JP3461054B2 - Composite material - Google Patents

Description

Detailed Description of the Invention

[0001]

The present invention relates to ceramics, metals,
The present invention relates to a composite material in which a dispersant is dispersed in a base material made of a polymer or the like.

[0002]

2. Description of the Related Art By combining two or more different materials, a single material is not sufficient, for example, wear resistance, oxidation resistance, corrosion resistance, heat resistance, electrical and thermal conductivity, It is possible to supplement characteristics such as optical characteristics and mechanical strength. In addition, the characteristics that do not appear only in each single material,
For example, new functionality such as magnetism, self-lubricity, thermoelectric conductivity, etc. can be imparted. Therefore, in order to realize desired properties, composite materials in which various materials are combined are being studied.

In particular, a composite material in which particles or whiskers, fibers and the like made of different kinds of materials are dispersed in a matrix (matrix), the dispersion material plays a role of expressing mechanical and functional properties. It is possible to design a wide range of materials with properties that cannot be obtained with a single material (monolithic material).

A conventional composite material in which a dispersant is dispersed is generally one in which a dispersant is uniformly dispersed in a matrix. This composite material can be given high performance and functionality by adding a dispersant, but since the dispersant is randomly separated and dispersed, there is a problem that the characteristics of the dispersant cannot be fully exhibited.

Therefore, in order to solve these problems, it has been proposed to disperse the dispersant in a continuous three-dimensional mesh pattern (Japanese Patent Laid-Open No. 60-243245, Japanese Patent Laid-Open No. 6-243245).
No. 2-4750, Japanese Patent Laid-Open No. 1-1119688,
JP-A-3-122060, JP-A-3-17435
No. 8, JP-A-4-37667). Since the dispersant is continuously distributed in this composite material, the characteristics of the dispersant can be sufficiently exhibited.

That is, Japanese Patent Laid-Open No. 60-243245 discloses a porous ceramic skeleton formed by sintering a mixture of ceramics and a whisker made of ceramics, and a metal impregnated in the pores of the ceramic skeleton. "Ceramics particle reinforced metal composite material" is disclosed. This composite material is a composite material in which a dispersion material composed of a mixture of ceramics and ceramics whiskers is dispersed in a metal matrix in a continuous skeletal structure state, so that it is a crack-free, high-quality, and thermal shock-resistant composite material. I am trying.

Further, in Japanese Patent Laid-Open No. 62-4750,
Crystalline polymer and average length 0.05 to 1 mm, diameter 3 to 2
A "positive temperature coefficient composition and method of manufacture" consisting of 0 μm short carbon fibers is disclosed. Since this composition is formed by forming a chain of three-dimensional micro-mesh structure of short carbon fibers in a polymer matrix, it is possible to reduce the amount of short carbon fibers to be used, and at a low cost, to obtain PTC characteristics. It is said that an excellent polymer composition can be obtained.

Further, in Japanese Patent Application Laid-Open No. 1-1119688, "resin-molded electrode and method for producing the same", in which conductive metal particles such as lead are continuously dispersed in a mesh in a substrate made of a thermoplastic resin. Is disclosed. This electrode is said to be excellent in corrosion resistance and mechanical strength and inexpensive.

Further, in Japanese Patent Laid-Open No. 3-122066, "Aluminum-impregnated silicon carbide composite material in which an aggregate is formed of a low-density silicon carbide porous body and aluminum is retained in the pores of the aggregate is disclosed. The manufacturing method "is disclosed. Since this composite material is obtained by impregnating continuous pores of a silicon carbide continuous body with aluminum, it is said that the composite material can be lightweight and excellent in strength, heat resistance and wear resistance.

Further, in JP-A-3-174358, 90 to 30 mol% of carbon and 10 to 70 mol% of silicon carbide are disclosed.
And a "composite material comprising a continuous phase of carbon and silicon carbide" having a structural structure of forming a continuous phase. It is said that this composite material has a large bending strength even if the carbon component disappears due to oxidation or the like because both components form a continuous phase, so that the shape can be maintained.

Further, in Japanese Patent Laid-Open No. 4-37667,
"Lightweight and high-rigidity ceramics and uses thereof" in which a three-dimensional continuous network structure is formed in a reactive sintering matrix are disclosed. This lightweight and high-rigidity ceramic is said to be a lightweight and highly rigid composite ceramic structure having a high specific elastic modulus.

[0012]

However, the above-mentioned Japanese Unexamined Patent Application Publication No.
0-243245, JP-A-64-2750, JP-A-1-119688, and JP-A-3-122.
The composite materials disclosed in JP-A-066, JP-A-3-174358, and JP-A-4-37667 all have strengths depending on the strength or densification degree of the low strength material of the base material or the dispersion material. Therefore, it is difficult to increase the strength only by continuously dispersing the dispersant in a three-dimensional mesh shape. Further, since internal stress is continuously generated due to a difference in thermal expansion between the base material and the dispersion material, mechanical characteristics such as impact resistance and thermal characteristics are deteriorated. Furthermore, the preparation of the composite material requires a special step of forming the network or porous material of the dispersion material and then infiltrating the other material. Therefore, it takes time to manufacture, is not suitable for mass production, and has a problem that densification is difficult.

Further, the light weight and high rigidity ceramics disclosed in Japanese Patent Laid-Open No. 4-37667 is a method in which a dispersion material is made into a mesh shape by using atomized powder or powder obtained by adhering ceramic powder to crushed metal powder. Although disclosed
Since the dispersant is continuously dispersed, it has poor sinterability,
As a result, there is a problem of low strength.

Therefore, the inventors of the present invention have earnestly studied to solve the above-mentioned problems of the prior art, and as a result of various systematic experiments, the present invention has been accomplished.

(Object of the Invention) An object of the present invention is to provide a composite material capable of sufficiently exhibiting the characteristics of the dispersant and the base material without deteriorating the mechanical characteristics.

[0016]

(Structure of the First Invention) The composite material of the present invention comprises a first phase composed of a matrix material and a dispersant formed so as to discontinuously surround the first phase. A composite material comprising a composite material cell composed of a second phase as a constituent unit, wherein the dispersant is dispersed discontinuously in a three-dimensional mesh in the composite material .

(Structure of Second Invention) The composite material of the present invention is
A composite material cell composed of a first phase composed of a matrix material and a second phase composed of a dispersant formed so as to discontinuously surround the first phase is used as a constituent unit, and the dispersant is a composite material.
A composite material which is three-dimensionally meshed and discontinuously dispersed in a material, wherein the second phase of the composite material cell has at least four discontinuities, and the discontinuities are A bond strengthening phase that bonds the first phase and another first phase adjacent to the first phase, a bond strengthening phase that bonds the first phase and the second phase, the second phase and the second phase It has at least one of the bond strengthening phases which couple | bonds the 2nd phase and the other adjacent 2nd phase,
The bond strengthening phase makes the first phases stronger, and the second phase is strongly fixed and held in the composite material.

(Structure of Third Invention) The composite material of the present invention is
A composite material cell composed of a first phase composed of a matrix material and a second phase composed of a dispersant formed so as to discontinuously surround the first phase is used as a constituent unit, and the dispersant is contained in the composite material. a composite material formed by discontinuously dispersed in a three-dimensional network in the composite material dispersed the dispersed material in the is a starting point any one dispersion material P _0, the next most proximate to the P ₀ The dispersant (the first selected discontinuity) is designated as P _1, and the dispersant that has not yet been selected is P _1.
Dispersant closest to ₁ (second discontinuous portion selected) is set to P ₂ , sequentially selected up to P _n (nth selected discontinuous portion), and the dispersant P ₀ to be the starting point is set. When a linear distance from each of the dispersants P _i (i = 1, 2, ..., N) is Ls _i , the distance Ls _i has a dispersion structure in which the distance fluctuates periodically within a predetermined range. It is characterized by being done.

[0019]

The mechanism by which the composite material of the present invention exhibits excellent effects is not yet clear, but
It can be considered as follows.

(Operation of First Invention) The composite material of the present invention is
A composite material cell composed of a first phase composed of a matrix material and a second phase composed of a dispersant formed so as to discontinuously surround the first phase serves as a constituent unit. With the composite cell configuration unit, the second phase forms a strong skeleton or path around a first phase, thereby strengthening the matrix, softening at high temperatures and dislocation or element diffusion Can be suppressed. Further, when a material for improving heat or electric conduction is selected as the dispersion material, it is considered that heat or electric conduction can be made possible by forming the path by the second phase.

In the composite material of the present invention, the composite material cells are used as constituent units, and the dispersant is three-dimensionally meshed and discontinuously dispersed in the base material, that is, in the composite material. As it has a three-dimensional network and is discontinuously dispersed, there are two types of reinforcing effect by the dispersant (disperse phase) itself such as particles, whiskers, and fibers, and reinforcing effect by the skeletal structure of the dispersant as follows. It is presumed that the synergistic effect of is obtained.

At room temperature, the base material, which has a higher strength than that of the dispersant, bears high stress, and at the same time, the dispersant dispersed in the composite material in a three-dimensional mesh shape prevents dislocation movement, or by bridging or the like. Crack growth can be suppressed.
Further, at high temperatures, the skeleton of the three-dimensional network dispersion structure of the dispersant suppresses softening deformation of the composite material, and the dispersant prevents grain boundary slip and dislocation movement between crystals,
Immediate breaking strength and creep properties can be improved. In particular, because the dispersant is dispersed discontinuously, cracks may occur in the dispersant or along the interface between the dispersant and the base material, as compared to those that are continuously dispersed in a three-dimensional mesh. However, it is difficult to propagate. In addition, it is easy to absorb thermal and mechanical shocks. Further, due to the high densification, pores that become a fracture source are hard to be formed in the composite material, so that strength reduction due to the pore formation is unlikely to occur. Thus, efficient tempering at room and elevated temperatures is possible.

That is, when a dispersant for the purpose of strengthening is used, the dispersant is particle-reinforced by a dispersant such as particles or whiskers in the base material and the composite material is used.
A skeleton structure which is discontinuous and dispersed in a three-dimensional network is formed therein, and the formation of the structure does not form pores or the like which are the main cause of strength reduction. Such skeleton structure is, at the same time responsible for high stress can be prevented from moving or crack growth of dislocation between mesh adjacent the dispersant itself. Thereby, strength and toughness can be improved. Further, when a highly heat-resistant dispersion material is used, a skeleton structure having high heat resistance can be formed, and this skeleton portion can suppress softening deformation of the base material. Furthermore, the movement of the grain boundary sliding and dislocation due to softening of the crystal grain boundary, it is possible also prevented by dispersion material itself, it is possible to improve the immediate rupture strength and creep resistance at high temperatures. In particular, since the dispersant is discontinuously dispersed, even if a crack propagates in the dispersant or along the interface between the dispersant and the base material, it is likely that the crack will greatly propagate to the whole like a continuous phase. There is no such path, and it is difficult to propagate. When a dispersant that imparts functionality is used as the dispersant, it is possible to achieve higher densification as compared to a continuous mesh, it is difficult to form pores that serve as a fracture source, and functionality is imparted without reducing strength. be able to.

Further, since the dispersant is arranged in the form of a mesh, the characteristics of the dispersant can be exhibited more strongly than in the case of the uniform dispersion system. Further, the addition amount can be reduced as compared with the continuous network structure.

From the above, it is considered that the composite material of the present invention can be a composite material in which the characteristics of the dispersant are sufficiently exhibited without deteriorating the mechanical characteristics of the base material.

(Operation of Second Invention) The composite material of the present invention is
In addition to the effects of the first aspect of the invention, the following effects are also achieved. The difference from the operation of the first invention will be mainly described.

In the composite material of the present invention, the second phase of the composite material cell has at least four discontinuities.
This makes it possible to strengthen the bond between the first phases and to strengthen the bond or the fixation / holding of the first phase and the second phase.

Further, the composite material of the present invention, the discontinuity is a bond reinforcing phase which bonds the other and a first phase adjacent to the first phase and the first phase, the said first phase the bond reinforcing phase which bonds the two phases, consisting have at least the second phase and either enhanced binding phase of coupling reinforcing phase that binds the other and a second phase adjacent to the second phase. This makes it possible to reduce interfacial peeling due to tension or twist between adjacent first phases, shearing force, and the like, and strengthen the bond between the first phase and the second phase, and / or the second phase, The first phases can be made stronger. Also, the first phase and the second
Since the phase and / or the second phase are strongly bound by the strengthening phase, it is possible to prevent them from peeling at the interface, and thus strongly fixing and holding the second phase in the composite material. You can

As described above, the composite material of the present invention is a composite material in which the characteristics of the dispersant are sufficiently exhibited without lowering the mechanical characteristics of the base material, as compared with the composite material of the first invention. It is thought that it can be done. Further, it is considered that it becomes possible to realize an excellent composite material having excellent mechanical properties and functional properties such as heat resistance, wear resistance, impact resistance, and fatigue resistance.

(Operation of Third Invention) The composite material of the present invention is
In addition to the effects of the first aspect of the invention, the following effects are also achieved. The difference from the operation of the first invention will be mainly described.

In the composite material of the present invention, the dispersant dispersed in the base material starts from any one dispersant P ₀ , then the dispersant closest to the P ₀ is P _1, and then The dispersant that has not yet been selected as the _first dispersant and is closest to the P ₁ is P ₂ , sequentially selected up to P _n , and the dispersant P _{0 as the} starting point and each dispersant P _i (i = 1, 2, ...
When the straight line distance to n) is Ls _i , the distance Ls _i has a distributed structure in which it fluctuates periodically within a predetermined range. Since the dispersion material dispersed in the base material, that is, in the composite material has such a dispersion structure, the dispersion material forming the second phase shares a contact point with each other in a predetermined size in the matrix. since has a configuration in which a plurality of closed loop that, this is due to serve as a skeletal structure of a kind, to strengthen the matrix, inhibit and transfer of softening and dislocation or element diffusion at high temperature be able to. Also, when a material for improving heat or electrical conduction is selected as the dispersion material, the formation of the path by the closed loop causes
It is thought that heat and electric conduction will be possible.

As described above, the composite material of the present invention has higher performance characteristics than the composite material of the first invention without lowering mechanical properties such as strength and impact resistance of the first phase and matrix. It is considered that the expression of

[0033]

【The invention's effect】

(Effect of First Invention) The composite material of the present invention can sufficiently exhibit the characteristics of the dispersant without lowering the mechanical characteristics of the base material.

(Effect of Second Invention) The composite material of the present invention is
The characteristics of the dispersant can be more sufficiently exhibited without deteriorating the mechanical characteristics of the base material.

(Effect of Third Invention) The composite material of the present invention is
The characteristics of the dispersant and the base material can be more sufficiently exhibited without deteriorating the mechanical characteristics of the base material.

[0036]

EXAMPLES First, the composite materials of the first invention to the third invention of the present invention, and the inventions (other inventions) such as more specific inventions and limited inventions will be described below.

[Description of Other Inventions]

(Base Material) The base material (matrix) serves as a base material of the composite material and forms the first phase. As the base material, materials such as ceramics, metals, resins, and intermetallic compounds can be applied, and crystalline materials or amorphous materials may be used.

(First Phase) The first phase is composed of the base material. The first phase constitutes a composite material cell as a constituent unit of the composite material. The shape of the first phase may be spherical, columnar, a combination thereof, or a modified shape thereof. The shape of the cross section (the cross section perpendicular to the longitudinal direction when the first phase is columnar) may be polygonal, circular, elliptical, or amorphous. At this time, the size of the first phase is preferably 1 μm to 10 mm in average diameter in the cross section. When the size of the first phase is less than 1 μm, the density of the mesh formed in the base material increases, and the sinterability decreases, and as a result, sufficient strength may not be obtained. On the other hand, when it exceeds 10 mm, the effect of improving the mechanical properties and / or functional properties of the dispersant becomes difficult to be exhibited. When the size of the first phase is in the range of 1 μm to 500 μm, the strength of the composite material cell is less likely to decrease due to peeling or the like at the outer peripheral portion, and the characteristics of the second phase can be sufficiently exhibited. Therefore, it is more preferable. The shape of the first phase may be any shape such as a spherical shape or a modified shape thereof, a columnar shape or a modified shape thereof. When the shape of the first phase is spherical or a modified shape thereof, it is preferable because it can have a structure capable of exhibiting isotropic mechanical and functional characteristics. When the shape of the first phase has a columnar shape or a modified shape thereof, as a structure capable of exhibiting directional functional and mechanical properties, and by aligning the pillars in the longitudinal direction, It is suitable as a structure that can be highly functionalized with a thin plate.

(Dispersant) The dispersant is dispersed in the matrix for the purpose of improving the mechanical properties and functionality of the matrix and forms the two phases.
The dispersion material has mechanical properties such as heat resistance, corrosion resistance, chemical resistance, high hardness, high elasticity, free-cutting resistance, and oxidation resistance, and thermal conductivity,
Materials having functionality such as heat insulation, electrical conductivity, magnetism, piezoelectricity, and optical characteristics can be used. As the material of the dispersant, materials such as ceramics, metals, resins, and intermetallic compounds can be applied, and may be crystalline or amorphous. The shape may be any shape such as particles, whiskers, fibers and the like.

In the case of particles, the size of the dispersant is such that the average value of the diameter is 0.01 μm to 1 mm and not more than ¼ of the size of the first phase (size in the cross section). Is preferred. If the diameter is less than 0.01 μm, the proportion of the discontinuous portion of the second phase in the outer peripheral portion of the composite material cell decreases,
There is a risk that the mechanical properties of the phase will likely deteriorate. Further, when the diameter exceeds 1 mm, the dispersion density of the second phase in the outer peripheral portion of the composite material cell becomes coarse, and thus the characteristics of the second phase may not be easily exhibited. Further, when the diameter is larger than ¼ of the size of the first phase (size in the cross section), it becomes difficult to form a skeleton structure or a path due to the second phase, and sufficient characteristics of the second phase are obtained. There is a possibility that the expression will not be possible. In this case, when the size of the dispersant is in the range of 0.05 μm to 100 μm, it is easy to properly adjust the distance between the discontinuous portions of the dispersant, and the strength and impact resistance of the first phase, etc. It is more preferable because the characteristics of the second phase can be sufficiently expressed without lowering the mechanical characteristics of.

In the case of whiskers and fibers, the size of the dispersant is preferably 300 μm or less in average of minor axis. In this case, it is easy to form a discontinuous network structure by adjusting the size of the dispersion material to 200 μm or less. If it exceeds the range, the dispersion density of the dispersant becomes low, so that it may be difficult to exert the mesh effect.

(Second Phase) The second phase is composed of a dispersion material formed so as to discontinuously surround the first phase. This second
Even if each of the dispersants forming the phase is composed of independent dispersants (particles, etc.), one is an aggregate of a plurality of dispersants and each aggregate is formed discontinuously. Also,
It may be a combination of these. One dispersion material or / and an aggregate of a plurality of dispersion materials are formed so as to respectively discontinuously surround the periphery of the first phase. At this time, the dispersant may be one kind or a plurality of kinds having different functional properties and / or strengthening properties to be imparted.

(Composite Material) The composite material of the present invention comprises a composite material cell composed of the first phase and the second phase formed so as to discontinuously surround the first phase, as a constituent unit, The dispersant is three-dimensionally meshed and discontinuously dispersed in the base material. That is, it is dispersed discontinuously in a three-dimensional network in the composite material. Here, an explanatory view conceptually showing a specific example of the structure of the composite material cell,
2 to 5. 2 and 3 are schematic explanatory views of the cross section of the specific example of the composite material cell, and FIG.
The first phase 3 is an example of a polycrystalline material, and the composite material cell 2 constitutes the first phase 3 by using a plurality of crystal grains 31 as one block, and the dispersion material 41 surrounds it in a discontinuous manner. Second
It is a structure in which phase 4 is formed. FIG. 3 shows an example of a material in which the first phase 3 is made of an amorphous or single crystalline substance such as a resin. A disk-shaped or a deformed mass of a predetermined size constitutes one block, and the dispersion material 41 is The structure is such that the second phase 4 is formed by surrounding the periphery discontinuously. 4 and 5
FIG. 4 is an explanatory view conceptually showing a concrete example of a composite material cell. FIG. 4 shows a second phase 4 in which a dispersant 41 discontinuously surrounds the entire circumference of a spherical or elliptical first phase 3 block. It is a structure like that. FIG. 5 shows a structure in which the second phase 4 is formed so that the dispersant 41 is discontinuously dispersed over the entire circumference of the columnar or oblong first phase 3.

The "three-dimensional mesh-like discontinuously dispersed" state means that the dispersion material is a single substance and / or an aggregate of the single substances (partially connected to each other, as shown in FIGS. 1 and 6). (Including the form of contact and the form of contact), the three-dimensional mesh array in the base material, that is, in the composite material. Further, when the matrix is composed of crystal grains, one mesh refers to one formed by surrounding several or more matrix crystal grains as one unit. Preferably, as shown in FIG. 7, the number of particles that are continuously connected is small, and the discontinuous phase made of a dispersant is dispersed at minute intervals. More preferably, each dispersed grain is connected through a grain boundary phase of about several μm.
It should be noted that the dispersion form of the dispersion material may be one that forms a mesh structure in a basically discontinuous state as described above, and the shape of one mesh is a polygon, a circle, or an ellipse. , Or an irregular shape. Further, in the dispersant, particles may be partially dispersed continuously or form a continuous body within a range not impairing the operation and effect of the present invention.

The proportion of the dispersant present in the matrix is
The range of 0.01 to 70% by volume is preferable. The ratio is 0.
If it is less than 01% by volume, the spacing between the dispersants becomes wide, and it may be difficult to achieve the effect of the skeletal structure and the functionality.
On the other hand, if it exceeds 70% by volume, the density of the mesh-like dispersed phase and the dispersant becomes high, so that the sinterability may be deteriorated and the strength may be deteriorated. In addition, when the ratio is in the range of 1% to 30%, the effect of the present invention can be more effectively exhibited, which is more preferable.

As the combination of the matrix and the dispersant, various materials such as ceramic materials, metal materials and polymer materials can be combined.

For example, when the matrix is made of a ceramic material as a matrix-dispersant combination, silicon nitride-silicon carbide, silicon nitride-silica, silicon nitride-boron nitride, silicon nitride-titanium nitride, silicon nitride-titanium carbide, Silicon nitride-ferrite magnet, silicon carbide-alumina, silicon carbide-aluminum nitride, silicon carbide-titanium nitride, titanium carbide-silicon carbide, alumina-titanium carbide, alumina-zirconia, alumina-zircon, alumina-silicon nitride, alumina-diamond. , Alumina-aluminum nitride,
Mullite-alumina, mullite-zirconia, sialon-silicon carbide, zirconia-alumina, glass-silicon carbide, glass-alumina, lead zirconate titanate-silicon carbide, lead zirconate titanate-barium titanate, lead titanate-titanium. Examples thereof include strontium acid, cordierite-mullite, and zirconia-nickel-chromium alloy. When the dispersion material is made of ceramics, the combination of the matrix and the dispersion material may be replaced.

When ceramics is used as a matrix,
For example, when a material with low electrical resistance such as silicon carbide, titanium carbide, or titanium oxide, or a nickel-chromium alloy is added as a dispersant to ceramics, the spacing of these dispersants impedes sinterability. By disperse the particles close to each other so as not to disperse them, it becomes possible to impart electric conductivity or thermal conductivity to the ceramic as a matrix. This enables electric discharge machining of ceramics. In particular, in the case of silicon carbide, carbide, boride, nitride, or a metal-based material having high thermal conductivity, it is possible to provide high thermal conductivity while providing electrical insulation by adjusting the spacing of the dispersant. Highly applicable to substrate materials. Also,
By using a free-cutting material as an additive, it becomes possible to improve the workability without lowering the strength.

When the matrix is a metal material, nickel-thorium, nickel-chromium alloy-thorium, nickel-chromium alloy-yttria, iron-chromium alloy-yttria, iron-chromium alloy-zirconia, iron-chromium alloy-
Alumina, aluminum-tungsten, aluminum-stainless steel, aluminum-carbon, aluminum-boron, aluminum-alumina, aluminum-silicon carbide, aluminum-yttria, magnesium (or magnesium alloy) -alumina, aluminum alloy-alumina, nickel (or nickel alloy) ) -Alumina, molybdenum (or molybdenum alloy) -alumina,
Magnesium-silicon carbide, copper-alumina, copper-tungsten, copper-yttria, nickel-chromium alloy-yttria, nickel-chromium alloy-zirconia, nickel
Examples include chromium alloy-calcia, nickel-chromium alloy-silica, and silver-tungsten. When the dispersant is made of a metal material, the combination of the matrix and the dispersant may be replaced.

When a metal material is used as a matrix, for example, by adjusting the distance between ceramics such as zirconia having a low thermal conductivity and a metal dispersion material, a metal having a heat insulating property can be obtained without lowering the mechanical properties. The material is obtained.

When the matrix is a polymer material, polyvinyl chloride-lead (or lead alloy), polyvinyl chloride-
Manganese dioxide, polypropylene-talc, polypropylene-calcium carbonate, polypropylene-magnesium carbonate, epoxy resin-silicon carbide, epoxy resin-silica, epoxy resin-glass, silicon resin-silicon carbide,
Examples thereof include polyethylene-carbon, thermosetting resin-silica, thermosetting resin-silica, rubber-carbon black, resin-graphite, resin-nickel, carbon-silicon carbide and the like.

The composite material of the present invention can sufficiently exhibit the characteristics of the dispersant such as the strengthening of the characteristics and the improvement of the functions without deteriorating the mechanical characteristics of the base material.

Further, since it is possible to disperse a dispersant having excellent electrical conductivity, thermal conductivity, magnetism and the like in a mesh shape at a very short interval, it is possible to optimize the interval between the dispersants. It becomes possible to exhibit both the characteristics close to those obtained when the continuous phase of the dispersion material is formed and higher mechanical characteristics.

When the dispersant has a high rigidity, disperse the dispersant discontinuously does not cause deterioration of properties such as strength, toughness and impact resistance due to the dispersant, and the base material is made composite. It is possible to achieve high rigidity.

When the whisker-like dispersion material is formed into a three-dimensional network structure in a direction perpendicular to the orientation direction, not only the strength in the orientation direction can be improved by the pinning effect, but also the strength can be enhanced three-dimensionally.

A more preferred composite material of the present invention is the first
It is characterized in that additives for strengthening properties and improving functions are uniformly dispersed in the phase. This makes the first
Phase internal movement restraining the grain slippage or dislocation, high hardness,
Higher elasticity is possible, and mechanical properties such as heat resistance, oxidation resistance, wear resistance, strength, and high rigidity, and functional properties such as thermal conductivity are improved. As the additive, mechanical properties such as heat resistance, corrosion resistance, chemical resistance, high rigidity, high hardness, free-cutting property, impact resistance, etc., optical properties, low expansion property, low dielectric conductivity, high Those having functionality such as resistance, high expansion, thermal conductivity, heat insulation, electrical conductivity, magnetism, and piezoelectricity can be used. At this time, as the material of the dispersion material, materials such as ceramics, metals, resins, and intermetallic compounds can be applied, and may be crystalline or amorphous. The shape may be any shape such as particles, whiskers, fibers and the like. In addition, when a material having mechanical properties is used as the additive and a material having functionality is used as the dispersion material forming the second phase, heat resistance, corrosion resistance, chemical resistance,
It is possible to obtain a functional composite material which has mechanical properties such as high hardness and free-cutting property.

If the base material is amorphous, the first
It is preferable that the additive (strengthening particles) is uniformly dispersed in the phase.

If the base material is crystalline, the first
It is preferable that the reinforcing particles are uniformly dispersed in or within the grain boundaries of the crystal grains contained in the phase. In this case, when improving the mechanical properties, the dispersant may be either in the grains or at the grain boundaries.

In a preferred composite material of the present invention, the second phase of the composite material cell has at least four discontinuities, and the discontinuities have a bond strengthening phase. The bond strengthening phase includes a bond strengthening phase that bonds the first phase and another first phase adjacent to the phase, a bond strengthening phase that bonds the first phase and the second phase, and the second phase. And another second adjacent to this phase
It comprises at least one of a bond strengthening phase that bonds with the phase. As a result, the first phases can be made stronger and the second phase can be fixed and held in the composite material.

(Bonding Strengthening Phase) FIG. 8 is an explanatory view conceptually explaining a specific example of the bonding strengthening phase. FIG. 8 shows that, in the second phase 4 in which the dispersion material 41 is distributed so as to form a three-dimensional mesh-like skeleton, the second phase 4 forms a partially discontinuous portion and is adjacent to the first phase. It is a structure in which the phases 3 are strongly bonded to each other through the bond strengthening phase 5 formed in the discontinuous portion.

The preferred structure of the bond strengthening phase is preferably such that the thickness of the bond strengthening phase is thin, the interval between the bond strengthening phases is small, and the number density is high so that the effect of the bond strengthening phase is better exhibited. Further, it is preferable that the shape of the interface between the bond strengthening phase and the second phase is somewhat complicated, because the contact area between the phases increases, the holding force increases, and the anchor effect can be expected.
As a result, the adjacent first phases can be firmly bonded to each other, and the second phase can be firmly fixed and held in the first phase.

Another preferred structure of the bond strengthening phase is that the first phase and the second phase together form a three-dimensional network structure, and the first phase and the second phase are connected via the discontinuous phase of the second phase. Is a structure in which is strongly bonded. As a result, it is possible to achieve the effect that the characteristics of the first phase can be sufficiently expressed and the characteristics of the second phase can be expressed without lowering the mechanical characteristics such as strength and impact resistance.

The bond strengthening phase is a phase which has a function of alleviating or preventing a decrease in strength that tends to occur when the dispersant is dispersed in a three-dimensional network. Macroscopically, for strengthening the particle dispersion, it is easier to increase the strength by uniformly dispersing the reinforcing material in the matrix. On the other hand, in order to efficiently develop the functional characteristics by adding a dispersant having properties such as electrical and thermal conductivity and magnetism, it is necessary to make the dispersant as high as possible to form a three-dimensional mesh-like path. It is more efficient to disperse in the density. However, if a path of the dispersant is formed in the composite material, there is a possibility that a low-strength phase may be formed because the sinterability locally deteriorates in the path portion,
There is a possibility that mechanical properties such as immediate fracture strength and fatigue strength may be deteriorated, for example, cracks may easily propagate along the path. Therefore, a preferred composite material of the present invention that solves these problems is a three-dimensional cell as one cell so as to take in the first phase composed of a plurality of matrix crystal grains as a matrix material and the periphery of the plurality of matrix crystal grains. A composite material comprising a composite material cell comprising a second phase in which a bond strengthening phase dispersed in a mesh form is formed, and a dispersion material is dispersed therein, wherein the second phase dispersion material is a composite material. In the material, three-dimensional mesh-like dispersed discontinuously, and
It is characterized in that the second bond strengthening phase is dispersed in the composite material continuously or / and discontinuously in a three-dimensional network. As a result, the effects of the present invention can be sufficiently exerted, and the reduction in strength of the high-density three-dimensional network dispersed phase can be sufficiently suppressed. As the bond strengthening phase, SiO ₂ , Si, Al ₂ O ₃ , Zr
O ₂ , MgO ₂ , AlN, La ₂ O ₃ , CeO ₂ , Yb
₂ O ₃ , Ta ₂ O ₅ , TiO ₂ , BaO, TiN, Sc
₂ O ₃ , BeO, Al ₂ O ₃ -BeSiO ₄ , YN, Y
₂ O ₃ , ZrSi ₂ , CrB ₂ and other easily sinterable oxides, nitrides, boride-based inorganic materials and / or fine particle inorganic materials are preferred. Further, a metal or polymer material that achieves the above characteristics may be used. These bond strengthening phases should have good wettability with the matrix and further contain at least one kind of material having a sinterability higher than that of the matrix, such as a matrix and a material less sinterable than the matrix. It may be composed of more than one kind of material. Further, it may be any of amorphous, crystalline, and a mixed phase of amorphous and crystalline. When used as a high temperature material, a crystalline material alone or a material having a high crystalline ratio is preferable. The structure of the bond strengthening phase, for example, when the substance forming the bond strengthening phase is a columnar crystal, the aspect ratio is large, elongated needle-like or plate-like, and a uniform structure with few coarse grains. preferable. Further, when the substance constituting the bond strengthening phase is a homogenous crystal, it is preferable that the substance has a uniform structure with a small grain size and few coarse grains. Further, it is preferable that there are no pores of a certain size or more and no foreign matter. Further, the strengthening phase may be further strengthened with whiskers, fibers or the like within a range that does not impair the sinterability. Further, the property of the substance constituting the bond strengthening phase is a substance having a thermal expansion coefficient and elastic modulus equal to or close to that of the matrix, or a substance having a thermal expansion coefficient and elastic modulus between the matrix and the dispersant and close to the matrix. Is preferred. As a result, the internal stress (thermal stress) generated between the matrix and the dispersant can be reduced, so that the strength reduction due to the path formation of the dispersant can be sufficiently suppressed. Further, it is preferable because it has good wettability with the matrix, that is, it is easy to get familiar with it.

(Periodically Dispersing Dispersion Structure) Another preferable composite material of the present invention will be described with reference to FIGS. 9 and 10. That is, as shown in FIG. 9, first, an arbitrary one dispersant is selected from among the dispersants dispersed in the base material, and this is designated as P ₀ . Then, this P ₀ is the starting point, closest to the dispersed material in the P ₀ to (P ₀ in which non-consecutive) Select 1st, and P _1. Then, the dispersant closest to P ₁ that is not yet selected (not discontinuous with P ₀ and P ₁ ) is second selected and designated as P ₂ . Next, in the same way, P sequentially
Select up to _n (the discontinuity selected at the nth position). Next, the dispersion material P _{0 serving as the} starting point and the respective dispersion materials P _i
The linear distance from (i = 1, 2, ..., N) is Ls _i . Next, as shown in FIG. 10, the horizontal axis represents the number of particles,
The vertical axis represents the distance Ls _i . At this time, the preferable composite material of the present invention is a composite material having a dispersed structure that periodically changes within a predetermined range, as shown in FIG.

Here, the periodically varying dispersion structure means that the dispersion material forms a large number of closed loops over the entire base material, and its cycle is circular or it, though it depends on the shape of the closed loops. When it is close, it has a diameter, and when it is elliptical or columnar, it has a dispersed structure that fluctuates within the range of the major axis diameter or less. Further, another preferred example of the periodically varying dispersion structure of the composite material of the present invention,
This is shown in FIGS. 11 and 12. Also, a suitable dispersion structure is
As shown in FIG. 13, the distance w between the dispersants is (1/2) d.
This is a structure in which the dispersant is dispersed in the following form. Further, another suitable dispersion structure is a structure in which the dispersion material forms a closed loop of a plurality of layers, as shown in FIG. The period may be constant or may vary, but the number of particles per period needs to be 4 or more, and is preferably 8 or more. The distance Ls _i is 0.0
The range of 1 μm ≦ Ls _i ≦ 20 mm is preferable, and the range of 0.1 μm ≦ Ls _i ≦ 1 mm is more preferable.

(Manufacturing Method of Composite Material) An example of a method of manufacturing the composite material of the present invention will be briefly described.

First, in the raw material powder adjusting step, the raw material powder is adjusted so that the dispersant having the predetermined shape is discontinuously present on the surface of the granulated powder having the predetermined shape as the main material of the base material. . That is, the raw material powder is adjusted so that the dispersion material is present in the granulated powder obtained by granulating the matrix powder so as to have a predetermined size or more. That is,
The dispersant is sprinkled discontinuously on the surface of the granulated powder, or a partial coating film of the dispersant is formed on the surface of the granulated powder by a CVD method, a PVD method, a chemical process or the like.

Next, in the molding step, the raw material powder obtained in the raw material powder adjusting step is molded into a predetermined shape to obtain a compact. As a result, the compact before sintering has the dispersant present discontinuously in the gaps between the granulated powders as the main material of the base material and the surface of at least one of the adjacent granulated powders. The dispersant can be present discontinuously throughout. In addition, you may perform CIP (cold isostatic press) as needed.

Next, in the composite material forming step, when the formed body obtained in the forming step is heated, the adjacent granulated powders are sintered or melted through the surface of the granulated powders in which the dispersant is not present. , The whole sintered body is densified.
After the sintering, HIP (hot isostatic pressing) treatment is performed to obtain a sintered body having a higher density.

As a result, the first phase composed of the base material,
A composite material comprising a composite material cell composed of a second phase composed of a dispersion material formed so as to surround the first phase discontinuously as a constituent unit, wherein the dispersion material is in a base material, that is, a composite material. A three-dimensional, mesh-like, discontinuously dispersed composite material is formed therein.

At this time, when a dispersant for the purpose of strengthening is used, the skeleton of the discontinuous three-dimensional network structure, which is particle-reinforced by the dispersant such as particles and whiskers in the matrix by the entire second phase. A structure is formed, and the present method does not generate pores or the like that are the main cause of strength reduction in this formation process. This skeletal structure is responsible for high stress and at the same time
The dispersant itself can prevent dislocation movement and crack propagation between the first phases adjacent to the second phase. Thereby, strength and toughness can be improved. Further, it is possible to suppress the mechanical and thermal impact resistance from being lowered due to the three-dimensional mesh structure. When a high heat resistant dispersion material is used, a skeleton structure having high heat resistance can be formed by the entire second phase, and the skeleton portion can suppress softening deformation of the composite material. Furthermore, the movement of grain boundary slips and dislocations due to the softening of the crystal grain boundaries can be prevented by the dispersant itself which constitutes the second phase, so that the immediate rupture strength and creep resistance at high temperatures can be improved. it can. In particular, since the dispersant that constitutes the second phase discontinuously disperses, even if a crack propagates in the dispersant or along the interface between the dispersant and the base material, a crack like a continuous phase easily propagates. There is no path and it is difficult to propagate. Further, when a dispersant that imparts functionality is used as the dispersant, it is possible to make the density higher than that of a continuous mesh, it is difficult to form pores that become a fracture source, and the functionality is improved without lowering the strength. Can be given.

As described above, according to the above-mentioned method for producing a composite material, it is possible to easily produce a composite material which can sufficiently exhibit the characteristics of the dispersant constituting the second phase without deteriorating the mechanical characteristics of the base material. It is thought that it can be manufactured to.

At this time, the particle size (dm) of the granulated powder obtained by granulating the matrix powder used as the raw material is 5.0 mm or less, and the average primary particle size or average diameter (dp) of the particles or the dispersing material such as whiskers. ) Is 500 μm or less, and dp /
It is preferable that dm is in the range of 0.50 to 1 × 10 ⁻⁶ . Within this range, it is possible to easily form a three-dimensional network structure of the dispersant for sufficiently exhibiting the characteristics of the dispersant. It is preferable to set dp / dm to 0.1 to 1 × 10 ⁻⁵ because it becomes easy to form a discontinuous network structure. Also, in this case, the size of the dispersion material should be 18
By adjusting the particle size to 0 μm or less, it becomes easy to form a discontinuous network structure. In addition, it is preferable that the matrix powder constituting the base material granulated powder has a particle diameter of about 2 μm to 2 mm. Also, more preferably,
It is in the range of 10 μm to 2 mm.

The method for producing the composite material of the present invention will be described below by further dividing the matrix by material.

(Manufacturing Method of Ceramics Composite Material) When the matrix is a ceramics material, the matrix material and the sintering aid are mixed in a wet or dry manner and granulated to a constant particle size or adjusted by a spray dry method. Disperse the dispersant on the surface of the powder in a discontinuous manner. The composite material of the present invention can be manufactured by subjecting this powder to die molding and CIP, and then firing it by atmospheric pressure sintering, hot pressing, hot isostatic pressing (HIP), or the like.

When the matrix is a metal material, the dispersant is sprinkled discontinuously on the surface of the powder of the matrix material pulverized or atomized to have a constant particle size, or a partial film is formed. Let After that, the composite material of the present invention can be manufactured by molding and sintering this powder.

When the matrix is a polymeric material, the matrix material and additives such as fillers and surface treatment materials are mixed to form spherical or columnar pellets, and the pellets are sprinkled with a dispersion material. The composite material of the present invention can be manufactured by filling this in a mold and heating and pressing.

As described above, when the composite material of the present invention is manufactured, the dispersant can be added in one step, and therefore the productivity is good.

The composite material of the present invention can be used as a structural material, a functional material, etc., since the function of the dispersant is sufficiently exhibited.

For example, when silicon carbide stable at high temperature is added to silicon nitride having high room temperature strength to form a three-dimensional network structure of silicon carbide in silicon nitride, room temperature strength, high temperature strength, creep resistance and oxidation resistance are obtained. The sex can be improved at the same time. In addition, mechanical conductivity such as imparting electrical conductivity and high elasticity
The electrical properties can be greatly improved over that of conventional composite materials.

Further, in the IC encapsulating resin, when a discontinuous three-dimensional network structure of silicon carbide, aluminum nitride, or boron nitride having high thermal conductivity is formed in the resin, heat insulation is not deteriorated. The conductivity can be further improved.

In the case of metal, high rigidity and high hardness zirconia, alumina, and yttria are dispersed in a discontinuous three-dimensional mesh in stainless steel to prevent abrasion and abrasion resistance without lowering the strength. The rigidity and oxidation resistance can be improved. Furthermore, zirconia, alumina,
A highly heat-insulating composite material can be obtained by adding a material having a low thermal conductivity such as silica.

A preferred method for producing a composite material of the present invention is to granulate a predetermined shape obtained by mixing a main raw material powder as a main material of a base material and an additive for reinforcing or adding a function to the base material. A method of forming a composite material by adjusting a raw material powder so that a dispersant having a predetermined shape is discontinuously present on the surface of the powder, and then shaping the raw material powder into a predetermined shape and heating. Is. By doing so, it is possible to obtain a composite material in which the dispersant is network-like discontinuously dispersed and the additive is uniformly dispersed inside the first phase.

Another preferred method for producing the composite material of the present invention is that a dispersant having a predetermined shape and the same dispersant as the base material are formed on the surface of granulated powder having a predetermined shape as the main material of the base material. The raw material powder is adjusted so as to be in a state in which a sintering improver having a size equal to or smaller than the size of the dispersion material is present in a discontinuous manner, and then the raw material powder is molded into a predetermined shape, It is a method of heating to form a composite material. By doing so, it becomes easy to disperse the dispersant in a three-dimensional mesh shape discontinuously, and also the sinterability can be improved.

As the sintering improver, the same material as the base material or the one generally used as the sintered material of the dispersion material can be adopted. In the system of silicon nitride-silicon carbide, as a sintering improver, silicon nitride, or yttria used as a sintered material of the silicon nitride, alumina, yttrium, spinel, magnesium oxide,
Carbon, boron, alumina, etc. used as a sintered material of silicon carbide can be used. Further, as the sintering improver, lanthanum oxide, neodymium,
Zirconia, nickel, copper, etc. are available. Further, as the sintering improver, finer particles than the dispersant and the base material are used, whereby the sinterability can be further improved.

Examples of the present invention will be described below.

(Example)

Example 1 Atomized SUS304 powder having an average primary particle size of 4 μm was prepared as a base material, and was granulated with ethanol, calcined at 900 ° C., and then sieved to obtain an average particle size. Granulation was performed so as to have a size of 500 μm. Next, ZrO ₂ powder (YZP: 3 mol Y ₂ O ₃ added) having an average primary particle diameter of about 0.1 μm was prepared as a raw material for the dispersion material, and the average particle diameter was adjusted to 60 μm using a ball mill and a mortar. Crushed. Then, in the SUS pot, the ZrO ₂ granulated powder was sprinkled on the surface of the base material granulated powder so as to be 10% by volume and discontinuously scattered to prepare a raw material powder. next,
The obtained raw material powder is put into a mold and press-formed (5 t /
cm ² ), sintered at 1280 ° C. × 4 hours (in vacuum),
A composite material according to this example was obtained (sample number: 1).

The cross section of the obtained composite material was microscopically observed. An optical micrograph (magnification: 100 times) showing the metal structure of the cross section of the composite material is shown in FIG. As is clear from FIG. 1, a composite material cell composed of a first phase composed of a matrix material and a second phase composed of a dispersant formed so as to surround the first phase discontinuously was used as a structural unit, It can be seen that a large number of composite cells of the structural units are combined and the dispersion material forming the second phase has a structure in which it is discontinuously dispersed in a three-dimensional network in the base material.

Comparative Example 1 For comparison, atomized SU having an average primary particle diameter of 4 μm
To the S304 powder, ZrO ₂ powder having an average particle size of about 0.1 μm (YZP: 3 mol Y ₂ O ₃ added) was added so as to be 10% by volume and uniformly mixed, and the mixed powder was put into a mold. It was press-molded (5 t / cm ² ) and sintered at 1280 ° C. for 4 hours (in vacuum) to prepare a comparative sintered body (sample number: C1). The cross section of the obtained composite material was microscopically observed. FIG. 15 shows an optical micrograph (magnification: 100 times) showing the metal structure of the cross section of the composite material. As is clear from FIG. 15, it is understood that the second phase has a structure in which the second phase is uniformly dispersed in the first phase of the base material.

Comparative Example 2 For comparison, atomized S having an average primary particle diameter of 10 μm
Around the US304 powder, Z with an average particle size of about 0.1 μm
A mixed powder obtained by continuously coating rO ₂ powder (YZP: 3 mol Y ₂ O ₃ added) at 10% by volume was placed in a mold and press-molded (5 t / cm ² ), and 1280 ° C. × 4
Sintering was performed for a period of time (in vacuum) to prepare a comparative sintered body (Sample No. C2). Microscopic observation of the cross section of the obtained composite material revealed a structure in which the second phase continuously surrounded the first phase having a size close to that of primary particles of about 10 μm. Was there.

Performance Evaluation Test As described above, the heat insulation evaluation test was performed on the composite materials obtained in the first example and the comparative sintered bodies obtained in Comparative Examples 1 and 2. That is, first, the obtained sintered body is processed into φ20 × 3 mm, and the surface thereof is # 500 to # 15.
After finishing with 00 abrasive paper, the heat conduction (insulation) characteristics were evaluated. The thermal conductivity was evaluated on the front and back of the sample at room temperature by 2
When a temperature difference of 00 ° C. was given, evaluation was performed by measuring the change with time of the temperature of the low temperature side surface. The results are shown in Table 1.
Shown in. For reference, the data of SUS alone is also shown in the table.

[0094]

[Table 1]

As is clear from Table 1, the sintered body of this example has a significantly improved heat insulating property as compared with SUS alone, and exhibits excellent heat insulating properties as compared with Comparative Examples 1 and 2. I found out.

Second Example 92% by weight of Si ₃ N ₄ powder having an average primary particle size of 0.1 μm
And 5% by weight of Y ₂ O ₃ powder having an average primary particle diameter of 0.5 μm,
And 3% by weight of Al ₂ O ₃ powder having an average primary particle diameter of 0.1 μm are wet mixed in a ball mill to obtain an average particle diameter of 500 μm.
A base material raw material granulated powder of m or less was produced. Next, the surface of the base material raw material granulated powder was sprinkled with SiC particles having an average primary particle diameter of 0.4 μm so as to be 10% by volume based on the total weight and discontinuously scattered to obtain the raw material powder. Got Next, this raw material powder is put into a mold and press-molded, and then pressure-sintered at 1850 ° C. for 4 hours under a N ₂ pressure of 10 kg / cm ² to obtain the composite material of the present invention according to this example. Obtained (sample number: 2).

The cross section of the obtained composite material was subjected to plasma etching, and the particle structure of the cross section was observed by SEM (scanning electron microscope). As a result, the matrix Si ₃
N ₄ has a first phase composed of a matrix material partitioned by SiC particles as a second phase and a constituent unit as a composite material cell together with the second phase, and a plurality of the composite cells are combined to form a composite material. Therefore, it was confirmed that the dispersant was dispersed discontinuously in a three-dimensional mesh in the matrix. In addition, a plurality of Si ₃ N is included in the first phase.
There were ₄ crystal grains.

Comparative Example 3 For comparison, 92% by weight of Si ₃ N ₄ powder (average primary particle size 0.1 μm) and 5% by weight of Y ₂ O ₃ powder (average primary particle size 0.5 μm) and An average primary particle diameter of 0.4 μm is formed on the entire surface of a granulated powder (average particle diameter of 500 μm or less) prepared by wet mixing 3% by weight of Al ₂ O ₃ powder having an average primary particle diameter of 0.1 μm with a ball mill. Of SiC powder was continuously sprinkled. Then, this granulated powder was molded and pressure-sintered under the same conditions as described above (sample number: C
3). When the cross section of this comparative sintered body was observed in the same manner as in the second embodiment, it was found that Si was contained in Si ₃ N _{4 of the} matrix.
The C particles were continuously dispersed in a three-dimensional network.

Comparative Example 4 For comparison, 82% by weight of Si ₃ N ₄ powder (average primary particle diameter 0.3 μm), 5% by weight of Y ₂ O ₃ powder (average primary particle diameter 1 μm) and average primary particle diameter were used. Al with a particle size of 0.1 μm
₂ O ₃ powder 3% by weight and 10% by weight average primary particle diameter of 0.
Wet-mix 4 μm SiC powder with a ball mill at the same time to prepare granulated powder (average particle size 500 μm or less) in which SiC particles are uniformly dispersed in the matrix, and otherwise the same as in the second embodiment. Molding and pressure sintering were performed under the conditions of (Sample No. C4). Observation of the cross section of this comparative sintered body revealed that SiC was found in the Si ₃ N ₄ matrix.
The particles were uniformly dispersed.

Performance Evaluation Test With respect to the composite materials obtained in the second embodiment and the comparative sintered bodies obtained in Comparative Examples 3 and 4, bending strength (in accordance with JIS 4-point bending strength test method, The measurement was performed at room temperature and 1400 ° C.), electric resistance value (four-contact method), and elastic modulus (resonance method). As a result, the sintered body of the present example has strengths at room temperature and high temperature in Comparative Example sample numbers C3 and C.
It was confirmed that it was larger than any of No. 4 and was superior in electrical resistance value and elastic modulus to the comparative example (sample number: C4) in which silicon carbide was uniformly dispersed.

Third Example Atomized SUS304 powder having an average primary particle diameter of 4 μm was prepared as a base material, granulated with ethanol, calcined at 900 ° C., and then averaged with a sieve. Granulation was performed so as to have a size of 500 μm. Next, ZrO ₂ powder (YZP: 12 mol CeO ₂ added) having an average primary particle diameter of about 0.1 μm was prepared as a raw material for the dispersion material, and the mixture was crushed using a ball mill and a mortar so that the average particle diameter was 60 μm. Crushed. Then, in the SUS pot, the ZrO ₂ granulated powder was sprinkled on the surface of the base material granulated powder so as to be 15% by volume and discontinuously scattered to prepare a raw material powder. Next, the obtained raw material powder is put into a mold and press-molded (5
t / cm ² ) and 1280 ° C. × 4 hours (in vacuum) to obtain a composite material according to this example (sample number:
3).

The cross section of the obtained composite material was microscopically observed with a microscope as in the first embodiment. As a result, a composite material cell composed of a first phase composed of a matrix material and a second phase composed of a dispersant formed so as to discontinuously surround the first phase was used as a constituent unit, and a composite of the constituent units was formed. It was confirmed that the dispersant composed of a large number of cells bonded to each other and constituting the second phase had a structure in which the dispersoid was dispersed discontinuously in a three-dimensional network in the base material.

Comparative Example 5 For comparison, atomized SU having an average primary particle size of 4 μm
To the S304 powder, ZrO ₂ powder (YZP: 12 mol CeO ₂ added) having an average particle size of about 0.1 μm was added so as to be 15% by volume, and the mixed powder was uniformly mixed and put into a mold and pressed. It was molded (5 t / cm ² ) and sintered at 1280 ° C. for 4 hours (in vacuum) to prepare a comparative sintered body (sample number: C5). The cross section of the obtained composite material was microscopically observed in the same manner as in the first embodiment. As a result, it was confirmed that the second phase had a structure in which the second phase was uniformly dispersed in the first phase of the base material.

Performance Evaluation Test The composite material obtained in Example 3 and the comparative sintered body obtained in Comparative Example 5 were subjected to a heat insulation evaluation test by the laser flash method. The results are shown in Table 2. For reference, the data of SUS alone is also shown in the table.

[0105]

[Table 2]

As is clear from Table 2, the sintered body of the present example has a significantly improved heat insulating property as compared with the SUS alone, and exhibits excellent heat insulating properties as compared with Comparative Example 5. Do you get it.

Fourth Example Atomized SUS304 powder having an average primary particle size of 4 μm was prepared as a raw material for the base material, granulated with ethanol, calcined at 900 ° C., and then averaged with a sieve. Granulation was performed so as to have a size of 500 μm. Next, Y ₂ O ₃ powder having an average primary particle size of about 0.5 μm was prepared as a raw material for the dispersion material, and the average particle size was 60 μm using a ball mill and a mortar.
It was crushed so that it became m. Then, in the SUS pot,
The Y ₂ O ₃ granulated powder was sprinkled on the surface of the base material granulated powder so as to be 10% by volume and discontinuously scattered to prepare a raw material powder. Next, the obtained raw material powder was put into a mold, press-molded (5 t / cm ² ), and sintered at 1280 ° C. for 4 hours (in vacuum) to obtain a composite material according to this example ( Sample number: 4).

The cross section of the obtained composite material was microscopically observed with a microscope as in the first embodiment. As a result, a composite material cell composed of a first phase composed of a matrix material and a second phase composed of a dispersant formed so as to discontinuously surround the first phase was used as a constituent unit, and a composite of the constituent units was formed. It was confirmed that the dispersant composed of a large number of cells bonded to each other and constituting the second phase had a structure in which the dispersoid was dispersed discontinuously in a three-dimensional network in the base material.

Comparative Example 6 For comparison, atomized SU having an average primary particle size of 4 μm
To S304 powder, the mixed powder was then uniformly mixed Y ₂ O ₃ powder having an average particle size of about 0.5μm such that 10 vol%, and press molding was placed in a mold (5t / cm ² ),
Sintering was performed at 1280 ° C. for 4 hours (in vacuum) to prepare a comparative sintered body (sample number: C6). The cross section of the obtained composite material was microscopically observed in the same manner as in the first embodiment. As a result, it was confirmed that the second phase had a structure in which the second phase was uniformly dispersed in the first phase of the base material.

Performance Evaluation Test Next, with respect to the composite material obtained in Example 4 and the comparative sintered body obtained in Comparative Example 6, an oxidation resistance strengthening test was conducted. The results obtained are shown in Table 3. For reference, the data of SUS alone is also shown in the table.

[0111]

[Table 3]

As is clear from Table 3, the composite material of this example greatly improved the oxidation resistance of SUS at high temperature, and the oxidation weight gain was reduced to 1/2 or less as compared with Comparative Example 6, It can be seen that it shows better characteristics.

[Brief description of drawings]

FIG. 1 is an optical micrograph (magnification: 10) showing a metal structure of a cross section of a composite material obtained in Example 1 of the present invention.
0 times).

FIG. 2 is an explanatory view conceptually explaining a specific example of the structure of the composite material cell of the composite material of the present invention.

FIG. 3 is an explanatory view conceptually explaining another specific example of the structure of the composite material cell of the composite material of the present invention.

FIG. 4 is an explanatory view conceptually explaining another specific example of the structure of the composite material cell of the composite material of the present invention.

FIG. 5 is an explanatory view conceptually explaining another specific example of the structure of the composite material cell of the composite material of the present invention.

FIG. 6 is an explanatory diagram illustrating a metal structure of a cross section of a specific example of the composite material of the present invention.

FIG. 7 is an explanatory view conceptually explaining a specific example of a mesh forming the composite material of the present invention.

FIG. 8 is an explanatory view conceptually explaining a specific example of a cross section of a composite material having a bond strengthening layer of the present invention.

FIG. 9 is an explanatory view conceptually explaining the structure of a specific example of a preferred composite material of the present invention.

FIG. 10 is a diagram conceptually illustrating the structure of a specific example of a preferable composite material of the present invention, and is a diagram showing the relationship between the selection order of dispersants and the distance.

FIG. 11 is a diagram conceptually explaining the structure of a specific example of another preferable composite material of the present invention, and is a diagram showing the relationship between the selection order of the dispersant and the distance.

FIG. 12 is a diagram conceptually explaining the structure of a specific example of another preferable composite material of the present invention, and is a diagram showing the relationship between the selection order of the dispersant and the distance.

FIG. 13 is an explanatory view conceptually explaining an example of a suitable dispersion structure of a dispersion material in the composite material of the present invention.

FIG. 14 is an explanatory view conceptually explaining an example of another suitable dispersion structure of the dispersion material in the composite material of the present invention.

FIG. 15 is an optical micrograph (magnification: 100 showing a metal structure of a cross section of the comparative composite material obtained in Comparative Example 1.
Times).

[Explanation of symbols]

1 ... Composite material 2 ... Composite material cell 3 ... Phase 1 31 ・ ・ ・ Phase 1 constituent substances 4 ... Phase 2 41 ... Dispersing material 5 ... Bonding strengthening layer

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Claims (14)

(57) [Claims] 1. A first phase composed of a matrix material and a second phase composed of a dispersant formed so as to discontinuously surround the first phase.
Composite material comprising a composite material made of a composite material cells as structural units consisting of a phase, the dispersed material, characterized by comprising discontinuously dispersed in a three-dimensional network in the composite material. 2. The second phase of the composite material cell comprises at least four discontinuities, the discontinuities being the first phase and another first phase adjacent to the first phase. Bond strengthening phase that bonds one phase, bond strengthening phase that bonds the first phase and the second phase, bond strengthening that bonds the second phase and another second phase adjacent to the second phase Having at least one of the phases,
The composite material according to claim 1, wherein the first phase is made stronger by the bond strengthening phase and the second phase is strongly fixed and held in the composite material. 3. The composite material according to claim 2, wherein the second bond strengthening phase is dispersed in the composite material in a three-dimensional network in a continuous or / and discontinuous manner. 4. A first phase composed of a plurality of matrix crystal grains as a matrix material, and a bond strengthening phase dispersed in a three-dimensional network as one cell so as to take in the periphery of the plurality of matrix crystal grains. And a composite material having a composite material cell composed of a second phase in which a dispersant is dispersed in the bond strengthening phase as a constituent unit, wherein the dispersant of the second phase is a three-dimensional mesh in the composite material. 7. A composite material, wherein the composite material is dispersed in a discontinuous shape, and the second bond strengthening phase is continuously or / and discontinuously dispersed in a three-dimensional network in the composite material. 5. The size of the base material forming the first phase is 1 μm to 10 mm, and the size of the dispersing material forming the second phase is 0.01 μm to 4 mm in major axis and the base material. The composite material according to claim 1 or 4, wherein the size is 1/4 or less of the size of the substance. 6. The composite material according to claim 1, wherein the matrix material forming the first phase is at least one of ceramic, metal, resin, and intermetallic compound. 7. The composite material according to claim 1, wherein the dispersant forming the second phase is at least one of ceramics, a metal, a resin, and an intermetallic compound. 8. The shape of the dispersion material forming the second phase is
The composite material according to claim 1 or 4, which is at least one of particles, whiskers, and fibers. 9. A combination of the base material and the dispersant, or a combination in which the base material and the dispersant are replaced with each other, silicon nitride-silicon carbide, silicon nitride-silica, silicon nitride-boron nitride, silicon nitride-titanium nitride, silicon nitride-. Titanium carbide, silicon nitride
Ferrite magnet, silicon carbide-alumina, silicon carbide-aluminum nitride, silicon carbide-titanium nitride, titanium carbide-silicon carbide, alumina-titanium carbide, alumina-zirconia, alumina-zircon, alumina-silicon nitride, alumina-diamond, alumina- Aluminum nitride, mullite-alumina, mullite-zirconia, sialon-silicon carbide, zirconia-alumina, glass-silicon carbide, glass-alumina, lead zirconate titanate-silicon carbide, lead zirconate titanate-barium titanate, titanate. The composite material according to claim 1, which is at least one of lead-strontium titanate, cordierite-mullite, and zirconia-nickel-chromium alloy. 10. A combination of the base material and the dispersant, or a combination in which they are replaced is nickel-thorium, nickel-chromium alloy-thorium, nickel-chromium alloy-yttria, iron-chromium alloy-yttria, iron.・
Chromium alloy-zirconia, iron / chromium alloy-alumina,
Aluminum-tungsten, aluminum-stainless steel, aluminum-carbon, aluminum-boron,
Aluminum-alumina, aluminum-silicon carbide, aluminum-yttria, magnesium or magnesium alloy-alumina, aluminum alloy-alumina, nickel or nickel alloy-alumina, molybdenum or molybdenum alloy-alumina, magnesium-silicon carbide, copper-alumina, copper- At least one of tungsten, copper-yttria, nickel-chromium alloy-yttria, nickel-chromium alloy-zirconia, nickel-chromium alloy-calcia, nickel-chromium alloy-silica, silver-tungsten. The composite material according to 1 or 4. 11. A combination of the base material and the dispersant is polyvinyl chloride-lead or lead alloy, polyvinyl chloride-manganese dioxide, polypropylene-talc, polypropylene-calcium carbonate, polypropylene-magnesium carbonate, epoxy resin. -Silicon carbide, epoxy resin-silica, epoxy resin-glass, silicon resin-silicon carbide, polyethylene-carbon, thermosetting resin-silica,
The composite material according to claim 1, which is at least one of thermosetting resin-silica, rubber-carbon black, resin-graphite, resin-nickel, and carbon-silicon carbide. 12. A combination of the base material and the dispersion material, or a combination in which the base material and the dispersion material are replaced with each other, silicon nitride-silicon carbide, silicon nitride-boron nitride, silicon nitride-titanium nitride,
Silicon carbide-alumina, silicon carbide-aluminum nitride, alumina-titanium carbide, alumina-zircon, sialon-silicon carbide, glass-silicon carbide, iron / chromium alloy-yttria, iron / chromium alloy-zirconia, iron / chromium alloy-alumina , Aluminum-stainless steel, aluminum-
The composite material according to claim 1, which is at least one of carbon, aluminum-silicon carbide, copper-alumina, and nickel-chromium alloy-zirconia. 13. A combination of the base material and the dispersant is at least one of epoxy resin-silicon carbide, silicon resin-silicon carbide, polyethylene-carbon, resin-graphite, resin-nickel, carbon-silicon carbide. The composite material according to claim 1 or 4, wherein 14. The composite material according to claim 2 , wherein the bond strengthening phase is an easily sinterable inorganic material and / or fine particle inorganic material.