1
And the base material 2 on which both surfaces are not applied at all are sequentially stacked and then joined and spread. In the application step, the release agent 1 is applied in this manner.

Next, the UV process will be described. In this manufacturing method, the base material 2 coated with the release agent 1 in the coating step
Is then cured and dried. That is, the base material 2 on which the release agent 1 is applied is immediately sent to an ultraviolet (UV) irradiating unit, passes through the ultraviolet light, and is irradiated with the ultraviolet light. And
With such ultraviolet rays, the prepolymer or monomer of the ultraviolet-curable resin as a binder or diluent contained in the applied release agent 1 undergoes a polymerization reaction, and is cured and dried to form a polymer (including oligomer). Becomes Then, the release agent 1 is firmly fixed to the base material 2. In the UV process, the release agent 1 is thus cured and dried.

Next, the stacking process will be described. In this manufacturing method, as shown in FIG. 1 (3), the base material 2 is stacked (see also FIG. 3 (2)). That is,
After the release agent 1 is applied in the application step described above, UV
Next, a plurality of base materials 2 in which the release agent 1 is cured and dried in the process are in a positional relationship in which the exposed ground 5 that is left between the release agents 1 in the form of striations is shifted by a half pitch. It is incontinent. For example,
Approximately 400 base materials 2 are stacked one above the other in a block shape. In this case, in the illustrated example, the ground 5 left in the form of striations on one side is halfway left and right between the upper and lower base materials 2. Positioning is performed in a positional relationship shifted by a pitch. In the stacking process, the base material 2 is stacked in this manner.

Next, the joining step will be described. In this manufacturing method, as shown in FIGS. 1 (4) and 3 (2), diffusion bonding between the base materials 2 is performed next. That is, by pressurizing and heating the base materials 2 stacked in the block shape in the above-described stacking process, the base materials 2 are diffusion-bonded between the contacting ground surfaces 5 in the form of striations. Such diffusion bonding will be described in more detail. The stacked block-shaped base material 2
The required load is applied while being restrained by an appropriate jig,
It is carried into a vacuum furnace etc. and heated at a predetermined temperature and time,
As a result, diffusion bonding is performed with the solid phase in the form of a stripe.

First, this solid phase diffusion bonding is performed in the following a. Temperature, b. Load, c. Atmosphere, d. It is performed under conditions such as time. Each of these conditions varies depending on the specific configuration content / material of the base material 2 and other conditions, but is often set as follows. a. The temperature condition is 800 when the base material 2 is stainless steel.
When the base material 2 is an aluminum alloy, the temperature is set to about 500 ° C. to 600 ° C., and the stacked base material 2 is heated. b. The load condition is 0.1 g / mm ² to 10 g / mm ² regardless of whether the base material 2 is stainless steel or aluminum alloy.
^The base material 2 which is set to about ² and thus stacked is pressed. c. A typical atmosphere condition is a vacuum atmosphere, and thus, the solid phase diffusion bonding is often carried out by carrying the stacked base material 2 into a vacuum furnace. In addition, a reduction atmosphere, an inert gas atmosphere, a reduced pressure atmosphere to which argon Ar or the like is added, and the like can be used. In these cases, respective dedicated furnaces are used. d. The time condition is set from 5 minutes to about 10 hours,
The pre-stacked base material 2 is heated and pressurized in a vacuum furnace or the like for the set time.

Such a. Temperature, b. Load, c. Atmosphere, d. Solid phase diffusion bonding is performed under conditions such as time. As a result, the striped surface 5 between the release agents 1 that defines the non-joined portions 3 of the base material 2 is contacted, abutted, and adhered as diffusion bonding target portions 4, respectively. In the illustrated example, the base material 2 that is stacked and opposed to each other in the vertical direction is
The surface between the surface 5 exposed in the form of striations and the surface 5 entirely exposed without the application of the release agent 1 on the rear surface of the upper base material 2 becomes the diffusion contact target portion 4 to be in contact with the surface. Contact and close contact.
Then, atoms of the metal elements constituting the stainless steel and the aluminum alloy of the base material 2 are diffused and moved at the grain boundary between the diffusion bonding target portions 4 of the background 5 and are stacked in a block shape. Solid phase diffusion bonding is performed between the base materials 2 in a linear manner.

FIGS. 4A and 4B show the progress of the essential parts of such solid phase diffusion bonding when the base material 2 is made of stainless steel. (3) in FIG.
In the figures, (4) and (5), the base material 2 is magnesium M
For the case of aluminum alloy containing g,
The progress of the main part of such solid phase diffusion bonding is shown. That is, as shown in FIG. 4 (3), the base material 2 made of an aluminum alloy before the solid phase diffusion bonding.
The surface of the ground 5 is firmly and stably covered with the oxide film 6. Then, as shown in FIG. 4 (4), by applying pressure and heating for solid phase diffusion bonding, magnesium Mg contained in the aluminum alloy as the base material 2 (about 400 ° C. in vacuum, It is known that the oxide film 6 evaporates and evaporates to destroy and disperse the oxide film 6. Thus, as shown in FIG. 4 (5), the aluminum Al of the aluminum alloy of the base material 2 is exposed in a solid state, and the desired solid-phase diffusion bonding proceeds.

In such a solid phase diffusion bonding, in order to promote the thermal decomposition, evaporation and disappearance of the binder and the diluent made of the ultraviolet curing resin (polymer) contained in the release agent 1, In order to decompose, evaporate, and dissipate as much as possible, it is good to hold once at the pyrolysis temperature.
That is, in the initial stage of the solid phase diffusion bonding, the heating temperature is once held as it is at the thermal decomposition temperature of the used ultraviolet curable resin (about 300 to 600 ° C. when the base material 2 is stainless steel). When the base material 2 is an aluminum alloy, the temperature is once maintained at about 300 ° C. to 400 ° C.). By temporarily maintaining the heating temperature at such a thermal decomposition temperature in the initial stage during the heating, the thermal decomposition, evaporation, and disappearance of the binder or diluent made of the ultraviolet-curable resin in the release agent 1 are prevented. Promoted. After the fact, the heating is further advanced, and when the temperature rises and reaches the above-described temperature condition, the solid-phase diffusion bonding is started. As described above, when the thermal decomposition of the binder and the diluent in the release agent 1 is promoted in the initial stage before the start of the solid phase diffusion bonding, the atmosphere at the start of the subsequent solid phase diffusion bonding is cleaned. There are advantages that can be kept. In the bonding step, diffusion bonding is performed in this manner.

Next, the expanding step will be described. In this manufacturing method, after slicing is performed as shown in FIG. 1 (5), expansion is performed as shown in FIG. 2 (1). That is, the base material 2 stacked in the form of a block, which has been diffusion-bonded in the form of a stripe in the bonding step described above, is first sliced along the length direction and cut into a required size. This slicing is performed by a method using, for example, a water jet, a wire discharge, a band saw, a cutting grindstone, or the like. Reference numeral 7 in the figure denotes the slicing tool. Then, the block-shaped base material 2 sliced to the required size in this manner is stretched by applying a tensile force in the stacking direction D. That is, the base material 2 stacked in a block shape and diffusion-bonded in a stripe shape is stretched by applying a tensile force in the vertical stacking direction D in the drawing. Accordingly, each of the base materials 2 is bent vertically along the edge of the strip-shaped diffusion bonding target portion 4, and the non-bonded portion covered with the release agent 1 other than the diffusion bonding target portion 4. 3 are vertically separated and separated so as to spread with elongation. In the expansion process, the expansion is performed in this manner.

Next, the cleaning step will be described. In this manufacturing method, the outer peripheral portion of the honeycomb core H obtained by expanding in the expanding step of FIG. 2A is trimmed as shown in FIG. 2B. , Is cut and trimmed to the required size. Trimming is performed by a method according to the above-described slice. Then, the manufactured honeycomb core H is thereafter washed by air blow, water washing, or the like, so that the remaining ceramic powder as the release powder of the release agent 1, the ash of the binder, and the like are removed. In the cleaning step, the cleaning is performed in this manner.

In the method for manufacturing a metal honeycomb, the honeycomb core H is manufactured by an expansion method in which the preparation step, the coating step, the UV step, the stacking step, the joining step, the expansion step, the cleaning step, and the like are sequentially performed. You. As shown in FIGS. 2 (2) and (3), the honeycomb core H manufactured as described above is made of a base material made of stainless steel or an aluminum alloy that is diffusion-bonded in the form of a striation, and the cell wall 8 is formed.
It is composed of a planar assembly of a large number of hollow columnar cells 9 defined by the cell walls 8. This honeycomb core H
As described above, stainless steel or an aluminum alloy is used as the base material 2 of the cell wall 8, and the cell wall 8 is joined to the base material 2 in a striped shape by diffusion bonding by heating and pressing. It becomes. The cross-sectional shape of the cell wall 8 and the cell 9 is typically a regular hexagonal shape as shown in the figure, but regardless of this, a vertically long or horizontally long hexagonal shape, other hexagonal shapes, trapezoidal shapes, substantially square shapes, and various other shapes are used. Shaped shapes are also possible.

In many cases, the honeycomb core H is bonded to the cell end faces, which are both open end faces, with a surface plate, respectively, and is thus used as a honeycomb sandwich panel. The honeycomb core H and the honeycomb sandwich panel are excellent in weight ratio strength, light in weight and have high rigidity / strength, and are excellent in rectification effect, and have a large surface area per unit volume, similarly to general ones. The honeycomb sandwich panel has excellent flatness accuracy, heat insulation, sound insulation and the like. The honeycomb core H further utilizes the basic performance of stainless steel or aluminum alloy as the base material 2 and is excellent in heat resistance, high temperature strength, oxidation resistance, corrosion resistance, workability, and the like. Structural materials for vehicles, uses as structural parts,
It is used for various other purposes. In the method for manufacturing a metal honeycomb, such a honeycomb core H is manufactured.

The present invention is configured as described above. Then, it becomes as follows. In the method for manufacturing a metal honeycomb according to the present invention, first, the base material 2 prepared in the preparation step, such as stainless steel or an aluminum alloy containing magnesium Mg, has an extremely thin foil shape having a thickness of 200 μm or less. Then, the release agent 1 is applied while leaving the background 5 in the form of striations, cured and dried in a UV process, and then, in a stacking process, a plurality of sheets are stacked while being shifted by a half pitch, and in the joining process The diffusion bonding is performed by applying pressure and heating in a vacuum furnace or the like (FIG. 1 (1), (2)
, (3), (4) and FIG. 3 (1), (2), etc. That is, the ground 5 exposed in the form of striations between the mold release agents 1 of the base material 2 becomes the diffusion bonding target portions 4, respectively.
As for the metal elements constituting the stainless steel and the aluminum alloy of the base material 2 which are in contact with and in close contact with each other, the atoms are diffused and moved at the grain interface, whereby diffusion bonding is performed between the stacked base materials 2 (see FIG. 4). (See (1) and (2) figures). In addition,
When the base material 2 is an aluminum alloy, first, the magnesium Mg contained therein evaporates to destroy and disperse the oxide film 6 covering the surface of the aluminum alloy base 5, so that the aluminum Al is in a pure state. With scalp 5
And the above-described diffusion bonding becomes possible (see FIGS. 4 (3), (4), (5), etc.).

Thereafter, the base material 2 thus stacked and diffusion-bonded is stretched by applying a tensile force in the stacking direction D in a stretching step, so that the base material 2 The release agent 1 is bent along the edge of the joining target portion 4 and
Is separated and separated (see FIG. 2 (1)). Thus, the base material 2 made of stainless steel or aluminum alloy is used as the cell wall 8 and the cell wall 8
A honeycomb core H, which is a planar assembly of a large number of hollow columnar cells 9 partitioned and formed in (2), is manufactured ((2) in FIG. 2).
Figure, (3) Figure etc.). Manufactured honeycomb core H
Are washed in a washing step.

Now, in the method for manufacturing a metal honeycomb of the present invention, the following release agent 1 is employed. That is, in the first example of the present invention, the release agent 1 containing the binder composed of the prepolymer of the ultraviolet curable resin and the solvent composed of water together with the release powder composed of the ceramic powder is used. In the second example of the present invention, a release powder composed of a ceramic powder, a binder composed of a prepolymer of two types of ultraviolet-curable resins having different thermal decomposition and evaporation temperatures, and a monomer of an ester-based ultraviolet-curable resin are used. A release agent 1 containing a diluent is used. In each of the first and second examples, the release agent 1 prepared in the preparation step and applied in the application step is obtained by first curing and drying (polymerizing) the ultraviolet curable resin in the UV step, In the bonding process after the laminating process, that is, in the diffusion bonding between the base materials 2 after the lamination, a part of the ultraviolet curing resin is thermally decomposed, evaporated, disappears by the pressure and heating in the initial initial stage, and the remaining Is incinerated and remains as ash, and the release powder and ash are removed in the washing step. Therefore, in the method for manufacturing a metal honeycomb of the present invention, the following first, second, third, fourth,
Fifth, sixth and seventh.

First, in the method for manufacturing a metal honeycomb of the present invention, in both the first and second examples, a prepolymer of an ultraviolet curable resin is used as a binder of the release agent 1.
In the first example, water is used as the solvent of the release agent 1,
In both the first and second examples, a monomer of an ultraviolet-curable resin is used as a diluent for the release agent 1. And these are
It is basically difficult to evaporate at room temperature. Therefore, in the application step, during the operation of applying the release agent 1 to the base material 2 by the printing method or the coating method, the binder, the solvent, the diluent, etc., contained in the release agent 1 to be applied become 100%. Drying, volatilization,
It does not evaporate (see FIG. 1 (2) and FIG. 3 (1)).

The release agent 1 applied in the coating step does not dry during the coating operation, and
In the next UV step, curing and drying are easily performed by applying ultraviolet rays. That is, the UV curable resin prepolymer or monomer used as a binder or diluent for the release agent 1 can be easily and easily cured in a very short time by passing ultraviolet rays in the UV process. , Dried polymer (including oligomer). Note that water used as a solvent evaporates and disappears during and after the UV process due to heat generated during the UV process.

Secondly, in the method for manufacturing a metal honeycomb of the present invention, in both the first and second examples, the ultraviolet curable resin contained in the release agent 1 and used as a binder or a diluent is used. The prepolymer and monomer are cured and dried by applying ultraviolet rays in a UV process. In the first example, the water used as the solvent evaporates and disappears after the fact. In other words, no organic solvent that is harmful to the human body when volatilized and evaporated is not used in the release agent 1. By the way,
The ultraviolet curable resin contained in the release agent 1 is used in a subsequent joining step (FIG. 1 (4), FIG. 3 (1)).
(Refer to the figure), most of them are ashed by the pressure and heating at the beginning of diffusion bonding. In addition, although a part is thermally decomposed and evaporated, even if it is inhaled by the human body, it is not harmful like an organic solvent.

Third, in the method for manufacturing a metal honeycomb of the present invention, the release agent 1 used in both the first and second examples is used.
First, a. Since a ceramic powder having a small particle size of 5 μm or less and a content set at 60% by weight or less is used as the release powder, it can be applied with a small application thickness T in the application process (FIG. 1 (2), FIG. (See FIG. 3 (1)). b. In both the first and second examples, a part of the ultraviolet curable resin used as a binder or diluent for the release agent 1 is thermally decomposed and evaporated by pressure and heating at the beginning of diffusion bonding in the bonding process. ,Disappear. c. The remaining incinerated ash has no strength and has a volume of less than half, and is compressed and filled in the gaps between the ceramic powders to a practically negligible level by the pressure for diffusion bonding (see FIG. 4) See FIG. 3 and FIG. 3 (1)). As a result, in the start stage following the initial stage of the diffusion bonding, the entire coating thickness T becomes extremely thinner than in the coating process.

Further, d. In the release agent 1 of the first example, water of 30% by weight or more is used as a solvent.
Evaporates and disappears during and after the UV process.
Therefore, from this aspect as well, at the time of diffusion bonding in the bonding step (see FIG. 1 (4) and FIG. 3 (1)), the entire coating thickness T is further thinned further than in the coating step. You. e. The release agent 1 of the second example uses, as a diluent, 15% by weight or more of an ester-based UV-curable resin monomer, and has a reduced viscosity. Therefore, in the coating step, the coating can be performed with a coating thickness T that is 30% by weight or more smaller than before (see FIG. 1 (2) and FIG. 3 (1)).
See figure).

These a. b. c. d. e. Accordingly, the release agent 1 can be applied with a thinner coating thickness T at the time of coating in the coating process, and the coating thickness T can be further reduced to be smaller than that at the time of diffusion bonding in the bonding process. . That is, the release agent 1 can be applied with a thin application thickness T of less than 30 μm at the time of application in a preliminary application step (see FIG. 1 (2) and FIG. 3 (1)).
At the start of diffusion bonding in the bonding process (FIG. 1 (4),
In FIG. 3 (2), the coating thickness T is further thinned further, and it is possible to set the coating thickness T to, for example, about 20 μm.

As described above, the release agent 1 has an extremely thin coating thickness T at the start of diffusion bonding in the bonding step. Therefore, the stacked base material 2 is such that the gap between the upper and lower ground surfaces 5 exposed in the form of striations between the left and right release agents 1 is obstructed by the applied thickness T of the left and right release agents 1. Pressurization and heating to ensure contact, contact, and close contact (FIG. 3
(2), (2) in FIG. 4, and (5) in FIG. 4). Accordingly, the stacked base materials 2 are surely diffusion bonded to each other in the form of striations. That is, in the joining step, the applied thickness T of the release agent 1 hinders, and the base 5 as the diffusion joining target portion 4 does not contact, abut, or adhere to the base 5, so that the joining strength is insufficient. It is possible to reliably avoid the occurrence of unbonded portions or occurrence of unjoined portions (in the manufactured honeycomb core H, skipping in which the spaces between the cells 9 are not reliably defined by the cell walls 8). These points become particularly remarkable when manufacturing a honeycomb core H having a small cell size S such as a cell size S (see FIG. 2 (3)) of, for example, 10 mm or less.

Fourth, in the method for manufacturing a metal honeycomb of the present invention, the coating thickness T of the release agent 1 does not hinder between the stacked base materials 2 in the bonding process as described above.
Diffusion bonding is surely performed between the lines. Therefore, pressure during diffusion bonding can be performed under relatively low pressure and low load. That is, under the general premise that the thickness of the base material 2 is 200 μm or less, as described above, 0.1 g /
The low load from mm ² of about 10 g / mm ^2, by pressurizing the preform 2 which is Juseki blocky, preform 2
Diffusion bonding is surely performed. On the other hand, if the coating thickness T of the release agent 1 remains about 30 μm or more, it is ensured that the coating thickness T of the release agent 1 is not hindered between the bases 5 of the base material 2. In order to realize proper contact, contact, close contact and reliable diffusion bonding, it is necessary to apply pressure with a high load of about 1 kg / mm ² . These points become particularly remarkable when manufacturing a honeycomb core H having a small cell size S, for example, a cell size S of 10 mm or less.

Fifth, in the method for manufacturing a metal honeycomb of the present invention, in the release agent 1 of the first example, 30
% By weight or more. Therefore, the content of the ultraviolet-curable resin used as a binder can be suppressed to be low by the amount of such a large amount of water. That is, the binder is diluted with water. As described above, the release agent 1 applied in the application step has a low content of the prepolymer of the ultraviolet-curable resin serving as the binder.
The amount of the ultraviolet-curable resin (polymer) as a binder which is pressed and heated in the joining step, that is, the amount of the organic component is small, and the amount of the ash which becomes ash and remains is also small. Accordingly, when the base material 2 is made of stainless steel, the carbon carbon of the remaining ash reacts with the stainless steel base material 2 by post-heating, thereby reducing carburization of the surface of the base material 2.

Sixth, in the method for manufacturing a metal honeycomb of the present invention, in the release agent 1 of the second example,
Prepolymers of two types of UV-curable resins having different thermal decomposition and evaporation temperatures are used, and an ester-type UV-curable resin monomer is used as a diluent. Thus, three kinds of components having different thermal decomposition and evaporation temperatures are mixed in the release agent 1 applied in the application step. Therefore, at the time of diffusion bonding between the base materials 2 in the bonding step, such three kinds of ultraviolet curable resins are sequentially decomposed at different temperatures by being pressed and heated in a vacuum furnace, for example. , And evaporates (of course, a large part is incinerated and remains as ash).
That is, when viewed as the release agent 1 as a whole, the thermal decomposition and evaporation are performed slowly and gradually at a slow speed in a wide temperature range.

In the joining step, a vacuum furnace maintained in a constant vacuum atmosphere is typically used. In this vacuum furnace, if the degree of vacuum is deteriorated during the diffusion bonding process, the apparatus is protected. Therefore, a safety device that operates is provided, and when the safety device operates, the diffusion bonding process is interrupted. (Note that in the case of atmosphere conditions such as a reducing atmosphere, an inert gas atmosphere, and a reduced pressure atmosphere, the same applies to each dedicated furnace. The same applies hereinafter.) If the ultraviolet curable resin of the mold release agent 1 is used at one time, In the case of thermal decomposition and evaporation at a stretch, for example, the degree of vacuum in the vacuum furnace may be deteriorated, and the complete apparatus may operate. On the other hand, in the second example, the thermal decomposition and evaporation are performed stepwise and gradually at a slow speed, so that the deterioration of the degree of vacuum is minimized, and the safety device is provided during the diffusion bonding process. Is less likely to operate.

Seventh, in the method for manufacturing a metal honeycomb according to the present invention, it is possible to avoid, for example, abrupt deterioration of the degree of vacuum in a vacuum furnace during diffusion bonding in the bonding step, and to provide an added safety. The device is less likely to work. Therefore, for practical convenience, the safety device is not turned off so as not to operate due to the progress of the diffusion bonding process. As described above, diffusion bonding between the base materials 2 in the bonding step is performed, for example, in a vacuum furnace maintained in a constant vacuum atmosphere as expected. Accordingly, the carbide, oxide, and other compounds in the form of a film do not react, generate, bend, or coarsen on the surface of the base material 2 accompanying the pressing and heating.

[0075]

As described above, in the method for manufacturing a metal honeycomb according to the present invention, in claim 1, a release powder composed of a ceramic powder, a binder composed of a prepolymer of an ultraviolet-curable resin, and water are used. And a mold release agent comprising a ceramic powder and a prepolymer of an ultraviolet curable resin having different thermal decomposition and evaporation temperatures. By adopting a release agent containing a binder and a diluent consisting of a monomer of an ester-based UV-curable resin, the following first, second, third, fourth, fifth and fifth 6, exert the seventh effect.

First, workability is improved because the material is not dried during the operation of applying the release agent and is cured and dried with ultraviolet rays in a short time. In this method for producing a metal honeycomb, a prepolymer of an ultraviolet curable resin is used as a binder of a release agent to be applied in both of the first and second aspects, and water is used as a solvent in the first aspect. In this case, a monomer of an ultraviolet curable resin is used as a diluent. Therefore, as described in the above-described conventional example in which the ultraviolet curable resin is not used as the release agent, that is, as in the above-described conventional example in which a general binder is dissolved in an organic solvent, when the release agent is applied, , The solvent during application work is dried,
There is no possibility of volatilization or evaporation, the release agent is easy to use, the operation of applying the release agent is simplified, and the workability is improved.

Further, the ultraviolet curable resin used as a binder in this release agent is easily cured and dried by exposing it to ultraviolet rays. That is, as in the above-described conventional example in which an ultraviolet curable resin is not used as the release agent, the applied release agent is dried with hot air in a drying furnace for a long time, thereby evaporating and evaporating the organic solvent. ， There is no need to make it disappear. The UV curable resin of this release agent is
By passing ultraviolet rays, it is easily and easily cured and dried in a very short time. Therefore, the release agent can be easily used from this aspect, and the operation of applying the release agent can be simplified.
Workability is improved.

Second, there is no volatilization or evaporation harmful to the human body.
That is, in the above-mentioned conventional example in which the ultraviolet curable resin is not used as the release agent, the organic solvent in the release agent is volatilized, evaporated and eliminated by drying.
The evaporated organic solvent is harmful to the human body, and a local exhaust device is often provided. On the other hand, the release agent used in the method for manufacturing a metal honeycomb does not use an organic solvent which is dangerous when it is volatilized and evaporated, which is excellent in safety and a local exhaust device. Is unnecessary and cost is excellent.

Third, the coating thickness of the release agent at the time of diffusion bonding can be reduced, and skipping can be avoided. That is, in this method for manufacturing a metal honeycomb, first, as a release powder of a release agent, a particle size of 5 μm or less and a content of 60% by weight.
By using ceramic powder limited to the following, it is possible to reduce the coating thickness of the release agent. In addition, in claim 1, 30% by weight or more of water is used as a solvent for the release agent to be applied, and this water evaporates and disappears by diffusion bonding. The coating thickness of the release agent becomes thinner than that. That is, as compared with the above-described conventional example in which an ultraviolet curable resin is similarly used as a binder, the coating thickness of the release agent at the time of diffusion bonding is smaller. Further, in claim 2, since a monomer of an ester-based UV-curable resin is used as a diluent for the release agent to be applied, the viscosity of the release agent is low, and the release agent may be applied thinly. It becomes possible. In other words, compared to the above-described conventional example using an ultraviolet curable resin as the binder,
At the time of application, the release agent can be applied with a smaller application thickness.

As described above, in the method for manufacturing a metal honeycomb, the coating thickness of the release agent is set to less than 30 μm, for example, 2 μm.
The thickness can be reduced to about 0 μm, and diffusion bonding is performed under such a thin coating thickness. Therefore, the base material is surely joined by diffusion in the form of striations. As in the above-described conventional example, the joining thickness of the release agent is as large as about 30 μm or more. Insufficient strength and occurrence of unjoined portions are prevented. Therefore, regarding the manufactured honeycomb core, the cells are not reliably partitioned by the cell wall as in the above-described conventional example of this type.
The occurrence of so-called skipped portions is avoided, and the quality of the honeycomb core is improved. In particular, if the cell size is 10
Even with a honeycomb core having a small cell size of, for example, mm or less, the honeycomb core can be manufactured while avoiding occurrence of skipping. or,
When applying the release agent, there is no need to consider the thickness of the release agent as much as possible, so that various coating methods and printing methods can be freely selected as the application method. Is easily and easily applied.

Fourthly, the pressure during diffusion bonding can be performed under low pressure and low load. That is, as in the above-described conventional example, when manufacturing a honeycomb core having a small cell size, pressurization in a vacuum furnace or the like for diffusion bonding is performed, for example, at 1 kg / mm in order to avoid skipping.
^It is not necessary to carry out under ^two or more high loads and high pressures.
In other words, there is no need to incorporate a flat press into a vacuum furnace or the like or to perform a hydrostatic press (HIP). in this way,
In this method for manufacturing a metal honeycomb, diffusion bonding can be reliably performed even under a low pressure and a low load by using a conventional vacuum furnace or the like. Therefore, it is excellent in cost, and it is easy to increase the size of a vacuum furnace and the like, and a honeycomb core having a large overall size can be easily manufactured.

Fifth, in the first aspect, when the base material is stainless steel, carburization can be suppressed. That is,
In the method for manufacturing a metal honeycomb according to claim 1, water is contained as a solvent in the release agent in an amount of 30% by weight or more.
The content of the ultraviolet curable resin used as a binder is reduced. Therefore, as compared with the above-described conventional example in which an ultraviolet-curable resin is similarly used as a binder, the amount of the ultraviolet-curable resin ashed during diffusion bonding is reduced. Therefore, as compared with the above-described conventional example of this type, the residual ash is less likely to react with the stainless steel base material by heating to cause carburization. As a result, the change in the mechanical strength of the base material is also reduced, and chromium carbides are formed, precipitated and coarsened in a high-temperature environment or a corrosive environment, leading to embrittlement, high-temperature oxidation, intergranular corrosion, etc. of the base material. Less to do. Therefore, a honeycomb core manufactured using stainless steel as a base material, that is, a cell wall, in this method for manufacturing a metal honeycomb can be used without trouble in a high-temperature environment or a corrosive environment.

Sixth, in the second aspect, the thermal decomposition and evaporation of the binder and the diluent of the release agent are gradually performed at a slow speed, so that the interruption of the diffusion bonding process is avoided. That is, in the method for manufacturing a metal honeycomb according to claim 2, a prepolymer of an ultraviolet curable resin having different thermal decomposition and evaporation temperatures is used as a binder of a release agent to be applied, and an ester ultraviolet curable resin is used as a diluent. Resin monomers are used.

Therefore, when performing diffusion bonding between base materials, pressurization,
These thermal decomposition and evaporation by heating are performed at different temperatures, respectively, and the thermal decomposition and evaporation of the release agent are gradually performed at a slow speed. That is, as in the above-described conventional example using an ultraviolet-curable resin, one type of ultraviolet-curable resin is thermally decomposed and evaporated at a stretch at a time, so that, for example, the degree of vacuum in a vacuum furnace is rapidly increased. It is also possible to avoid that the attached safety device is activated and the diffusion bonding process is interrupted. As described above, according to the method for manufacturing a metal honeycomb, interruption of the diffusion bonding process is avoided, and a problem in production efficiency is solved.

Seventh, in the second aspect, heating for diffusion bonding is not performed in a bad atmosphere with a reduced degree of vacuum, and the generation of carbides, oxides, and the like is avoided. That is, in the method for manufacturing a metal honeycomb according to the second aspect of the present invention, as described in the sixth aspect, during the diffusion bonding, for example, it is avoided that the degree of vacuum in the vacuum furnace suddenly deteriorates, and the attached safety device operates. There is little to do. Therefore, unlike the above-described conventional example using an ultraviolet curable resin, the safety device is not turned off so that the safety device does not operate due to the progress of the diffusion bonding process. Therefore, as in the above-described conventional example, heating for diffusion bonding is performed in a bad atmosphere in which the degree of vacuum is reduced. As a result, carbides, oxides, and other compounds are deposited on the surface of the base material. , Reaction, generation, deposition, and coarsening are also eliminated.

Therefore, for example, when the base material is stainless steel, carburization and generation of chromium carbide are avoided from this surface. For example, when the base material is an aluminum alloy, the oxide film made of alumina is destroyed and No longer formed. In addition, the formation of carbides, oxides, other compounds, and the like on the surface of the base material, which causes the base material to become brittle, high-temperature oxidation, and intergranular corrosion, is prevented. Therefore, even if the manufactured honeycomb core is used in a high-temperature environment or a corrosive environment, it can be used without any trouble without inducing the base material, that is, the cell wall, high-temperature oxidation, intergranular corrosion, etc. Becomes As described above, the effects exhibited by the present invention are remarkable and large, for example, all the problems existing in this type of conventional example are solved.

[Brief description of the drawings]

FIG. 1 is a perspective explanatory view for explaining an embodiment of a method for manufacturing a metal honeycomb according to the present invention, wherein FIG. 1A illustrates a prepared base material, and FIG. Fig. 3 (3) shows the state in which the mold is applied,
FIG. 4D shows a state of diffusion bonding, and FIG. 5B shows a state of slicing.

FIGS. 2A and 2B are perspective explanatory views for explaining the embodiment of the present invention, wherein FIG. 1A shows an expanded state, FIG. 2B shows a trimmed state, and FIG. The main parts of the honeycomb core are shown below.

FIG. 3 is an enlarged front view for explaining the embodiment of the present invention, and FIG. 3 (1) shows a state where a release agent is applied, and FIG.
The figure shows a state during diffusion bonding.

FIG. 4 is an explanatory front view of a main part used for describing the embodiment of the present invention; FIG. 4A is a diagram showing a state before diffusion bonding between stainless steel base materials; FIG. (3) shows a state before diffusion bonding between aluminum alloy base materials, and FIG. (4) shows a state before diffusion bonding between the base materials. The state immediately before the diffusion bonding is performed, and FIG. 5 (5) shows the state after the base metal is diffusion bonded.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Release agent 2 Base material 3 Non-bonding part 4 Diffusion bonding target part 5 Background 6 Oxide film 7 Slicing tool 8 Cell wall 9 Cell D Stacking direction H Honeycomb core Mg Magnesium S Cell size T Coating thickness

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B32B 3/12 B32B 3/12 A // B23K 101: 02 103: 04 103: 10 103: 20 F term ( Reference) 4E067 AA03 AA05 AC06 AD04 BA03 BA05 BB02 DA12 DA17 EC09 4F100 AB04A AB04B AB09A AB09B AB33A AB33B AD00H AK01H BA02 BA03 BA04 BA05 BA14 CA30A CA30B CC01 DC04 DE01H EH012 EH46A EH46B EJ08AEJ EJ08BEJ EJ08AEJEJBEJ

Claims (2)

[Claims] 1. A base material is a stainless steel foil or a foil-like aluminum alloy containing magnesium, and a mold release agent is applied to the base material while leaving the background in a line shape, and is irradiated with ultraviolet rays. After curing, a plurality of the base materials are piled up in a positional relationship in which the stripped lines exposed between the release agents are shifted by half a pitch, and then pressurized and heated. Then, the base material is diffused and joined in the form of striations between the contacted surfaces, and then expanded by applying a tensile force in the direction of stacking, thereby forming the base material into a cell wall. In a method for producing a metal honeycomb, which obtains a honeycomb core as a planar aggregate of a large number of hollow columnar cells partitioned by cell walls, the mold release agent is not less than 5% by weight and not more than 60% by weight. Release powder composed of ceramic powder with a particle size of 5 μm or less, and water-soluble ultraviolet curing A binder consisting of a prepolymer of the resin, 30 a solvent consisting of% by weight or more of water, that those comprising is used, method for producing a metal honeycomb, characterized in. 2. A stainless steel foil or a foil-like aluminum alloy containing magnesium is used as a base material, and a release agent is applied to the base material while leaving the background in the form of striations. After curing, a plurality of the base materials are piled up in a positional relationship in which the stripped lines exposed between the release agents are shifted by half a pitch, and then pressurized and heated. Then, the base material is diffused and joined in the form of striations between the contacted surfaces, and then expanded by applying a tensile force in the direction of stacking, thereby forming the base material into a cell wall. In a method for producing a metal honeycomb, which obtains a honeycomb core as a planar aggregate of a large number of hollow columnar cells partitioned by cell walls, the mold release agent is not less than 5% by weight and not more than 60% by weight. Release powder composed of ceramic powder having a particle size of 5 μm or less, and evaporation temperature due to thermal decomposition A binder comprising a binder made of a prepolymer of two kinds of UV-curable resins different from each other, and a diluent consisting of a monomer of an ester-based UV-curable resin, wherein a metal is used. Honeycomb manufacturing method.