JPH024935A - Manufacture of metal matrix composite - Google Patents

Abstract

PURPOSE:To effectively manufacture a composite in which different metals are regulated to its matrix at low cost by impregnating matrix metals having different compsn. into the different parts of a molded body constituted of fine pieces of inorganic reinforcing material, metals and metallic fluoride. CONSTITUTION:An inorganic fibrous reinforcing material 10 constituted of a fiber made of ceramics such as SiC and Al2O3 contg. or plated with fine pieces of metals such as Ni, Fe, Co and Cr or a metallic fiber of Fe, W, etc., or a carbon fiber or the like is passed into slurry 12 contg. the fluoride of transition metals or Al to impregnate the fluoride into the inorganic fibrous reinforcing material 10; after that, the material is passed through a drying furnace 13 and is dried. The material is charged into a stainless pipe 14 contg. many pores 14a to prepare a molded body 11. The molded body is fixed into a board 16 made of ceramics in the form of dividing into two and is fixed into a mold 18; the molten metals 20 and 22 of Al, Mg and their alloys having different compsn. are simultaneously poured into both the parts divided by the board 16 and are impregnated into the molded body 11. The molded body is drawn up from the mold 18, by which a composite body 24 contg. matrix 24a and 24b of the alloys having different compsn. on both the sides of a boundary C can be manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a metal matrix composite material, more particularly comprising a first part in which the matrix is a first matrix metal and a second part in which the matrix is a second matrix metal. The present invention relates to a method for manufacturing a metal matrix composite material having the following.

BACKGROUND OF THE INVENTION Method for producing a composite material having dissimilar metals as a matrix, that is, a metal matrix composite material having a first part whose matrix is a first matrix metal and a second part whose matrix is a second matrix metal. For example, as described in Japanese Patent Publication No. 57-50595,
A fiber-reinforced composite characterized by separately pouring different types of molten metals to become matrix metals into a casting mold through a fiber molded body, and filling and compounding each molten metal into the fiber molded body by high-pressure solidification casting method. "Method for manufacturing parts" is known.

In addition, as another manufacturing method, as described in JP-A-62-184654 filed by the same applicant as the applicant of the present application, ``a metal with a melting point higher than that of the first matrix metal can be dissolved in a solvent. Prepare a material that disappears by melting and form a fiber molded body of a predetermined shape with reinforcing fibers.
A melt of the material is filled between the individual reinforcing fibers in a part of the fiber molded body, and the melt is solidified by cooling it, and the individual reinforcing fibers in the remaining part of the fiber molded body are filled. Filling the gap with a melt of the first 7 trisox metal, solidifying the melt of the first matrix metal, removing the solidified material by dissolving it in a solvent, and forming the fiber molded body. A method for producing a composite material is known, in which the spaces between the individual reinforcing fibers of the part are filled with a melt of the second matrix metal, and the melt of the second matrix metal is solidified.

Problems to be Solved by the Invention In the former method mentioned above, a high-pressure solidification casting method is used, which requires expensive press equipment and molds that can withstand high pressure, which makes the manufacturing cost of the composite material extremely high. There is a problem that the amount of metal is high, and that it is difficult to set the interface between the two types of matrix metals at a predetermined position.

In addition, in the latter method mentioned above, the manufacturing process is complicated, and a material that has a higher melting point than the first matrix metal and disappears by dissolving in the solvent is essential.
There is a problem that the manufacturing cost of the composite material tends to be high and that a good composite material cannot be manufactured unless the evanescent material is completely removed.

In view of the above-mentioned problems in the conventional method for manufacturing composite materials using different metals as matrices, the present invention provides a composite material in which the first and second matrix metals are well filled between individual reinforcing materials. The purpose is to provide a method that can be manufactured efficiently and inexpensively.

Means for Solving the Problems According to the present invention, a porous molded body containing an inorganic reinforcing material, a metal, and fine pieces of metal fluoride is formed, and one part of the molded body is Part is Al5A1 alloy, Mg,
The other part of the molded body is brought into contact with a molten metal of a first matrix metal selected from the group consisting of Mg alloy and Mg alloy.
, A1 alloy, Mg, and a Mg alloy.

Effects and Effects of the Invention According to the method of the present invention, a porous molded body containing an inorganic reinforcing material, a metal, and fine pieces of metal fluoride is formed, and a part of the molded body is formed by a first matrix metal. The other part of the molded body is brought into contact with the molten metal of the second matrix metal.

In general, metals, such as A1 alloy, have excellent wettability to molten metal, so the molten metal penetrates into the molded body through the metal. The metal fluoride also removes the oxide film on the surface of the molten metal and metal, thereby improving the wettability of the molten metal to the reinforcing material. In addition, the molten metal and the metal generate heat as they react with each other, and the heat heats the molten metal and the reinforcing material, which improves the permeability of the molten metal into the molded object and the wettability of the reinforcing material. It penetrates well into the body, and the matrix is made up of the first matrix metal part and the matrix is the second matrix metal part, and a composite material is formed in which these parts are integrally bonded to each other.

Therefore, according to the method of the present invention, it is not necessary to pressurize the molten metal or preheat the reinforcing material to a high temperature, and therefore, there is no need for extensive equipment for pressurizing the molten metal or preheating the reinforcing material to a high temperature. Therefore, a composite material having dissimilar metals as matrix metals can be produced more efficiently and at a lower cost than conventional methods such as high-pressure casting.

Also, according to the method of the present invention, there is no need for fugitive materials to prevent penetration of the molten matrix metal, and they can be applied to portions of the compact or removed from between the individual reinforcements of the compact. Since it is not necessary to do this, composite materials having dissimilar metals as a matrix can be manufactured more efficiently and at lower cost than in the conventional method according to the above-mentioned earlier proposal.

Furthermore, according to the method of the present invention, as described above, the molten metal penetrates into the molded body well, so that the molded body containing the reinforcing material, the metal, and fine pieces of metal fluoride can be formed into a predetermined shape and size. If a part of the formed body is brought into contact with the molten metals of the first and second matrix metals, the molten metals of the first and second matrix metals will quickly penetrate into the entire molded body in just the right amount. A composite material of substantially predetermined shape and dimensions is formed. Composite materials of substantially predetermined shapes and dimensions can therefore be manufactured efficiently and at low cost with very high yields.

According to one particular feature of the invention, the metal is used in fine pieces, such as short fibers, whiskers, powder, and thus by mixing the reinforcement with metal fines and metal fluoride fines, or By attaching fine pieces of metal and fine pieces of metal fluoride to the surface of the reinforcing material, a molded body made of these is formed.

According to another detailed feature of the invention, the metal is coated on the surface of the reinforcement. Therefore, in this case, by mixing the reinforcing material coated with metal and the metal fluoride,
Alternatively, by attaching a metal fluoride to the surface of a reinforcing material coated with metal, a molded body made of the reinforcing material is formed.

According to another detailed feature of the invention, the surface of the reinforcing material is coated with metal, fine particles of metal fluoride are dispersed in the coating layer, and the reinforcing material with such a composite coating layer is used. A molded body is formed.

Further, in the method of the present invention, the metal fluoride may be a fluoride of any metal element, for example, 2 ZrF6
, K4y TiF6 , KAlF4 , K3AlF6
, K2AlF5 ・H2O, Cs A I F 4, C
Contains transition metals such as Ti, Zr, Hf, V, Nb, Ta or AI combined with electrically positive elements such as alkali metals, alkaline earth metals, and rare earth metals, such as s A I F 5 ・H2O Preferably, it is a fluoride. According to another detailed feature of the invention, therefore, the metal fluoride is a fluoride containing a transition metal or AI in combination with an electrically positive metal element.

Further, in the method of the present invention, the metal contained in the molded body is A
Any metal may be used as long as it reacts with L or Mg to form an intermetallic compound, especially NiSF eSCo.
, Cr, Mn, CuXAg, Si, Mg, Zr, Zn,
5SnSPb, Ti, Nb.

Or an alloy containing any of these as a main component is preferable. According to another detailed feature of the invention, therefore, the metal is Ni, Fe5Co, Cr.

Mn, CuXAg, Si, Mg, Zr, Zn, Sn
-, Pt) s Tl % N b % and an alloy containing any of these as a main component.

According to yet another detailed feature of the invention, the molded body has a predetermined shape and dimensions, and only a portion thereof is immersed in the molten metal. According to this method, a composite material of a predetermined shape and size can be produced efficiently and inexpensively at a very high yield without pressurizing molten metal or using a mold to define a predetermined product shape. can be manufactured.

In the method of the present invention, it is not necessary to preheat the molded body, but when preheating the molded body to improve the wettability of the reinforcing material and the metal to the molten metal, the temperature may be set at the same temperature as in the conventional method. It is preferable that the temperature is lower than that shown in the figure. In addition, the form of the fine pieces of metal fluoride in the present invention is short fibers,
It may be in any form such as whiskers or powder.

In addition, in the method of the present invention, the reinforcing material may have any form and material, for example, silicon carbide fibers, ceramic fibers such as alumina fibers, iron fibers, metal fibers such as tungsten fibers, carbon fibers, etc. The particles may be inorganic fibers other than ceramics and metals such as ceramics and metals, whiskers such as silicon carbide whiskers, silicon carbide particles, and titanium carbide particles.

The invention will now be described in detail by way of example embodiments with reference to the accompanying drawings.

Example 1 As shown in FIG. 1, carbon fiber yarn 10 with an average fiber diameter of 7 μm plated with Nl at a thickness of 1 μM (“Torayca T300J, manufactured by Toshi Co., Ltd., number of filaments: 30
00 bottles) were prepared, and slurry 12 in which KAlF4 powder was dispersed in water was prepared. The yarn 10 is then continuously passed through the slurry while applying ultrasonic vibrations to the slurry, and then the yarn is continuously passed through a drying oven 13 for approximately 1
It was dried by heating to 50° C., thereby finely adhering KA I F4 to the surface of each carbon fiber.

Next, as shown in Fig. 2, it has dimensions of an inner diameter of 8n+m, an outer diameter of 10mm, a length of 150n+m, and a diameter of 2mm.
A stainless steel pipe 14 having a large number of holes], 4 a is prepared, and 150
The carbon fibers were cut into lengths of +nm, oriented in one direction, and filled into the pipe 14 so that the volume ratio was about 50%, thereby forming a cylindrical molded body 11 made of carbon fiber inside the pipe. .

Next, the molded body is heated to about 300°C for about 1 hour in an electric furnace for each pipe.
After heating for 5 minutes, as shown in FIG. 3, a molded board 16 made of short ceramic fibers is fixed in the center of the pipe by fitting, and these are placed in a mold 18.
A board 16 partitioned the inside of the mold into two parts.

Next, 20 and 700 molten metals of aluminum alloy Ors standard AC8A) at 700°C were placed in two parts in the mold, respectively.
Molten aluminum alloy (JIS standard AC4C) at ℃ 2
2 were poured at the same time, and after about 10 seconds (before the molten metal solidified), the pipe and board were taken out from the molten metal.

After the pipe and its interior have sufficiently cooled, the pipe and the composite material 24 formed therein are cut longitudinally substantially along its axis, as shown in FIG.
When the cross section of the composite material was investigated, it was found that the composite material has a part 24a whose matrix metal is aluminum alloy (JIS standard AC8A) and an aluminum alloy (JIS standard AC4).
A part 24b having C) as a matrix metal,
These parts bond well with each other and their interface 24
c was found to be located substantially in the longitudinal center of the composite material. It was also found that all the aluminum alloys were well filled between the individual carbon fibers 10a and were in good contact with the carbon fibers.

For comparison purposes, we attempted to manufacture a composite material using the same procedure and conditions as in the above example, except that carbon fibers that were not plated with Ni were used, and the result was shown in Figure 5. As shown, aluminum alloy (JIS standard AC8A
) as the matrix metal and the portion 24b as the matrix metal made of aluminum alloy (JIS standard AC4C) were both formed within a range of about 15 mm from the end of the pipe.

Example 2 6°7 g of Ni short fibers with an average fiber diameter of 20+czms and an average fiber length of 1.5111 m and 4 g of A with an average particle size of 40 μm
By substantially uniformly mixing 1 alloy powder (AI-12%Si) and 0.005 g of 2 ZrFa powder and compression molding the mixture in a mold, the material shown in Fig. 6 was obtained. As shown, a molded body 32 having dimensions of <50 x 10 x 10 mm and consisting of 2ZrF6 powder 30 on Ni short fibers 26 and A1 alloy powder 28 was formed.

Next, the molded body 32 is preheated to about 200°C, and the subsequent section 7
As shown in the figure, one end of the molded body has a length of 10111 m.
aluminum alloy (JIS
The molded body is immersed in a molten metal 34 of standard AC8A), and when the molten metal penetrates to a position 25 mm from one end of the molded body, the molded body is pulled up from the molten metal, and then immediately immersed from the other end of the molded body.
The part in the 0 mm range is heated to approximately 750°C using an aluminum alloy (
The molded body was immersed in a molten metal 36 of ASTM standard A390) and maintained until the molten metal completely penetrated into the molded body, and then the molded body was pulled up from the molten metal and the molten metal was solidified as it was. In this case, the molten metal remained attached to the molded body due to surface tension until it solidified, and substantially did not drip from the molded body.

After the molten metal had completely solidified, the dimensions of the composite material thus obtained were measured and it was found that the composite material had substantially the same shape and dimensions as the original compact. Furthermore, when this composite material was cut substantially along the longitudinal axis, and the cross section was polished and observed under an optical microscope, it was found that this composite material had a part with an aluminum alloy (JIS standard AC8A) as the matrix metal. It is recognized that these parts are well bonded to each other, and that their interface is located substantially in the longitudinal center of the composite material. It was done. Furthermore, it was found that all the aluminum alloys were well filled between the individual short Ni fibers and adhered well to the short Ni fibers.

Example 3 An average fiber diameter of 20 was used instead of the N1 short fiber in Example 2.
μM, using 7.7 g of stainless steel short fibers (JIS standard 5US430) with an average fiber length of 1 mm, K2ZrF6
Using 0.0005g of powder, about 80℃ was used instead of molten aluminum alloy (JIS standard AC8A) at about 720℃.
Using pure magnesium molten metal at 0°C, magnesium alloy at about 800°C (JIS standard MC
A composite material was manufactured in the same manner and under the same conditions as in Example 3, except that the molten metal of 2) was used, and its cross section was examined.

As a result, the composite material of this example also consists of a part using pure magnesium as the matrix metal and a part using magnesium alloy (JIS standard MC2) as the matrix metal.
It was observed that these parts bonded well to each other and their interface was located substantially in the longitudinal center of the composite. It was also observed that each matrix metal was well filled between the individual short stainless steel fibers, and was well adhered to the short stainless steel fibers.

Example 4 Average fiber diameter 0.5t plated with N1 at 0.3μm
TMS average fiber length 150. By substantially uniformly mixing 14 g of SiC whiskers from CZ River (Tokai Carbon Co., Ltd., "Tokamax") and 0.6 g of 2ZrF6 powder, and compression molding the mixture in a mold, the 9
As shown in the figure, outer diameter 40mm, inner diameter 25mm,
It has a height of 7 mm and has 2Z with SiC whisker 38.
An annular molded body 42 made of rF6 powder 40 was formed. The molded body 42 is then preheated to about 150°C, and then one side 4 of the molded body is heated as shown in FIG.
2a to an aluminum alloy (ASTM standard A) at approximately 700°C.
390) and about 4 mm from the side surface 42a.
When the molten metal penetrated to the position , the molded body was pulled out from the molten metal. In this case, the molten metal remained attached to the molded body due to surface tension until it solidified, and substantially did not drip from the molded body. FIG. 11 shows a molded body 42 treated in this way, with one end 42a of the molded body
The part in the 4mm range is made of aluminum alloy (ASTM
Composite material 46 whose matrix metal is standard A390)
It became.

Next, although not shown in the figure, the molded body 42 partially made of composite material is placed at the position of the valve seat in a mold for casting a cylinder head, and a molded body 74 is placed in the mold.
Aluminum alloy (JIS standard AC2A) at 0° C. was poured and a cylinder head was cast by low pressure casting. After the molten metal had completely solidified, the valve seat portion of the obtained cylinder head was cut along a plane along its axis, and the cross section was observed, as shown in Fig. 12.
Aluminum alloy (JIS standard AC2A) has penetrated into the part of the molded body 42 where the aluminum alloy has not penetrated, and a composite material 48 having the aluminum alloy as a matrix metal is formed by the solidity. It was also found that the cylinder head 50 was in good condition. In FIG. 12, the imaginary line indicates the valve seat surface 52 to be formed by machining after casting.

Although the present invention has been described above in detail with reference to several embodiments, the present invention is not limited to these embodiments, and various other embodiments are possible within the scope of the present invention. It will be clear to those skilled in the art that

[Brief explanation of the drawing]

1 to 3 are process diagrams of one embodiment of the method of the present invention, and FIG. 4 is a cross section along the axis of a composite material manufactured by the embodiment shown in FIGS. 1 to 3. 5 is a sectional view similar to FIG. 4 showing the cross section of a composite material of a comparative example, and FIGS. 6 to 8 are process diagrams showing another embodiment of the method of the present invention, 9 to 11 are process diagrams showing still another embodiment of the method of the present invention, and FIG.
FIG. 12 is a partial cross-sectional view showing the hull root portion of the cylinder head formed according to the embodiment shown in FIGS. 11 to 11. FIG.

Claims (1)

[Claims] A porous molded body containing an inorganic reinforcing material, a metal, and fine pieces of metal fluoride is formed, and a part of the molded body is made of Al.
, the other part of the molded body is brought into contact with a molten metal of a first matrix metal selected from the group consisting of Al alloy, Mg, and Mg alloy, and the other part of the molded body is selected from the group consisting of Al, Al alloy, Mg, and Mg alloy. A method for producing a metal matrix composite material, which comprises contacting a second matrix metal.