JP2022034760A - Method for manufacturing low temperature spray coating coated member - Google Patents

Abstract

To provide a method for manufacturing a low temperature spray coating coated member, capable of suppressing the deformation of an aluminum alloy material caused by forming a low temperature spray coating on the surface of the aluminum alloy material.SOLUTION: A method for manufacturing a low temperature spray coating coated member includes a step of spraying a metal powder including at least one kind selected from pure iron, carbon steel, stainless steel, nickel, nickel alloy, cobalt and cobalt alloy at a low temperature in at least a part of a region on the surface of an aluminum alloy material 11 having an open cross section or a closed cross section to form a low temperature spray coating 33. The aluminum alloy material 31 has an outer surface 31c having the metal powder sprayed at a low temperature and an inner surface being a surface on the side opposite to the outer surface 31c, and, for example, a core material 36 is inserted into a space part surrounded by an inner surface corresponding to the region having the low temperature spray coating 33 as a reinforcing member for suppressing the deformation of the aluminum alloy material 31.SELECTED DRAWING: Figure 1A

Description

The present invention relates to a method for manufacturing a low temperature sprayed coating member capable of suppressing deformation of aluminum or an aluminum alloy material when forming a low temperature sprayed coating on the surface of an aluminum or aluminum alloy material.
In the following, aluminum or aluminum alloy material may be collectively referred to as "aluminum alloy material".

Conventionally, there have been proposed techniques for improving various properties of the surface of an aluminum alloy material by brazing or spraying a metal made of a specific material on the surface of the aluminum alloy material.
For example, in Patent Document 1, an alloying layer having excellent adhesion is formed by forming an additive material film on the surface of an aluminum alloy material and irradiating the additive substance film with a pulse oscillation laser to heat the aluminum alloy material. It is described that a composite layer can be formed.

By the way, when a low-temperature sprayed film is formed by low-temperature spraying metal powder on the surface of a thin-walled aluminum alloy material formed by extrusion processing, if the thermal expansion rates of the aluminum alloy material and the low-temperature sprayed film are different, Due to the difference in cooling behavior between the two, the aluminum alloy material may be thermally deformed. It should be noted that the thermal deformation of the aluminum alloy material due to the formation of such a low temperature sprayed coating occurs not only in the aluminum alloy material formed by the extrusion process but also in the aluminum alloy material formed by the casting process.
Generally, at the time of manufacturing an extruded material, a step of straightening to a desired shape is carried out after extrusion molding. Also in Patent Document 1, it is described that after forming a thermal spray coating on one side of an extruded material made of an aluminum alloy, tensile straightening is performed to correct bending and the like.

Japanese Unexamined Patent Publication No. 9-170037

However, since the low-temperature sprayed coating is brittle, cracks occur in the low-temperature sprayed coating when straightened by the same method as the straightening step performed on a general aluminum alloy material, and this crack is the cause. The low temperature sprayed coating may peel off from the surface of the aluminum alloy extruded material. As a result, there arises a problem that desired characteristics cannot be obtained in the region where the low temperature sprayed coating is peeled off.

The present invention has been made in view of the above-mentioned problems, and manufactures a low-temperature sprayed coating member capable of suppressing deformation of the aluminum alloy material generated by forming a low-temperature sprayed coating on the surface of the aluminum alloy material. The purpose is to provide a method.

The method for manufacturing a low-temperature sprayed coating member according to the present invention comprises the following configuration (1).

(1) At least one selected from pure iron, carbon steel, stainless steel, nickel, nickel alloy, cobalt and cobalt alloy in at least a part of the surface of aluminum or an aluminum alloy material having an open cross section or a closed cross section. A method for manufacturing a low-temperature spray film covering member, which comprises a step of forming a low-temperature spray film by low-temperature spraying a metal powder containing the above.
The aluminum or aluminum alloy material has an outer surface on which the metal powder is sprayed at a low temperature and an inner surface which is a surface opposite to the outer surface.
A low-temperature sprayed coating covering member comprising a step of providing a reinforcing member for suppressing deformation of the aluminum or aluminum alloy material in at least a part of the inner surface corresponding to the region where the low-temperature sprayed coating is formed. Manufacturing method.

Further, a preferred embodiment of the method for manufacturing a low-temperature sprayed coating member according to the present invention comprises the following configurations (2) to (12).

(2) The method for manufacturing a low-temperature sprayed coating member according to (1), wherein the reinforcing member has a shape having a longitudinal direction in substantially the same direction as the extending direction of the low-temperature sprayed coating.

(3) The method for manufacturing a low-temperature sprayed coating member according to (1) or (2), wherein the aluminum or aluminum alloy material has a shape in which ribs are provided on the inner surface.

(4) The reinforcing member is a core material inserted into a gap surrounded by the inner surface.
At least in the step of forming the low temperature sprayed coating, the core material is in contact with at least a part of the inner surface corresponding to the region where the low temperature sprayed coating is formed.
The method for manufacturing a low-temperature sprayed coating member according to any one of (1) to (3), further comprising a step of removing the core material after the step of forming the low-temperature sprayed coating.

(5) The method for manufacturing a low temperature sprayed coating member according to (4), wherein the step of removing the core material is carried out after the low temperature sprayed coating is cooled to room temperature.

(6) The aluminum or aluminum alloy material is fixed by being pressed from the outer surface at least in the step of forming the low temperature sprayed coating.
Further, the production of the low temperature sprayed coating member according to (4) or (5), further comprising a step of releasing the pressure on the aluminum or the aluminum alloy material after the step of forming the low temperature sprayed coating. Method.

(7) Manufacture of the low-temperature sprayed coating member according to (6), wherein the step of releasing the pressure on the aluminum or the aluminum alloy material is performed after the low-temperature sprayed coating is cooled to room temperature. Method.

(8) The core material is pressed toward the center from both ends in the longitudinal direction of the core material at least in the step of forming the low temperature sprayed coating.
Further, any one of (4) to (7), further comprising a step of releasing the pressure on the core material between the step of forming the low temperature sprayed coating and the step of removing the core material. The method for manufacturing a low temperature sprayed coating member according to one.

(9) The method for manufacturing a low-temperature sprayed coating member according to (8), wherein the core material is made of an elastic body having a longitudinal direction.

(10) The step of releasing the pressure on the core material is carried out after the low temperature sprayed coating is cooled to room temperature, according to the low temperature sprayed coating member according to (8) or (9). Production method.

(11) The method for manufacturing a low-temperature sprayed coating member according to any one of (1) to (10), wherein the aluminum or aluminum alloy material is an extruded material having a closed cross section.

(12) The method for manufacturing a low-temperature sprayed coating member according to any one of (1) to (10), wherein the aluminum or aluminum alloy material is a cast material having an open cross section or a closed cross section.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a method for manufacturing a low temperature sprayed coating member capable of suppressing deformation of the aluminum alloy material generated by forming a low temperature sprayed coating on the surface of the aluminum alloy material.

FIG. 1A is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to the first embodiment of the present invention, and is a diagram showing a step of forming a low temperature sprayed coating. FIG. 1B is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to the first embodiment of the present invention, and is a diagram showing a state in which a low temperature sprayed coating is formed. FIG. 1C is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to the first embodiment of the present invention, showing the low temperature sprayed coating member manufactured according to the first embodiment. It is a figure. FIG. 2A is a schematic perspective view for explaining a conventional method for manufacturing a low temperature sprayed coating member, and is a diagram showing a process of forming a low temperature sprayed coating. FIG. 2B is a schematic perspective view for explaining a method of manufacturing a conventional low temperature sprayed coating member, and is a diagram showing a low temperature sprayed coating member manufactured by the conventional manufacturing method. FIG. 3 is a perspective view schematically showing the shape of the low temperature sprayed coating member manufactured by the conventional manufacturing method. FIG. 4A is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a second embodiment of the present invention, and is a diagram showing a step of forming a low temperature sprayed coating. FIG. 4B is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a second embodiment of the present invention, and is a diagram showing a state in which a low temperature sprayed coating is formed. FIG. 4C is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a second embodiment of the present invention, showing the low temperature sprayed coating member manufactured according to the second embodiment. It is a perspective view. FIG. 5A is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a third embodiment of the present invention, and is a diagram showing a step of forming a low temperature sprayed coating. FIG. 5B is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a third embodiment of the present invention, and is a diagram showing a state in which a low temperature sprayed coating is formed. FIG. 5C is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a third embodiment of the present invention, and is a diagram showing a step of releasing pressing. FIG. 5D is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a third embodiment of the present invention, showing the low temperature sprayed coating member manufactured according to the third embodiment. It is a figure. FIG. 6A is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a fourth embodiment of the present invention, and is a diagram showing a step of forming a low temperature sprayed coating. FIG. 6B is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a fourth embodiment of the present invention, and is a diagram showing a state in which a low temperature sprayed coating is formed. FIG. 6C is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a fourth embodiment of the present invention, and is a diagram showing a step of releasing pressing. FIG. 6D is a schematic perspective view for explaining a method for manufacturing a low temperature sprayed coating member according to a fourth embodiment of the present invention, showing the low temperature sprayed coating member manufactured according to the fourth embodiment. It is a figure.

Hereinafter, embodiments of the present invention will be described in detail. The present invention is not limited to the embodiments described below, and can be arbitrarily modified and implemented without departing from the gist of the present invention. Further, in the specification of the present application, "-" indicating a numerical range is used to mean that the numerical values described before and after the numerical range are included as the lower limit value and the upper limit value.

The present inventors have earnestly studied a method for suppressing deformation of the aluminum alloy material when a low-temperature sprayed coating is formed on the surface of the aluminum alloy material. As a result, it was found that it is effective to prevent deformation that the reinforcing member is previously arranged on the back surface side of the region where the low temperature sprayed coating is formed in the aluminum alloy material.

Hereinafter, a method for manufacturing the low temperature sprayed coating member according to the present invention will be described.

[Manufacturing method of low temperature sprayed coating member]
In the method for manufacturing a low temperature spray coating member according to the present invention, pure iron, carbon steel, stainless steel, nickel, nickel alloy, in at least a part of the surface of aluminum or an aluminum alloy material having an open cross section or a closed cross section. It has a step of forming a low-temperature sprayed film by low-temperature spraying a metal powder containing at least one selected from cobalt and a cobalt alloy. Further, the aluminum or aluminum alloy material has an outer surface on which the metal powder is sprayed at a low temperature and an inner surface which is a surface opposite to the outer surface, and corresponds to a region where a low temperature sprayed film is formed. It has a step of providing a reinforcing member for suppressing deformation of aluminum or an aluminum alloy material in at least a part of a region of the surface.

Hereinafter, the method for manufacturing the low temperature sprayed coating member according to the embodiment of the present invention will be described in more detail with reference to the drawings.

(First Embodiment)
1A to 1C are schematic perspective views for explaining a method for manufacturing a low temperature sprayed coating member according to the first embodiment of the present invention.

As shown in FIG. 1A, the aluminum alloy material 31 is an extruded material having a closed cross section, and has a void portion (not shown) surrounded by an inner surface 31d.
First, before forming the low-temperature sprayed coating 33, the core material 36 is inserted as a reinforcing member in the void portion of the aluminum alloy material 31. The core material 36 has a cross-sectional shape fitted in the gap portion of the aluminum alloy material 31, and is formed longer than the length in the longitudinal direction of the aluminum alloy material 31. Therefore, both ends of the core material 36 project from one end 31a and the other end 31b of the aluminum alloy material 31, and are inserted without a gap between the core material 36 and the aluminum alloy material 31. The core material 36 is also referred to as a "core".

Next, the metal powder is sprayed at a low temperature by a low temperature spraying method (cold spray method) on a part of the outer surface 31c of the aluminum alloy material 31 into which the core material 36 is inserted. The cold spray method is a method of spraying gas and metal powder from the spraying head 14 to a predetermined region at a high speed higher than the speed of sound.
As a result, as shown in FIG. 1B, the low temperature sprayed coating 33 is formed on the outer surface 31c of the aluminum alloy material 31 in the region extending from one end 31a to the other end 31b in the longitudinal direction.

Then, as shown in FIG. 1C, the core material 36 is removed from the aluminum alloy material 31 to manufacture the low temperature sprayed coating member 35. The timing for removing the core material 36 is not particularly limited, but as will be described later, the low temperature sprayed coating 33 is deformed in the process of cooling the aluminum alloy material 31 and the low temperature sprayed coating 33. Is preferably after cooling to room temperature. The room temperature is specifically 5 to 45 ° C.

In the first embodiment, the core material 36 is fitted without a gap in the gap portion of the aluminum alloy material 31. Further, the core material 36 has a shape having a longitudinal direction in the same direction as the extending direction of the low temperature sprayed coating 33, and is arranged so as to be in contact with the inner surface corresponding to the region where the low temperature sprayed coating 33 is formed. There is. Therefore, the core material 36 acts as a reinforcing member, and after the formation of the low temperature sprayed coating 33, the low temperature sprayed coating member 35 is deformed before the aluminum alloy material 31 and the low temperature sprayed coating 33 are cooled. It can be suppressed.

In the present invention, the shape is not limited to the shape of the core material 36, and at least in the step of forming the low temperature sprayed coating 33, at least a part of the inner surface corresponding to the region where the low temperature sprayed coating 33 is formed. , It suffices if the core material is in contact. However, as shown in the first embodiment, when the core material 36 is fitted tightly in the gaps of the aluminum alloy material 31, the position where the low temperature sprayed coating 33 is formed can be freely designed. At the same time, deformation of the low-temperature sprayed coating member can be further suppressed.
Further, in the present invention, the material of the core material 36 is not particularly limited, but for example, sand, an elastic body, a ceramic, a resin, a metal, or a mixture thereof, or a material obtained by solidifying these into a desired shape with a binder or the like. Etc. can be used.

(Conventional method for manufacturing low temperature sprayed coating member)
For comparison, an example in which a low-temperature sprayed coating is formed on the surface of an aluminum alloy material without inserting the core material 36 will be described. 2A and 2B are schematic perspective views for explaining a conventional method for manufacturing a low temperature sprayed coating member. Further, FIG. 3 is a perspective view showing the shape of the low temperature sprayed coating member manufactured by the conventional manufacturing method.

As shown in FIG. 2A, in the conventional method for manufacturing a low-temperature sprayed coating member, a metal powder is sprayed onto a part of the outer surface 71c of the hollow aluminum alloy material 71 by using the sprayed head 74.
As a result, as shown in FIG. 2B, the low temperature sprayed coating 73 is formed in the region extending from one end 71a to the other end 71b in the longitudinal direction of the aluminum alloy material 71, and the low temperature sprayed coating member 75 is manufactured.
In the low temperature sprayed coating member 75 manufactured in this way, the surface on which the low temperature sprayed coating 73 is formed is deformed in a protruding shape in a cross-sectional view in a direction orthogonal to the longitudinal direction. Further, as shown in FIG. 3, in the manufactured low-temperature sprayed coating member 75, focusing on the surface on which the low-temperature sprayed coating 73 is formed, the central portion in the longitudinal direction is recessed from both ends, and the shape is curved as a whole. It has become.

The reason why the low temperature sprayed coating member 75 manufactured by the conventional manufacturing method is deformed will be specifically described below.

When the low temperature sprayed coating 73 is formed on the outer surface 71c of the aluminum alloy material 71 by the cold spray method, the region where the low temperature sprayed coating 73 is formed becomes high temperature. Here, the aluminum alloy material 71 and the low temperature sprayed coating 73 The characteristics such as thermal conductivity, specific heat, and linear expansion coefficient are different from each other, and the shrinkage speeds of both are different. However, since the aluminum alloy material 71 and the low-temperature sprayed coating 73 are bonded to each other, if one of them shrinks rapidly in the cooling process, the other will also be in the direction shown by arrow A1 and the direction shown by arrow A2 in FIG. Stress due to shrinkage is applied. As a result, the low temperature sprayed coating member 75 is deformed in the cooling process.

On the other hand, in the first embodiment, since the core material 36 as a reinforcing member for suppressing stress due to shrinkage is inserted into the void portion of the aluminum alloy material 31, deformation of the low temperature sprayed coating member 35 can be suppressed. ..

(Second Embodiment)
4A to 4C are schematic perspective views for explaining a method for manufacturing a low temperature sprayed coating member according to a second embodiment of the present invention. In the present embodiment, the shape of the aluminum alloy material used is different from that of the first embodiment.

As shown in FIG. 4A, the aluminum alloy material 11 is an extruded material having a closed cross section, and one rib 12 is provided on the inner surface thereof. More specifically, the rib 12 crosses the gap portion 17 surrounded by the inner surface of the aluminum alloy material 11 from one wall surface toward the other wall surface, and further, one end in the longitudinal direction of the aluminum alloy material 11. It has a shape extending from the portion 11a to the other end portion 11b.

First, the core material 46a and the core material 46b are inserted into the two gaps partitioned by the ribs 12 in the aluminum alloy material 11. The core material 46a and the core material 46b each have a cross-sectional shape that is fitted into the two gaps, and both are formed longer than the length of the aluminum alloy material 11 in the longitudinal direction. Therefore, both ends of the core material 46a and the core material 46b protrude from one end 11a and the other end 11b of the aluminum alloy material 11, and the core material 46a and the core material 46b have no gap between the core material 46a and the core material 46b. It is inserted in the state.

Next, the metal powder is sprayed at a low temperature from the thermal spray head 14 from the one end portion 11a to the other end portion 11b in the longitudinal direction with respect to the outer surface 11c of the aluminum alloy material 11 into which the core material 46a and the core material 46b are inserted. do. As a result, as shown in FIG. 4B, the low temperature sprayed coating 13 is formed on the outer surface 11c of the aluminum alloy material 11.

Then, as shown in FIG. 4C, the core material 46a and the core material 46b are removed from the aluminum alloy material 11 to manufacture the low temperature sprayed coating member 45. The timing for removing the core material 46a and the core material 46b is not particularly limited, but it is preferable that the low temperature sprayed coating 13 is cooled to room temperature as in the first embodiment.

In the second embodiment, the core material 46a and the core material 46b are fitted tightly into the gaps of the aluminum alloy material 11. Further, the core material 46a and the core material 46b have a longitudinal direction in the same direction as the extending direction of the low temperature sprayed coating 13, and are arranged so as to be in contact with the inner surface corresponding to the region where the low temperature sprayed coating 13 is formed. Has been done. Therefore, the core material 46a and the core material 46b act as reinforcing members, and it is possible to prevent the low temperature sprayed coating member 45 from being deformed until the aluminum alloy material 11 and the low temperature sprayed coating 13 are cooled. ..
Further, also in the second embodiment, since the core material 46a and the core material 46b are fitted without gaps in the two gaps of the aluminum alloy material 11, the position where the low temperature sprayed coating 13 is formed can be freely designed. Can be done.

In the second embodiment, the core material 46a and the core material 46b are fitted tightly in the gaps of the aluminum alloy material 11, but the present invention is not limited to such a configuration. For example, at least one of the core material 46a and the core material 46b is arranged so as to be in contact with at least a part of the inner surface corresponding to the region where the low temperature sprayed coating 13 is formed in the step of forming at least the low temperature sprayed coating 13. It suffices if it is installed.
Further, when the aluminum alloy material 11 having the shape shown in the second embodiment is used, it is not always necessary to insert both the core material 46a and the core material 46b into the gap portion, and either of the two gap portions is used. A core material to be a reinforcing member may be inserted only in one of the gaps.

Further, the number, shape and thickness of the ribs 12 of the aluminum alloy material 11 are not particularly limited, and for example, an aluminum alloy material provided with two or more ribs according to the required strength of the aluminum alloy material. It can also be used. Specifically, in the void portion surrounded by the inner surface of the aluminum alloy material, two ribs parallel to each other cross from one wall surface toward the other wall surface, and in the longitudinal direction of the aluminum alloy material. It may have a shape extending from one end to the other end of the.
Further, the plurality of ribs do not have to be parallel to each other, and the two ribs may have a shape in which they intersect in a cross shape.

For example, when an aluminum alloy material having two ribs parallel to each other is used, since it has three voids, at least one void is provided depending on the region where the low temperature sprayed coating is formed. For example, if the core material is inserted into the central gap, the effect of suppressing deformation can be obtained.
Further, by inserting the three core materials into the respective voids, deformation due to the formation of the low temperature sprayed coating can be further suppressed.
Further, the aluminum alloy material having the ribs intersecting in a cross shape has four voids, but like the aluminum alloy material having two parallel ribs, at least one core material. May be inserted into the voids, and it is most preferable to insert the core material into all the voids.

(Third Embodiment)
5A to 5D are schematic perspective views for explaining a method for manufacturing a low temperature sprayed coating member according to a third embodiment of the present invention. Since the third embodiment is a modification of the first embodiment shown in FIGS. 1A to 1C, the same or equivalent parts as those of the first embodiment are designated by the same reference numerals and the description thereof is omitted. Simplify.

As shown in FIG. 5A, in the present embodiment, the core material 36 is inserted into the gap portion of the aluminum alloy material 31. The core material 36 has, for example, a cross-sectional shape that is fitted without gaps in the gaps of the aluminum alloy material 31.
After that, the aluminum alloy material 31 is fixed by pressing the core material 36 from both ends thereof and pressing the outer surface 31c of the aluminum alloy material 31. Specifically, the core material 36 is pressed in the direction indicated by the arrow P1 so as to sandwich the core material 36 from both ends in the longitudinal direction toward the center portion. Further, on the outer surface 31c of the aluminum alloy material 31, the aluminum alloy material 31 is pressed in the direction indicated by the arrow P2 so as to sandwich the aluminum alloy material 31 from the surface forming the low temperature sprayed coating 33 and the surface on the opposite side thereof.

The position of pressing against the outer surface 31c of the aluminum alloy material 31 is not particularly limited, but when the surface forming the low temperature sprayed coating 33 is viewed from the front, the region close to the four corners is pressed and the low temperature sprayed coating 33 is formed. It is preferable to press the region close to the four corners also on the surface opposite to the surface to be surfaced. The regions close to the four corners of the surface forming the low temperature sprayed coating 33 are regions close to one end 31a and the other end 31b of the aluminum alloy material 31, and are symmetrical with respect to the low temperature sprayed coating 33, respectively. Two regions are shown.
As described above, as a means for fixing the aluminum alloy material 31, it is preferable to use a method of pressing a total of eight regions corresponding to each of the surface forming the low temperature sprayed coating 33 and the surface on the opposite side thereof. As long as it is a corresponding region, it is more preferable that the region to be pressed increases. Further, it is more preferable to press the entire region where the low temperature sprayed coating 33 is not formed and the corresponding entire region on the opposite surface thereof on the surface where the low temperature sprayed coating 33 is formed.

After that, as shown in FIG. 5B, the low temperature sprayed coating 33 is formed in a state where both ends of the outer surface 31c of the aluminum alloy material 31 and the core material 36 are pressed.

After that, as shown in FIG. 5C, the pressure on the outer surface 31c of the aluminum alloy material 31 is released, and the pressure on the core material 36 is released. The timing at which the pressure on the aluminum alloy material 31 and the core material 36 is released is not particularly limited, but it is preferably after the low-temperature sprayed coating 33 has been cooled to room temperature, similar to the timing at which the core material 36 is removed.

Then, as shown in FIG. 5D, the core material 36 is removed from the aluminum alloy material 31 to manufacture the low temperature sprayed coating member 55. The timing for removing the core material 36 is not particularly limited as long as the pressure on the core material 36 is released, but it is preferable that the low temperature sprayed coating 33 is cooled to room temperature.

In the manufacturing method according to the third embodiment, by pressing the core material 36 in the direction shown in P1, the effect of suppressing the stress in the direction shown by the arrow A2 in FIG. 3 on the aluminum alloy material 31 is improved. Can be made to. Further, by pressing the aluminum alloy material 31 in the direction shown in P2, it is possible to improve the effect of suppressing the stress in the direction shown by the arrow A1 in FIG. 3 on the aluminum alloy material 31. As a result, the deformation of the low temperature sprayed coating member 55 can be further suppressed as compared with the first embodiment shown in FIGS. 1A to 1C.

(Fourth Embodiment)
6A to 6D are perspective views schematically showing a method for manufacturing a low temperature sprayed coating member according to a fourth embodiment of the present invention. Since the fourth embodiment is a modification of the third embodiment shown in FIGS. 5A to 5D, the same or equivalent parts as those of the third embodiment are designated by the same reference numerals and the description thereof is omitted. Simplify.
In this embodiment, a core material 66 made of an elastic body is used. Further, the core material 66 has a longitudinal direction, and the cross section in the direction orthogonal to the longitudinal direction of the core material 66 is designed to be slightly smaller than the cross section in the void portion of the aluminum alloy material 31.

First, the core material 66 is inserted into the void portion of the aluminum alloy material 31. At this time, since the core material 66 is slightly smaller than the void portion of the aluminum alloy material 31, a slight gap is generated between the core material 66 and the aluminum alloy material 31.
After that, as shown in FIG. 6A, the core material 66 is pressed from both ends thereof, and the outer surface 31c of the aluminum alloy material 31 is pressed. Since the core material 66 is made of an elastic body, when pressed from both ends thereof, the length in the longitudinal direction becomes smaller, but the cross-sectional area of the surface orthogonal to the longitudinal direction becomes larger, and the core material 66 and the aluminum alloy material 31 become larger. There is no gap between them. As a result, the aluminum alloy material 31 is fixed. The positions and directions for pressing the aluminum alloy material 31 and the core material 66 are the same as those in the third embodiment.

After that, as shown in FIG. 6B, the low temperature sprayed coating 33 is formed in a state where both ends of the outer surface 31c of the aluminum alloy material 31 and the core material 66 are pressed.

After that, as shown in FIG. 6C, the pressure on the outer surface 31c of the aluminum alloy material 31 is released, and the pressure on the core material 66 is released. As a result, a gap is generated again between the aluminum alloy material 31 and the core material 66. The timing for releasing the pressure on the aluminum alloy material 31 and the core material 66 is the same as that in the third embodiment.

Then, as shown in FIG. 6D, the low temperature sprayed coating member 65 is manufactured by removing the core material 66 from the aluminum alloy material 31.

In the fourth embodiment, since the cross-sectional area of the core material 66 is smaller than the cross-sectional area of the gap portion of the aluminum alloy material 31, the core material 36 is inserted into the gap portion of the aluminum alloy material 31 without any gaps. The core material 66 can be easily inserted as compared with the three embodiments.
Further, as described above, by pressing from both ends of the core material 66 toward the center portion, the aluminum alloy material 31 and the core material 66 are completely in close contact with each other, so that the aluminum alloy material is effectively fixed. This makes it possible to suppress deformation of the low temperature sprayed coating member 65.
Further, by releasing the pressure on the core material 66, a gap is generated again between the aluminum alloy material 31 and the core material 66, so that the core material 66 can be easily removed from the aluminum alloy material 31.

The embodiments of the first to fourth embodiments have been described in detail above. Subsequently, the aluminum alloy material, the metal powder used as the material of the low temperature sprayed coating, and the core material that can be used in the first to fourth embodiments will be described in detail below.

<Aluminum alloy material>
In the present invention, the material of the aluminum alloy material is not particularly limited, but for example, 5000 series, 6000 series and 7000 series aluminum alloys can be applied. Further, the thickness of the rib as the aluminum alloy material and the reinforcing member is not particularly limited, but is preferably 0.5 mm to 5.0 mm, for example. However, as described above, the thickness of the rib can be freely designed according to the width of the low temperature sprayed coating.

In the above embodiment, the aluminum alloy material uses an extruded material formed by extrusion molding, but may be a cast material formed by casting using a mold. An aluminum alloy material having a closed cross section can be manufactured by extrusion molding, and an aluminum alloy material having an open cross section or a closed cross section can be manufactured by casting. Even if the cast material has an open cross section, deformation may occur due to the formation of the low temperature sprayed coating. Therefore, by applying the method for manufacturing the low temperature sprayed coating member according to the present invention, the deformation can be suppressed. ..

<Metal powder>
The metal powder for forming the low-temperature spray film shall contain at least one selected from pure iron, carbon steel, stainless steel, nickel, nickel alloys, cobalt and cobalt alloys, and the purpose thereof is among these. The metal type can be selected according to the above. The thickness of the low-temperature sprayed coating formed by using these metal powders is not particularly limited, but is preferably 0.2 mm to 3.0 mm, for example.
In the specification of the present application, pure iron is easily available for industrial use and has a purity of 99.9% by mass or more. Further, carbon steel represents a steel material containing iron and carbon as main components and containing a small amount of silicon, manganese, impurity phosphorus, sulfur, copper, etc., and stainless steel means iron to which Cr, Ni, etc. are added. Represents a steel material. As the nickel alloy, an alloy containing Ni as a main component, which is commonly called an inconel alloy, an inconel alloy, or a hastelloy alloy, and an appropriate amount of Mo, Fe, Co, Cr, Mn, or the like can be used.

The particle size of the metal powder is not particularly limited, but when the gas pressure of the cold spray is set to a low pressure condition of 1 MPa or less, it is preferably 20 μm or less, more preferably 10 μm or less, for example.
On the other hand, when the gas pressure is set to a high pressure condition of 1 MPa to 5 MPa, it is preferably 100 μm or less, more preferably 50 μm or less, for example.
Further, the particle shape of the metal powder is not particularly limited.

<Core material>
The material of the core material is not particularly limited, but for example, sand, an elastic body, a ceramic, a resin, a metal, or a mixture thereof, or a material obtained by solidifying these into a desired shape with a binder or the like can be used. For example, when the core material is formed of metal, copper, an aluminum alloy, or the like having excellent thermal conductivity may be used.
Further, the core material produced by solidifying the sand with a binder is easy to process, and can be removed while destroying the core material after the formation of the low temperature sprayed coating. Further, when the elastic body is used as the core material, it is preferable because it can be easily inserted and removed from the aluminum alloy material and can be reused.
It is preferable to use rubber as the elastic body, and it is more preferable to use rubber having a high heat resistant temperature in order to form a low temperature sprayed coating. As the rubber having a high heat resistant temperature, for example, silicone rubber, fluororubber, or the like can be used.

11,31,71 Aluminum alloy material 12 ribs 13,33,73 Low temperature sprayed coating 14,74 Thermal spray head 35,45,55,65,75 Low temperature sprayed coating coating member 36,46a,46b, 66 Core material

Claims (12)

At least a portion of the surface of an aluminum or aluminum alloy having an open or closed cross section contains at least one selected from pure iron, carbon steel, stainless steel, nickel, nickel alloys, cobalt and cobalt alloys. A method for manufacturing a low-temperature spray film covering member, which comprises a step of forming a low-temperature spray film by low-temperature spraying a metal powder.
The aluminum or aluminum alloy material has an outer surface on which the metal powder is sprayed at a low temperature and an inner surface which is a surface opposite to the outer surface.
A low-temperature sprayed coating covering member comprising a step of providing a reinforcing member for suppressing deformation of the aluminum or aluminum alloy material in at least a part of the inner surface corresponding to the region where the low-temperature sprayed coating is formed. Manufacturing method. The method for manufacturing a low-temperature sprayed coating member according to claim 1, wherein the reinforcing member has a shape having a longitudinal direction in substantially the same direction as the extending direction of the low-temperature sprayed coating. The method for manufacturing a low-temperature sprayed coating member according to claim 1 or 2, wherein the aluminum or aluminum alloy material has a shape in which ribs are provided on the inner surface. The reinforcing member is a core material inserted into a gap surrounded by the inner surface.
At least in the step of forming the low temperature sprayed coating, the core material is in contact with at least a part of the inner surface corresponding to the region where the low temperature sprayed coating is formed.
The method for manufacturing a low-temperature sprayed coating member according to any one of claims 1 to 3, further comprising a step of removing the core material after the step of forming the low-temperature sprayed coating. The method for manufacturing a low-temperature sprayed coating member according to claim 4, wherein the step of removing the core material is performed after the low-temperature sprayed coating is cooled to room temperature. The aluminum or aluminum alloy material is fixed by being pressed from the outer surface at least in the step of forming the low temperature sprayed coating.
The method for manufacturing a low temperature sprayed coating member according to claim 4 or 5, further comprising a step of releasing the pressure on the aluminum or the aluminum alloy material after the step of forming the low temperature sprayed coating. The method for manufacturing a low-temperature sprayed coating member according to claim 6, wherein the step of releasing the pressure on the aluminum or the aluminum alloy material is performed after the low-temperature sprayed coating is cooled to room temperature. The core material is pressed toward the center from both ends in the longitudinal direction of the core material at least in the step of forming the low temperature sprayed coating.
Further, any one of claims 4 to 7, further comprising a step of releasing the pressure on the core material between the step of forming the low temperature sprayed coating and the step of removing the core material. The method for manufacturing a low temperature sprayed coating member according to. The method for manufacturing a low-temperature sprayed coating member according to claim 8, wherein the core material is made of an elastic body having a longitudinal direction. The method for manufacturing a low-temperature sprayed coating member according to claim 8 or 9, wherein the step of releasing the pressure on the core material is performed after the low-temperature sprayed coating is cooled to room temperature. The method for manufacturing a low-temperature sprayed coating member according to any one of claims 1 to 10, wherein the aluminum or aluminum alloy material is an extruded material having a closed cross section. The method for manufacturing a low-temperature sprayed coating member according to any one of claims 1 to 10, wherein the aluminum or aluminum alloy material is a cast material having an open cross section or a closed cross section.

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