JP2021151746A - 複合部材の製造方法、及び複合部材 - Google Patents
複合部材の製造方法、及び複合部材 Download PDFInfo
- Publication number
- JP2021151746A JP2021151746A JP2020053199A JP2020053199A JP2021151746A JP 2021151746 A JP2021151746 A JP 2021151746A JP 2020053199 A JP2020053199 A JP 2020053199A JP 2020053199 A JP2020053199 A JP 2020053199A JP 2021151746 A JP2021151746 A JP 2021151746A
- Authority
- JP
- Japan
- Prior art keywords
- aluminum
- aluminum member
- resin
- blasting
- composite
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 83
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 54
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 283
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 283
- 239000011347 resin Substances 0.000 claims abstract description 117
- 229920005989 resin Polymers 0.000 claims abstract description 117
- 238000005422 blasting Methods 0.000 claims abstract description 95
- 230000033444 hydroxylation Effects 0.000 claims abstract description 74
- 238000005805 hydroxylation reaction Methods 0.000 claims abstract description 74
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims abstract description 46
- 238000005304 joining Methods 0.000 claims abstract description 34
- 238000000034 method Methods 0.000 claims abstract description 32
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 24
- 239000000463 material Substances 0.000 claims description 77
- 238000001556 precipitation Methods 0.000 claims description 33
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical compound [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 claims description 17
- 239000002245 particle Substances 0.000 claims description 17
- 229910001593 boehmite Inorganic materials 0.000 claims description 14
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 14
- 125000004430 oxygen atom Chemical group O* 0.000 claims description 14
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims description 11
- 239000011231 conductive filler Substances 0.000 claims description 10
- 229910001648 diaspore Inorganic materials 0.000 claims description 10
- 229910001679 gibbsite Inorganic materials 0.000 claims description 10
- 239000006061 abrasive grain Substances 0.000 claims description 9
- 238000005275 alloying Methods 0.000 claims description 6
- 238000002347 injection Methods 0.000 description 79
- 239000007924 injection Substances 0.000 description 79
- 230000000052 comparative effect Effects 0.000 description 42
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- 238000012545 processing Methods 0.000 description 33
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- 238000005260 corrosion Methods 0.000 description 14
- 230000007797 corrosion Effects 0.000 description 14
- 230000000694 effects Effects 0.000 description 14
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- 238000003860 storage Methods 0.000 description 13
- 239000007789 gas Substances 0.000 description 11
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 9
- 239000000428 dust Substances 0.000 description 9
- 239000004734 Polyphenylene sulfide Substances 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
- 238000001746 injection moulding Methods 0.000 description 8
- 239000011777 magnesium Substances 0.000 description 8
- 229920000069 polyphenylene sulfide Polymers 0.000 description 8
- 230000007423 decrease Effects 0.000 description 7
- 238000010586 diagram Methods 0.000 description 7
- 239000000843 powder Substances 0.000 description 7
- 239000003380 propellant Substances 0.000 description 7
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 6
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 6
- 238000012790 confirmation Methods 0.000 description 6
- 239000010949 copper Substances 0.000 description 6
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- 229910052749 magnesium Inorganic materials 0.000 description 6
- 238000004881 precipitation hardening Methods 0.000 description 6
- 229910000838 Al alloy Inorganic materials 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 5
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 5
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 5
- 239000011148 porous material Substances 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 4
- 238000002441 X-ray diffraction Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000001514 detection method Methods 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 239000000835 fiber Substances 0.000 description 4
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 239000000377 silicon dioxide Substances 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- -1 Ketjen black Chemical compound 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 238000011049 filling Methods 0.000 description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 3
- 229910052759 nickel Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000011787 zinc oxide Substances 0.000 description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910019018 Mg 2 Si Inorganic materials 0.000 description 2
- 241000209094 Oryza Species 0.000 description 2
- 235000007164 Oryza sativa Nutrition 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
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- 238000005259 measurement Methods 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
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- 150000004706 metal oxides Chemical class 0.000 description 2
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- 239000011780 sodium chloride Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000005514 two-phase flow Effects 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- 229920000106 Liquid crystal polymer Polymers 0.000 description 1
- 239000004977 Liquid-crystal polymers (LCPs) Substances 0.000 description 1
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- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 238000007545 Vickers hardness test Methods 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 229910021393 carbon nanotube Inorganic materials 0.000 description 1
- 239000002041 carbon nanotube Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
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- 239000000945 filler Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 229910021389 graphene Inorganic materials 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000000640 hydroxylating effect Effects 0.000 description 1
- 229910003437 indium oxide Inorganic materials 0.000 description 1
- PJXISJQVUVHSOJ-UHFFFAOYSA-N indium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[In+3].[In+3] PJXISJQVUVHSOJ-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000003273 ketjen black Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 238000002161 passivation Methods 0.000 description 1
- 230000010287 polarization Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
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- 238000002360 preparation method Methods 0.000 description 1
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- 238000001308 synthesis method Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Images
Classifications
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B24C1/08—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
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- C—CHEMISTRY; METALLURGY
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Abstract
Description
図1は、実施形態に係る複合部材1を示す斜視図である。図1に示されるように、複合部材1は、複数の部材が接合により一体化された部材である。例えば、複合部材1は、樹脂部材と、樹脂部材に対する異種部材とを接合させた部材である。樹脂部材に対する異種部材とは、熱膨張率、熱伝達率、強度などが樹脂部材に対して異なる性質を有する材料で形成された部材である。
複合部材1の製造方法に用いる装置概要を説明する。最初に、アルミ部材2の表面にブラスト加工を行う装置を説明する。ブラスト加工装置は、重力式(吸引式)のエアブラスト装置、直圧式(加圧式)のエアブラスト装置、遠心式のブラスト装置、等何れのタイプを用いてもよい。本実施形態に係る製造方法は、一例として、いわゆる直圧式(加圧式)のエアブラスト装置を用いる。図3は、複合部材1の製造方法に用いるブラスト加工装置10の概念図である。ブラスト加工装置10は、処理室11、噴射ノズル12、貯留タンク13、加圧室14、圧縮気体供給機15及び集塵機(不図示)を備える。
上記実施形態に係るアルミ部材2及び樹脂部材3として、板状部材を例として示したが、形状に限定されることはなく、互いに接触可能なあらゆる形状を採用できる。上記実施形態に係る樹脂部材3は、アルミ部材2の表面の一部に接触していたが、アルミ部材2の表面全てに接触していてもよい。
アルミ部材2と樹脂部材3との接合は、プレス成形であってもよい。プレス成形において、アルミ部材2及び樹脂部材3は金型により固定されるため、他の接合方法に比べて接合後の複合部材1の寸法精度を高くできる。また、アルミ部材2と樹脂部材3との接合は、超音波接合であってもよい。超音波接合では、成形機は、アルミ部材2及び樹脂部材3の少なくとも一方を超音波振動させてアルミ部材2と樹脂部材3とを接合させてもよい。超音波接合では、アルミ部材2と樹脂部材3との接合箇所のみが加熱されるので、アルミ部材2及び樹脂部材3の熱膨張率の差による接合後の複合部材1の反りの発生を抑えることができる。
最初にブラスト加工工程(S12)を実行する前のアルミ部材2の酸化被膜の膜厚を計測した。「オージェ電子分光法(AES:Auger electron spectroscopy)」を用いてアルミ酸化皮膜の深さ方向分析を行った。酸化物/金属の界面付近では酸化物と金属成分が同時に検出されるためにこれらをスペクトル合成法によって分離して、酸化被膜の膜厚を求めた。酸化被膜の膜厚は72nmであった。次に、図3〜図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行後、アルミ部材2の酸化被膜の膜厚を計測した。砥粒の中心粒径が600μm〜710 μmの噴射材を用いた場合、酸化被膜の膜厚は13 nmであった。砥粒の中心粒径が41 μm〜50 μmの噴射材(最大粒子径127 μm以下、平均粒子径57μm ± 3 μm)を用いた場合、酸化被膜の膜厚は9 nmであった。このため、少なくとも710 μm以下の噴射材を用いることで、アルミ部材2の表面2aの酸化被膜を除去できることが確認された。
アルミ部材は、アルミニウム板(JIS:A5052)を用いた。アルミ部材に対し、表面水酸化工程(S14)を実行した。表面水酸化工程(S14)として、オートクレーブ内に純水を10ml投入し、アルミニウム板を配置して、処理時間を24時間とした水蒸気処理をおこなった。以下、水蒸気処理の処理時間を単に「処理時間」と記載する場合がある。水蒸気処理の加熱温度は、それぞれ140℃、180 ℃、及び220 ℃である。なお、加熱温度が140 ℃の場合におけるオートクレーブ内の圧力は0.5 MPaとなり、加熱温度が180 ℃の場合におけるオートクレーブ内の圧力は1.0MPaとなり、加熱温度が220 ℃の場合におけるオートクレーブ内の圧力は2.3 MPaとなった。そして、電界放出形走査電子顕微鏡(FE−SEM:Field Emission Scanning Electron Microscope)を用いて表面観察し、表面粗さを確認した。
図3〜図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行した。アルミ部材は、アルミニウム板(JIS:A5052)を用いた。ブラスト加工には、材料がアルミナ、砥粒中心粒径が106μm〜125μmの噴射材を用いた。ブラスト圧は1.0 MPaとした。ブラスト加工工程後に、電界放出形走査電子顕微鏡(FE−SEM)を用いて表面観察した。
アルミ部材は、アルミニウム板(JIS:A5052)を用いた。アルミ部材に対し、表面水酸化工程(S14)を実行した。表面水酸化工程(S14)として、オートクレーブ内に純水を10ml投入し、ブラスト加工されたアルミニウム板を配置して、加熱温度を180℃とした水蒸気処理をおこなった。水蒸気処理の処理時間は、それぞれ2時間、24時間、及び36時間である。なお、オートクレーブ内の圧力は1.0MPaとなった。
実施例1〜7及び比較例1〜6を用意してせん断強度を確認した。
実施例1は、図3〜図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行した。アルミ部材は、アルミニウム板(JIS:A5052)を用いた。表面水酸化工程(S14)を実行した。オートクレーブ内に純水を10ml投入し、ブラスト加工されたアルミニウム板を配置して、加熱温度を180 ℃とし、処理時間を2時間とした水蒸気処理をおこなった。続いて、接合工程(S16)を実行した。図6及び図7に示される金型20を用いて、アルミ部材2に樹脂部材3を接合させた。樹脂部材3は、PPS(Polyphenylenesulfide)樹脂を用いた。樹脂部材3は、縦、横、厚さが10 mm×45 mm×3.0 mmとなるように設定した。射出成形の保持時(型閉じ時)において、金型温度は220℃、保持圧力は5MPa、保持時間は300 sとした。アルミ部材2と樹脂部材3との重なりは5 mmとした。
比較例1は、アルミ部材として、ブラスト加工工程(S12)、表面水酸化工程(S14)を実行していないアルミニウム板(JIS:A5052)を用いた。このアルミ部材とPPS樹脂とを接合させた部材を比較例1とした。
上記条件で作成された実施例1〜7及び比較例1〜6のせん断強度を測定した。評価装置は、ISO 19095に準拠する試験方法で測定した。図16は、実施例に係る加工条件及びせん断強度の結果である。図16に示されるように、実施例1のせん断強度は、21MPaであり、実施例2のせん断強度は、30 MPaであり、実施例3のせん断強度は、38 MPaであり、実施例4のせん断強度は、26 MPaであり、実施例5のせん断強度は、13MPaであり、実施例6のせん断強度は、30 MPaであり、実施例7のせん断強度は、35 MPaであった。比較例1のせん断強度は、1 MPaであり、比較例2のせん断強度は、15MPaであり、比較例3のせん断強度は、11 MPaであり、比較例4のせん断強度は、7.2 MPaであり、比較例5のせん断強度は、9.9 MPaであり、比較例6のせん断強度は、3.9MPaであった。
実施例8及び比較例7を用意して耐食性を確認した。
実施例8は、実施例4と同一のブラスト加工工程(S12)、表面水酸化工程(S14)、及び接合工程(S16)を実行し、複合部材を形成した。
比較例7は、アルミ部材として、ブラスト加工工程(S12)、表面水酸化工程(S14)を実行していないアルミニウム板(JIS:A5052)を用いた。このアルミ部材とPPS樹脂とを接合させた複合部材を比較例7とした。
上記条件で作成された実施例8及び比較例7の耐食性として、NaCl水溶液中を用いて電流密度を測定した。実施例8の複合部材及び比較例7の複合部材を、室温中の5wt%(重量パーセント)濃度のNaCl水溶液に浸漬させ、分極抵抗法により腐食電流密度を算出する。この結果、実施例8の複合部材の腐食電流密度は、比較例7の複合部材の腐食電流密度と比較して約1/100になった。表面水酸化工程(S14)における水蒸気処理において、アルミ部材の表面に不動態の機能を有するアモルファス層が形成されたことで、アルミ部材の表面における電流密度の低下につながったと考えられる。
実施例9,10及び比較例8を用意して硬さを確認した。
実施例9は、図3〜図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行した。アルミ部材は、アルミニウム板(JIS:A5052)を用いた。ブラスト加工には、材料がアルミナ、砥粒中心粒径が106μm〜125μmの噴射材を用いた。ブラスト圧は1.0 MPaとした。このとき、アルミ部材の表面の算術平均傾斜は、0.17以上0.50以下となった。続いて、表面水酸化工程(S14)を実行した。オートクレーブ内に純水を10ml投入し、ブラスト加工されたアルミニウム板を配置して、加熱温度を180℃とし、処理時間を30分とした水蒸気処理をおこなった。続いて、接合工程(S16)を実行した。図6及び図7に示される金型20を用いて、アルミ部材2に樹脂部材3を接合させ、複合部材を形成した。樹脂部材3は、PPS(Polyphenylenesulfide)樹脂を用いた。樹脂部材3は、縦、横、厚さが10 mm×45 mm×3.0 mmとなるように設定した。射出成形の保持時(型閉じ時)において、金型温度は220℃、保持圧力は5MPa、保持時間は300 sとした。アルミ部材2と樹脂部材3との重なりは5 mmとした。
比較例8は、アルミ部材として、ブラスト加工工程(S12)、表面水酸化工程(S14)を実行していないアルミニウム板(JIS:A5052)を用いた。このアルミ部材とPPS樹脂とを接合させた複合部材を比較例8とした。
上記条件で作成された実施例9,10の複合部材及び比較例8の複合部材の硬さとして、ビッカース硬さ試験(JIS Z 2244/ISO 6507−1)に準拠した硬さ試験を実行してビッカース硬さを測定した。このとき、試験力は0.05kgf/mm2である。図17は、アルミ部材のビッカース硬さの測定結果である。図17に示されるように、実施例9のビッカース硬さは165HV0.05となり、実施例10のビッカース硬さは178HV0.05となり、比較例8のビッカース硬さは80HV0.05となった。この結果から、実施例9,10の各複合部材のビッカース硬さは、比較例8の複合部材のビッカース硬さと比較して約2倍以上になることが確認された。表面水酸化工程(S14)における水蒸気処理において、アルミ部材の表面に析出層が形成されたことで、アルミ部材の表面におけるビッカース硬さの向上につながったと考えられる。
Claims (9)
- アルミ部材と樹脂部材とを接合した複合部材の製造方法であって、
前記アルミ部材の表面をブラスト加工するブラスト加工工程と、
前記ブラスト加工された前記アルミ部材の表面と水蒸気とを、大気圧を超える圧力を加えて反応させて、前記アルミ部材の表面をアルミニウム水酸化物に改質する表面水酸化工程と、
前記アルミニウム水酸化物に改質された前記アルミ部材の表面に前記樹脂部材を直接接合する接合工程と、
を含む、複合部材の製造方法。 - 前記表面水酸化工程は、前記ブラスト加工された前記アルミ部材の表面と水蒸気とを、140℃以上の熱を加えて反応させる、請求項1に記載の複合部材の製造方法。
- 前記表面水酸化工程は、前記ブラスト加工された前記アルミ部材の表面と水蒸気とを、2時間以上24時間以下の処理時間で反応させる、請求項1又は2に記載の複合部材の製造方法。
- 前記アルミニウム水酸化物は、ダイアスポア、ベーマイト、擬ベーマイト、バイヤライト、ノルストランダイト、ギブサイト及びドイライトの少なくとも1つを含む、請求項1〜3の何れか一項に記載の複合部材の製造方法。
- 前記ブラスト加工工程で用いられる砥粒の粒子径は、30μm〜710 μmである、請求項1〜4の何れか一項に記載の複合部材の製造方法。
- 前記樹脂部材は、導電性フィラーを含み、導電性を有する、請求項1〜5の何れか一項に記載の複合部材の製造方法。
- 凹凸が形成された表面を有するアルミ部材と、
前記アルミ部材の表面に直接接触する樹脂部材と、
を備え、
前記アルミ部材の表面は、
アルミニウムの母材上に配置され、前記母材から析出した合金元素を含む析出層と、
前記析出層上に配置され、アルミニウム原子及び酸素原子を含むアモルファス層と、
前記アモルファス層上に配置され、アルミニウム水酸化物を含み、前記樹脂部材と直接接触する接触層と、
を有する、複合部材。 - 前記アルミニウム水酸化物は、ダイアスポア、ベーマイト、擬ベーマイト、バイヤライト、ノルストランダイト、ギブサイト及びドイライトの少なくとも1つを含む、請求項7に記載の複合部材。
- 前記樹脂部材は、導電性フィラーを含み、導電性を有する、請求項7又は8に記載の複合部材。
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