JP3962501B2 - Tape-shaped preform and method for manufacturing the same, and composite material using the tape-shaped preform and method for manufacturing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a composite material having high strength and high rigidity, which can be applied to, for example, aircraft engine components, a tape-shaped preform used for producing this composite material, and a method for producing the same. The aircraft engine components include fan rotors, rod-shaped and tubular components such as actuator rods and aircraft legs.
[0002]
[Prior art]
A fan rotor, which is a component of an aircraft engine, is an important part and is very expensive because it requires high strength to withstand high-speed rotation. Further, if the weight of the fan rotor is slightly reduced, the engine as a whole can be considerably reduced in weight and fuel consumption can be reduced.
Therefore, conventionally, trial production has been carried out with the aim of developing and putting into practical use a metal matrix composite material in which a base material made of various metals or alloys is reinforced with a reinforcing material such as carbon fiber, for example, a titanium (Ti) matrix composite material. Yes. This Ti-based composite material is manufactured by, for example, arranging a plurality of reinforcing fibers obtained by coating carbon fibers with a Ti alloy and hot rolling them to produce a monotape preform; And a step of producing a Ti-based composite material by forming a composite by hot isostatic pressing (hereinafter referred to as HIP). In addition, when Ti alloy foil and reinforcing fiber are alternately laminated and spirally formed into a composite by hot pressing and HIP treatment, reinforcing fiber coated with Ti alloy on the reinforcing fiber surface is wound cold, hot pressing and HIP In some cases, it may be combined by processing.
For example, a monotape preform has been manufactured as follows.
As shown in FIG. 9, a core layer 100 of carbon or the like is coated with silicon carbide (SiC) by a chemical vapor deposition method (hereinafter referred to as a CVD method) to form a SiC layer 101, and electrons are formed on the surface of the SiC layer 101. A Ti alloy layer 102 is formed by coating a Ti alloy using a beam type physical vapor deposition method (hereinafter referred to as an EB-PVD method), and the reinforcing fiber 103 is manufactured. At that time, a carbon layer, a TiB2 layer, or other metal layers (Au, Ag, Pt, Pd, etc.) are singly or in combination between the SiC layer 101 and the Ti alloy layer 102, CVD method, PVD method, plating, etc. Depending on the case, it may be coated.
Next, as shown in FIG. 10, the plurality of reinforcing fibers 103 are arranged in parallel and inserted between the rolling rolls 104 and 104 disposed above and below and hot-rolled to form a monotape preform. 105 was produced.
[0003]
Next, the monotape preform 105 is wound around a roll (not shown) coldly as shown in FIG. 11 (a) and then combined by HIP treatment, as shown in FIG. 11 (b). Ti-based composite material 106 was manufactured.
[0004]
[Problems to be solved by the invention]
However, the above-described monotape preform and its manufacturing method, the composite material using the monotape preform and its manufacturing method have the following problems.
1) The EB-PVD method has a much higher deposition rate than conventional PVD methods such as sputtering, but it is difficult to control the alloy composition maintenance and coating thickness uniformity, etc. The production of reinforcing fibers by this method was very expensive.
2) Moreover, it has been difficult to stably produce a continuous monotape preform in a long length, for example, a length of several hundred meters.
3) When the monotape preform is wound, the deformation of the material at the time of compounding is large, and therefore, in the cold process, the reinforcing fiber may be damaged, and stable production is difficult.
[0005]
The present invention has been made in view of the above-mentioned problems, and its object is to provide a tape-shaped preform (above-mentioned “monotape” that is low in cost and can suppress a change in the shape of the material when combined. And a method for producing the same, and a method for producing a composite material using the tape-shaped preform.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, a method for producing a tape-shaped preform according to the present invention includes a plurality of reinforcing fibers arranged substantially in parallel and sandwiched between a plurality of, for example, two metal foil recesses. Then, these reinforcing fibers and metal foil are hot-rolled in a vacuum.
Examples of the reinforcing fiber include a fiber in which boron (B) is vapor-deposited on a tungsten (W) core wire, a fiber in which boron is deposited on a tungsten core wire, and a SiC-coated fiber, carbon (C) core wire (carbon Fiber), a fiber in which SiC is vapor-deposited on the fiber, a fiber in which SiC is vapor-deposited on a tungsten core, or a fiber without the core itself. Furthermore, not only the silicon carbide vapor-deposited but also a fiber obtained by firing organic fiber such as polycarbosilane can be employed.
The metal foil has a recess. For example, a foil made of Ti, a Ti alloy, or the like can be used as the metal foil. Hot rolling in vacuum prevents the metal foil from oxidizing and becoming brittle. The temperature at which the hot rolling is performed is preferably in the temperature range where the metal foil is moderately softened.
[0007]
In the titanium foil and titanium alloy foil (hereinafter referred to as Ti alloy foil) used as one embodiment of the present invention, (a) Ti-4.5Al-3V-2Mo-2Fe alloy (SP700), (b) Pure Ti, (c) Ti-6Al-4V alloy, (d) Ti-6Al-6V-2Sn alloy, (e) Ti-6Al-2Sn-2Mo alloy, (f) Ti-15V-3Cr-3Sn-3Al alloy (G) Ti-5.8Al-4Sn-3.5Zr-0.7Nb-0.5Mo-0.35Si (IML834), (h) Ti-6Al-2.8Sn-4Zr-0.4Mo-0. 45Si-0.0702 alloy (Ti-1100), (i) Ti-15Mo-3Nb-3Al-0.2Si alloy (beta21s), (j) Ti-41 to 52Al-X alloy (TiAl intermetallic compound: X is another additive element, for example, Ti-48Al-2Cr-2Nb), (k) Ti-25Al-10Nb-3V-1Mo alloy (superα2), (l) Ti-14Al-19.5Nb-3V-2Mo alloy (Ti3Al intermetallic compound), (m) Ti-24Al-11Nb alloy (Ti2AlNb: ortholonbic) and the like are included.
[0008]
Conventionally, it has been technically difficult to coat a Ti alloy to a sufficient thickness while maintaining a uniform alloy composition by the EB-PVD method. According to the present invention, by using a metal foil, a tape-shaped preform including reinforcing fibers using a Ti alloy foil can be manufactured relatively easily without using an EB-PVD method.
The hot rolling can be performed in a temperature range of 700 to 1200 ° C, preferably in a temperature range of 700 to 900 ° C. According to this temperature range of 700 to 1200 ° C., the Ti alloy foil is moderately softened and it becomes easy to produce a tape-shaped preform.
In the present invention, recesses are formed in the metal foil, and the reinforcing fibers are sandwiched with these recesses facing each other. When the thickness of the metal foil is 100 to 200 μm, the depth of the recess is preferably about 1 μm to 50 μm, and particularly preferably about 40 μm to 50 μm. A reinforcing fiber is disposed in the recess. Next, the metal foil sandwiching the reinforcing fibers is hot-rolled in vacuum to obtain a tape-shaped preform.
Further, in the method for producing a composite material of the present invention, a recess is formed in the longitudinal direction of the metal foil, the metal foil is disposed so as to face the recess, and a plurality of reinforcing fibers are disposed substantially in parallel in the recess, The reinforcing fibers are sandwiched between metal foils, and the reinforcing fibers and the metal foils are hot-rolled in a vacuum to form a tape-shaped preform. This is a method for producing a composite material by forming a roll-shaped preform by wrapping while pressing at a constant pressure within a pressure range, and compositing the roll-shaped preform.
[0009]
By pressing the tape-shaped preform at a constant pressure under the above conditions, dense winding can be performed, and the shape change of the reinforcing fibers at the time of compositing can be minimized. The pressure is 0.1 to 200 MPa, preferably 1 to 200 MPa. Further, the tape-shaped preform is wound in a vacuum in a temperature range of 700 to 1200 ° C, preferably 700 to 1000 ° C. In the temperature range of 700 to 1200 ° C., the Ti alloy foil is moderately softened and can be densely wound. Furthermore, the above-described combination can be performed by HIP processing.
According to the composite material manufactured by the above manufacturing method, the weight can be reduced by about 30%. For example, in the fan rotor of an aircraft engine, the maximum weight can be reduced by about 50%.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The method for producing a composite material according to the present invention includes (A) a step of producing a tape-shaped preform using reinforcing fibers and a Ti alloy foil, and (B) a compounding step of compounding the tape-shaped preform. Separated.
The tape-shaped preform manufacturing process can be divided into (1) a reinforcing fiber manufacturing process, (2) a Ti alloy foil processing process, and (3) a rolling process in which the reinforcing fiber is hot-rolled with Ti alloy foil. The compounding step (B) is divided into (1) a winding step for winding the tape-shaped preform and (2) a step for compounding the wound roll-shaped tape-shaped preform by HIP processing.
[0011]
Below, the processing content in each process is demonstrated.
(A) Manufacturing process of tape-shaped preform
(1) Reinforcing Fiber Manufacturing Process First, as shown in FIG. 1, SiC is deposited on the surface of the carbon core wire 1 by the CVD method to form the SiC layer 2, and the reinforcing fiber 3 is manufactured. The diameter of the carbon core wire 1 is preferably 30 μm to 40 μm and the length is preferably 1 m to 1000 m, and the diameter of the reinforcing fiber 3 after the SiC is deposited is about φ140 μm.
The plurality of reinforcing fibers 3 are arranged substantially in parallel as shown in FIG. 2, and the reinforcing fibers 3 are formed by using wefts 4 arranged at intervals of about 5 to 10 mm in a direction substantially orthogonal to the reinforcing fibers 3. Combine. The weft 4 is made of, for example, a TiNb alloy, and has a width of about 100 μm, a plate thickness of 50 μm, and a length of 1-1000 m. In order to bond the reinforcing fibers 3 to each other, an organic binder may be used instead of the weft yarn 4.
[0012]
(2) Process Step of Ti Alloy Foil Next, as shown in FIGS. 3 and 4, a recess 11 is formed in the Ti alloy foil 10 by, for example, a chemical milling method. In this method, a mask material is disposed on the alloy foil leaving a portion to be etched, and the recess 11 is formed by immersing the alloy foil in an etching solution such as a hydrofluoric acid-nitric acid solution. The depth D1 of the recess 11 is preferably about 40 μm to 50 μm, and the thickness D2 of the edge 12 is preferably 100 μm to 200 μm, particularly about 150 μm. In addition, as for the dimension of the said Ti alloy foil, thickness is 100-200 micrometers, width is 20-100 mm, and length is 10-500 m.
In the Ti alloy foil, as matrix, (a) Ti-4.5Al-3V-2Mo-2Fe alloy (SP700), (b) pure Ti, (c) Ti-6Al-4V alloy, d) Ti-6Al -6V-2Sn alloy, (e) Ti-6Al-2Sn-2Mo alloy, (f) Ti-15V-3Cr-3Sn-3Al alloy, (g) Ti-5.8Al-4Sn-3.5Zr-0.7Nb -0.5Mo-0.35Si (IML834), (h) Ti-6Al-2.8Sn-4Zr-0.4Mo-0.45Si-0.0702 alloy (Ti-1100), (i) Ti-15Mo- 3Nb-3Al-0.2Si alloy (beta21s), (j) Ti-41 to 52Al-X alloy (TiAl intermetallic compound: X is an additive element other than Ti and Al. For example, Ti-48Al-2Cr- Nb), (k) Ti-25Al-10Nb-3V-1Mo alloy (super α2), (l) Ti-14Al-19.5Nb-3V-2Mo alloy (Ti3Al intermetallic compound), (m) Ti-24Al-11Nb An alloy (Ti2AlNb: ortholone big) is included.
[0013]
(3) Rolling process Two Ti alloy foils 10 and 10 are arranged so that the respective concave portions 11 and 11 face each other, and the reinforcing fiber 3 is sandwiched between them. In this state, the Ti alloy foils 10 and 10 and the reinforcing fibers 3 are inserted between rolling rolls 20 and 20 that are supported so as to be vertically rotatable as shown in FIG. The tape-shaped preform 21 is manufactured by hot rolling under vacuum.
The reason for working in vacuum is to prevent the Ti alloy from oxidizing and embrittlement. By hot rolling at 700 to 1200 ° C., where the Ti alloy becomes moderately soft, the Ti alloy is softened and processed. Make it easier to do. Moreover, the thickness D3 of the tape-shaped preform 21 after rolling is 200 μm to 400 μm. For example, when the thickness D2 of the Ti alloy foil 10 before rolling is 150 μm, the tape-shaped preform 21 after rolling is The thickness D3 is 300 μm. The direction of the reinforcing fiber 3 may be a direction substantially orthogonal to the rotating shaft 22 of the rolling roll 20 or a direction substantially parallel to the rotating shaft 22. However, if there is only one direction and they are orthogonal to each other so as to cross each other, the composite material will not be strengthened in a specific direction, and accuracy will deteriorate.
In addition, if the recessed part 11 is not formed in the said Ti alloy foil 10, the possibility that the reinforcing fiber 3 will be cut | disconnected when it hot-rolls becomes large.
[0014]
Next, a process for producing a composite material according to the present invention using this tape-shaped preform 21 will be described.
(B) Compounding process
(1) Winding step The tape-shaped preform 21 is wound using a winding device 30 as shown in FIG. The winding device 30 includes a winding roll 31 that is rotatably supported in a substantially horizontal manner, and a lower portion of the winding roll 31, and is directed toward the winding roll 31 by an elastic body 32 such as a spring. And a lower roll 33 pressed with a constant force.
With this winding device 30, the tape-shaped preform 21 is densely wound in a vacuum at 700 to 1200 ° C. where the Ti alloy is moderately softened with a constant pressing force within a range of 0.1 to 200 MPa.
[0015]
(2) HIP Step Next, the wound tape-shaped preform 21 is composited by HIP processing to produce a composite material 40 as shown in FIG.
When the matrix of the Ti alloy foil is the above (a), the HIP treatment is preferably performed for 2 hours under conditions of a pressure of 150 MPa and a temperature of 800 ° C. Moreover, when the matrix material of Ti alloy foil is said (b)-(f), it is preferable to perform the conditions of HIP processing at a pressure of 50-200 MPa and a temperature of 850-950 degreeC for 0.1 to 4 hours. When the matrix is (g) to (i), (k), (l), or (m), the HIP treatment conditions are a pressure of 50 to 200 MPa and a temperature of 950 to 1100 ° C. for 0.1 to 4 hours. Is preferred. Furthermore, the HIP processing conditions of (j) are preferably performed at a pressure of 50 to 200 MPa and a temperature of 950 to 1200 ° C. for 0.1 to 4 hours. Although performing this HIP process is not an essential condition, it is desirable to carry out in order to stabilize the quality of the composite material 40.
[0016]
【Example】
Hereinafter, the tape-shaped preform according to the present invention, a method for producing the same, and a method for producing a composite material using the tape-shaped preform will be described more specifically with reference to examples.
(A) Tape-shaped preform manufacturing process First, a reinforcing fiber 3 called a warven preform (manufactured by Textron, USA) is sandwiched between the recesses of the two Ti alloy foils 10 and 10, and this is heated. The tape-shaped preform 21 was produced by rolling.
As shown in FIGS. 1 and 2, the above-mentioned Woven Preform forms a reinforcing fiber 3 having a diameter of 140 μm by depositing SiC on a carbon core wire 1 by a CVD method, and a plurality of these reinforcing fibers 3 are substantially parallel. In this state, weft yarns 4 made of TiNb alloy are arranged at intervals of about 5 to 10 mm in a direction substantially orthogonal to these reinforcing fibers 3, and the reinforcing fibers 3 are bonded using the weft yarns 4. It has been made.
The Ti alloy foil 10 has a thickness of 150 μm, a width of 30 mm, and a length of 10 m. As shown in FIGS. 3 and 4, a recess 11 having a depth of 100 to 110 μm is formed at the center by a chemical milling method. Formed.
And two Ti alloy foils 10 and 10 were arrange | positioned so that each recessed part 11 might oppose, and the said Woven preform was clamped between the recessed parts of these Ti alloy foils 10 and 10. FIG. In this state, as shown in FIG. 5, by inserting these Ti alloy foils 10 and 10 and the wobble preform between the rolling rolls 20 and 20, and hot rolling in a vacuum of 800 ° C., A tape-shaped preform 21 having a thickness of 300 μm was manufactured. At this time, the reinforcing fibers 3 of the wobble preform were arranged in a direction orthogonal to the rotation axis 22 of the rolling roll 20.
[0017]
(B) Compounding Step Next, the tape-shaped preform 21 was wound to form a roll-shaped preform, and then composited by HIP treatment to produce a Ti-based composite material 40.
The tape-shaped preform 21 was wound at a temperature of 800 ° C. in a vacuum with a pressing force of 10 MPa using a winding device 30 shown in FIG. This roll-shaped preform was vacuum-sealed in a stainless steel container and subjected to HIP treatment for 2 hours under conditions of a pressure of 150 MPa and a temperature of 800 ° C.
The Ti-based composite material 40 thus obtained is reinforced in the circumferential direction as shown in FIG. 8 (a) by arranging the reinforcing fibers 3 in the winding direction of the tape-shaped preform 21. Can be planned. Further, if the reinforcing fibers 3 are arranged so as to be orthogonal to the winding direction of the tape-shaped preform 21, the longitudinal direction (axial direction) of the composite material 40 can be reinforced as shown in FIG. 8 (b). it can.
[0018]
【The invention's effect】
As described above, the tape-shaped preform according to the present invention, the method for manufacturing the tape-shaped preform, and the method for manufacturing a composite material using the tape-shaped preform have the following effects.
(1) A recess is formed in the metal foil, and the metal foil is arranged facing the recess, and a plurality of reinforcing fibers are arranged substantially in parallel in the recess and hot-rolled to form a tape-shaped preform. Therefore, there is no possibility that the reinforcing fiber is cut when hot rolled.
(2) Since it is not necessary to use the EB-PVD method, it is easy to use almost any existing Ti alloy as a matrix, and the cost is low.
(3) By forming the roll-shaped preform by tightly winding the pre-combination tape-shaped preform while applying pressure, it is possible to minimize the shape change of the roll-shaped preform at the time of compounding, and the cost is reduced. It is inexpensive and improves yield.
(4) When the composite material is formed in a roll shape, it can be strengthened not only in the circumferential direction but also in the longitudinal direction.
[Brief description of the drawings]
FIG. 1 is an enlarged perspective view of a partial cross section showing a reinforcing fiber used in the present invention.
FIG. 2 is a perspective view showing an arrangement of fibers using the reinforcing fibers.
FIG. 3 is a perspective view showing a Ti alloy foil according to the present invention.
4 is a cross-sectional view taken along line AA in FIG.
FIG. 5 is a conceptual diagram showing a hot rolling process for forming a tape-shaped preform according to the present invention.
FIG. 6 is a conceptual diagram showing a winding process of a tape-shaped preform according to the present invention.
FIG. 7 is a perspective view showing a roll-shaped composite material according to the present invention.
8A is a perspective view showing a composite material whose reinforcing direction is a circumferential direction, and FIG. 8B is a perspective view showing a composite material whose reinforcing direction is a longitudinal direction.
FIG. 9 is an enlarged perspective view of a partial cross section showing a conventional reinforcing fiber.
FIG. 10 is a perspective view showing a manufacturing process of a conventional monotape preform.
FIG. 11A is a conceptual diagram showing a winding process of a conventional monotape preform, and FIG. 11B is a perspective view showing a conventional roll-shaped Ti-based composite material.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Core wire 2 SiC layer 3 Reinforcing fiber 4 Weft 10 Ti alloy foil 11 Recess 12 Edge 20 Roll roll 21 Tape preform 22 Rotating shaft 30 Winding device 31 Winding roll 32 Elastic body 33 Lower roll 40 Composite material 105 Mono Tape preform

Claims (9)

  A concave portion is formed in the longitudinal direction of the metal foil, the metal foil is arranged facing the concave portion, a plurality of reinforcing fibers are arranged substantially in parallel in the concave portion, and the reinforcing fibers are sandwiched between the metal foils. Then, a tape-shaped preform is formed by hot rolling these reinforcing fibers and metal foil in a vacuum, and a method for producing a tape-shaped preform.   The method for producing a tape-shaped preform according to claim 1, wherein the metal foil is a titanium alloy foil.   The tape-shaped plug according to claim 2, wherein the titanium alloy foil uses a TiAl intermetallic compound of a Ti-41 to 52Al-X alloy (X is an additive element other than Ti and Al) as a matrix material. Reform manufacturing method.   The said hot rolling is performed at the temperature of 700-1200 degreeC, The manufacturing method of the tape-shaped preform in any one of Claims 1-3 characterized by the above-mentioned.   A tape-shaped preform manufactured by the manufacturing method according to claim 1.   A concave portion is formed in the longitudinal direction of the metal foil, the metal foil is arranged facing the concave portion, a plurality of reinforcing fibers are arranged substantially in parallel in the concave portion, and the reinforcing fibers are sandwiched between the metal foils. Then, these reinforcing fibers and metal foil are hot-rolled in vacuum to form a tape-shaped preform, and the tape-shaped preform is vacuumed at a temperature of 700 to 1200 ° C. and a pressure of 0.1 to 200 MPa. A composite material using a tape-shaped preform characterized in that a roll-shaped preform is formed by winding while pressing with a constant pressure within a range, and the roll-shaped preform is composited to produce a composite material Manufacturing method.   The said metal foil is titanium alloy foil, The manufacturing method of the composite material using the tape-shaped preform of Claim 6 characterized by the above-mentioned.   8. The tape-shaped plug according to claim 7, wherein the titanium alloy foil uses a TiAl intermetallic compound of a Ti-41 to 52Al-X alloy (X is an additive element other than Ti and Al) as its matrix material. A method for producing a composite material using reform.   The method for producing a composite material using a tape-shaped preform according to any one of claims 6 to 8, wherein the compounding means is HIP treatment.

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