JPH0475759A - Method for inserting metal-base material as internal chill - Google Patents

Abstract

PURPOSE:To obtain a good quality complex material having high joined strength by using molten aluminum after forming vapor deposition film composed of metal having excellent wettability with the aluminum on the surface of a base material and inserting the vapor deposition film forming base material as internal chill with high pressure casting. CONSTITUTION:After forming the vapor deposition film of metal having excellent wettability with aluminum or aluminum alloy on the surface of a base material of aluminum or aluminum alloy or composed of fiber reinforced metal reinforcing the aluminum or the aluminum alloy with fiber, by using the molten metal composed of the aluminum or the aluminum alloy to insert the vapor deposition film forming the base material with high pressure casting as internal chill, the good quality complex material having high joined strength at the interface of the base material and the inserting metal can be obtd.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method of casting a metal base material with another metal, and more specifically, aluminum (hereinafter referred to as Al).
Alternatively, the present invention relates to a method of casting a metal matrix composite material made of a fiber-reinforced metal composite material having an Al alloy as a matrix or a metal matrix material mainly composed of Al2 with Al or A[alloy.

[Prior art and its problems]

In recent years, Aj is the most commonly used metal after iron.
is being actively developed as a high-performance material. One example of this is the use of fiber-reinforced metal composite materials (F 1
ber ReinforeedMetalS: Hereinafter, F
RM) is being actively developed. In particular, this FRM is lightweight compared to conventional metal materials, has a high specific strength,
Because it has advantages such as high specific stiffness, excellent heat resistance, and improved fatigue strength, it is being developed mainly in the aerospace and aerospace fields. Recently, high-quality reinforcing fibers such as carbon fiber, silicon carbide fiber, and alumina fiber have been developed.
Combined with composite technology and molding technology, rapid technological progress is being seen, and it is spreading not only to the aerospace and aerospace fields, but also to fields such as general machinery and automobile engines.

However, as mentioned above, although this FRM has excellent properties not found in conventional metal materials, its manufacturing cost is extremely high, so it is currently only applied to limited fields such as the space and aerospace fields.

The present inventors have proposed a method to solve this problem of the prior art by effectively using expensive FRM only in the necessary parts and using conventional cheap metal materials in other parts. , focused on composite materials of FRM and other metals.

By the way, the method for manufacturing this composite material is FRM.
There is a method of casting it in metal. A conventional example of this method is the fiber reinforcement method for U calipers, which improves the rigidity and high-temperature strength of the caliper by compositing fiber aggregates with 1 and casting this into the caliper as a reinforcing material. 6
1-293650) has been proposed. However, this method did not take any measures to strengthen the casting interface, and the problem was that the excellent properties of FRM were not fully utilized.

On the other hand, as a method of combining Af and dissimilar metal members, "
``Method for manufacturing aluminum-dissimilar metal composite articles'' (Japanese Patent Application Laid-open No. 1258/1983) has been proposed.

This method uses iron (Fe), copper (Cu), titanium (Ti)
, and the insert metal plated with nickel (Ni) on the surface of these alloys and electrodeposited pyramidal Ni crystals to form a Ni plating layer surface having a large number of pyramidal protrusions, and then molded into a die-casting mold. By casting L inside the plating layer, Al is firmly fused to the plating layer, thereby improving the quality of the Al-dissimilar metal composite article. At this time, the formation of the Ni plating film involves applying N chloride to the fused surface of the dissimilar metal member.
Contains i and boric acid, pH 1.0 = 3.0, temperature 50-70°
Plating is performed by electrodeposition in a C plating bath. At this time, the electrodeposition is performed at a current density of 2.0 to IOAfdm2, and a large number of conical projections having sharp tips are formed on the surface of the Ni plating layer with a thickness of 15 μm or more. According to this method, Al2 and a dissimilar metal member can be extremely firmly fused together by die-casting, thereby producing an Ai-dissimilar metal composite article of excellent quality.

However, in the case of dissimilar metal parts or materials with a strong oxide film on the surface such as aluminum or aluminum alloy, this conventional method requires intermediary methods such as replacing zinc to ensure the adhesion of the plating film. Since a plating process is required, there is a problem in that the plating process involves a large number of fibers, resulting in high costs. This method also applies to FRM and AA
There is no disclosure regarding the method of combining '.

Therefore, the present inventors conducted intensive research to solve the problems of the above-mentioned prior art, and as a result of repeated systematic experiments, they came up with the present invention.

[Purpose of the invention]

The object of the present invention is to determine whether l or Aj? To provide a casting method capable of obtaining a high-quality composite material with high bonding strength at the interface between an alloy or a fiber-reinforced metal material obtained by reinforcing said material with fibers and a metal to be cast.

[Structure of the invention]

The method for casting a metal base material of the present invention includes Af or A[
In a method in which a base material made of an alloy or a fiber-reinforced metal material obtained by reinforcing this material with fibers is cast with a molten metal made of A7 alloy or A7 alloy, the surface of the base material is coated with Aj? Alternatively, after forming a vapor deposited film made of a metal that has excellent wettability with one alloy, the plating film forming base material is cast by a high pressure casting method using a molten metal made of Al or Al gold alloy. .

〔Effect of the invention〕

By the method of the present invention, it is possible to obtain a high-quality composite material with high bonding strength at the interface between the AI-based lid base material or a base material made of a fiber-reinforced metal material obtained by reinforcing the base material with fibers and the metal to be cast. can.

Here, an invention in which the base material of the present invention is made of a base material made of l or AA gold alloy and a composite material made by reinforcing the material with fibers, and further specific inventions thereof will be described below. .

That is, in a method in which a fiber-reinforced metal material reinforced with AI or Af gold alloy fibers is cast with a molten metal made of AA or one alloy, the surface of the fiber-reinforced metal material is coated with An.
Alternatively, after forming a vapor deposited film made of a metal that has excellent wettability with A1 alloy, the glazed film-forming fiber-reinforced metal material is cast by a high-pressure casting method using a molten metal made of AA or A1 alloy. A method for casting a metal base material (hereinafter referred to as the first invention).

In a method in which a base material made of Af or A1 alloy is cast with a molten metal made of AI2 or A/gold alloy, Aj? Alternatively, after forming a vapor-deposited film made of a metal that has excellent wettability with A1 alloy, a molten metal made of Af or A1 alloy is cast over the plating film forming base material by a high-pressure casting method. A method for casting a base material (third invention).

[Description of the first invention] The object of the first invention is to obtain a high-quality composite material with high bonding strength at the interface between the FRM and the metal to be cast, without having a thermal effect on the FRM. The present invention provides a method for casting base alloy composite materials.

The present inventors have focused on the following regarding the problems of the prior art described above. In other words, first, when an FRM made of AA or 1 alloy is cast with molten metal of AA or A1 alloy, the oxide of l, which is normally formed on the surface of the FRM, is cast with the FRM of the composite material. It remains as an oxide layer between it and the metal, and this oxide layer interferes with the bonding between the FRM and the metal it is cast into, causing no strength to be obtained at all.

Therefore, after forming a thin metal film layer on the surface of the FRM that improves the wettability between the FRM and the metal to be cast, by casting A1 or 1 alloy, the two are closely bonded. We focused on improving strength. Note that this adhesion strength improving metal thin film layer can be formed without removing adhesion strength inhibiting substances such as oxide films that are normally formed.

- On the other hand, if the casting is performed using a casting method such as gravity casting in which only a small amount of pressure is applied, casting defects such as shrinkage cavities may occur at or near the interface during cooling, resulting in a high quality composite material. I can't do anything but get the materials.

Secondly, in order to prevent this casting defect, FRM is
Or Aj? We focused on using high-pressure casting as a method for casting molten alloy.

Structure of the first invention The method for casting a metal base material according to the first invention includes AI or A
Is fiber-reinforced metal material made by reinforcing an alloy with fibers AI or Aj? In the method of casting with molten metal made of alloy,
After forming a vapor deposited film made of a metal with excellent wettability with AI or 1 alloy on the surface of the fiber-reinforced metal material, l
Alternatively, the method is characterized in that a molten metal made of one alloy is cast into the deposited film-forming fiber-reinforced metal material by a high-pressure casting method.

The effect of the first invention, that is, the method for casting a metal matrix composite material of the first invention is to first form a vaporized film made of a metal having excellent wettability with the FRM on the surface of the FRM, and then: FRM having such a vapor deposited film is made of Al or A1 by high pressure casting method.
Cast with molten alloy.

The vapor deposited film of FRM has good wettability with AI or A1 alloy, so the vapor deposited film easily melts into the molten metal, and at the same time, the FR
Directly wets the surface of M, improving the adhesion between PR,M and the casting alloy. In addition, by performing casting using the high-pressure casting method, it is possible to shorten the solidification time, which prevents deterioration of the FRM properties due to thermal effects, and allows Al2 or A1 alloy to be pressed onto the surface of the FRM under high pressure. Therefore, the wettability between the deposited film and the cast metal is further increased, and it is thought that sufficient adhesion can be obtained even if solidified in a short time. Furthermore, in the case of this method, it is possible to suppress the formation of cavities due to the coagulating acid bath, so it is thought that a healthy and high quality cast body can be obtained.

In this way, after depositing a metal with excellent wettability with the FRM on the surface of the FRM, by casting molten metal of A [or alloy 1] through the high-pressure casting method, it is possible to form a cast-filled interface without thermally affecting the FRM. It is believed that a healthy cast body with excellent adhesion can be produced.

Effects of the Invention According to the method of the present invention, a high-quality composite material with high bonding strength at the interface between the FRM and the metal to be cast can be obtained without thermally affecting the FRM.

Furthermore, it is possible to easily obtain a composite material that fully takes advantage of the excellent properties of FRM.

Furthermore, since the amount of FRM used to satisfy required performance can be reduced, product cost can be reduced.

[Description of the second invention] Below, a second invention that is a more specific version of the first invention will be described.

In the method for casting gold@base composite material thorns of the present invention, first, a fiber-reinforced metal material in which l or A[alloy is reinforced with fibers is prepared (fiber-reinforced metal material preparation step).

Al or Al as the 7 trix (matrix) of fiber reinforced metal material (FRM). The alloys are pure Aρ, Al-Mg alloy, Af-Ca alloy, Al-Ni alloy, AI! −
Metals such as Cu-based alloys are preferred, but other AA gold alloys are also suitable. These matrices are preferably selected appropriately in consideration of compatibility with the fibers to be reinforced. For example, when carbon fibers are used as reinforcing fibers, Af-Mg alloys or A1-Ca alloys are particularly preferred.

Further, the reinforcing fibers may be carbon fibers, silicon carbide fibers, alumina fibers, and various other fibers commonly used for reinforcing AA' or A1 alloys.

The manufacturing method of this fiber-reinforced metal material is not particularly limited, and is a general AI! Or AI! Is it possible to adopt a composite method of alloy and reinforcing fiber?
An example of a typical method is as follows. That is, there are high-pressure casting methods, hollow press methods, etc., but the present invention can produce the effects of the present invention no matter what method is used to manufacture the FRM. In addition, when producing FRM by the high-pressure casting method, a molten metal made of 1 or A1 alloy at 700 to 800°C is poured into a fiber aggregate preheated to 300 to 750°C, and the temperature is 10 to 10°C.

A method of solidifying by applying pressure at O atmosphere for 30 to 120 seconds is preferred. On the other hand, if the preheating temperature, pouring temperature, and casting pressure are lower than the above, or if the pressurization time is short, the molten metal will not sufficiently penetrate into the gaps between the fibers, resulting in insufficient composite formation. Also,
If the preheating temperature or pouring temperature is too high, fibers and Al or A
As the reaction with 1 alloy progresses and the strength of FRM decreases,
Both are undesirable.

Next, Ajl? Alternatively, a vapor deposited film made of a metal having excellent wettability with one alloy is formed (deposited film forming step).

Among these methods, when forming the gold*g deposited film by sputtering, the substrate is first cleaned, and then placed in a vacuum processing device such as a multi-source simultaneous sputtering device.
Evacuate to approximately X 10-” Torr. Then,
A sputtering atmosphere gas such as argon gas or a mixed gas of argon gas and oxygen gas is introduced, and a metal having excellent wettability with the fiber-reinforced metal material as the metal target of the present invention is sputtered to a desired thickness. Coat the membrane.

Note that before metal film deposition, a rare gas such as argon gas is introduced to a temperature of about lXlO-3 to lX10-' Torr, and ion etching is performed on the substrate surface for about 3 minutes using about 7-IIW. It's okay.

Further, in the vacuum evaporation method or the ion blating method, the metal film of the present invention, that is, the A [or Aj? The substrate is coated with the metal film using a metal pellet that has excellent wettability with the alloy.

Note that, before forming the above-mentioned vapor deposited film, it is desirable to completely remove dirt such as oil on the surface of the substrate by ultrasonic cleaning or the like. If the dirt remains, there is a risk that problems such as an adverse effect on film formation during sputtering or weakening of the adhesion between the deposited film and the substrate may occur.

Al2 or AI! Among metals that have excellent wettability with alloys, metals suitable for formation by the vapor deposition method of the present invention include gold (Au), silver (Ag), copper (Cu), and the like. Among these, Au is widely used as a vapor-deposited metal.
It is preferable because it exhibits an excellent effect on improving wettability.

The thickness of the deposited film is preferably about 0.01 to 0.0511 m. The film thickness is 0. If it is thinner than 1 μm, the film thickness will become non-uniform, which is undesirable, and if it is thicker than 0.05 μm, the wettability improvement effect will not improve much further, so from the cost standpoint, the above range is appropriate.

Next, the vapor-deposited film forming edge 1 fiber-reinforced metal material is placed in a high-pressure casting apparatus, and further A[or Aj? Pouring a molten metal made of an alloy and casting the molten metal around the vapor-deposited film-forming fiber-reinforced metal material under a high-pressure atmosphere (casting process)
.

As a casting metal for FRM having a vapor-deposited film, pure 1. Au2-Cu alloy, AA'-Cu-3i alloy, 1-3i alloy, AI!
-Mg-based alloys, 1-Mg-5i-based alloys, etc. can be used. Among these, Al2-3i alloy and Aj?
-Cu-based alloys are preferable because they provide a cast body with high adhesion to the FRM having a vapor-deposited film.

If the contact time between the FRM and the molten metal is too long, there is a risk that the parent phase L or A1 alloy that makes up the FRM will melt and the characteristics of the FRM will deteriorate. It is preferable to shorten the contact time with the molten metal by devising a method. In addition, if the pouring temperature of the casting metal is too high, it will deteriorate the characteristics of FRM for the same reason as mentioned above, and if it is too low, it will solidify before it gets sufficiently wet with the deposited film, so the casting metal will solidify. 3 from the starting temperature
It is preferable that the temperature is higher by about 0 to 150°C.

The casting pressure is preferably about 10 to 1000 atm so that defects such as cavities do not occur in the cast body and the FRM does not deform. In addition, it usually takes about 30 minutes until coagulation is complete.
A pressurizing time of about seconds to 2 minutes is required. In this way, by optimizing the high-pressure casting conditions, a healthy cast body with good interfacial adhesion can be obtained.

[Description of the third invention] The third invention is directed to Ajl? This invention relates to a casting method for a metal base material (hereinafter referred to as A [based material)] mainly composed of A.

Object of the Third Invention The object of the third invention is to obtain a high-quality composite material with high bonding strength at the interface between the metal-based material mainly composed of AI and the metal to be cast. To provide a casting method.

Structure of the Third Invention The method for casting a metal base material according to the third invention is characterized in that a base material made of Aj? Or An? In a method of casting with a molten metal made of an alloy, the above-mentioned A is applied to the surface of the base material.
After forming a vapor deposited film made of a metal that has excellent wettability with I or A1 alloy, the vapor deposited film forming base material is cast by a high pressure casting method using a molten metal made of I or A1 alloy. do.

The effect of the third invention, that is, the method for wrapping a metal matrix composite material according to the third invention, first forms a vapor deposited film made of a metal having excellent wettability on the Al-based substrate on the surface of the Al-based substrate. Next, the Ail-based base material having such a vapor deposited film is cast in a molten Af or A1 alloy by high-pressure casting. The vapor deposited film of the l-based base material is A
j? Alternatively, since it has good wettability with 1 alloy, the deposited film easily penetrates into the molten metal, and at the same time directly wets the surface of the AIl base material, resulting in good adhesion to the AIl base material casting alloy. In addition, by performing casting using a high-pressure casting method, AI! Or AI! Since the alloy is pressed under high pressure, the wettability between the deposited film and the cast metal is further increased, and it is thought that sufficient adhesion can be obtained even if the alloy is solidified in a short time. moreover,
In the case of this method, it is possible to suppress the formation of cavities due to solidification shrinkage, so it is thought that a healthy and high quality cast body can be obtained.

In this way, after depositing a metal with excellent wettability with the 1-based base material on the surface of the 1-based base material, by casting molten Au7 or A1 alloy around the surface of the 1-based base material, the interface between the cast parts is formed. It seems possible to produce a healthy cast body with excellent adhesion.

Effects of the Invention By the method of the present invention, it is possible to obtain a high-quality composite material with high bonding strength at the interface between the Al base material and the metal to be cast.

Further, it is possible to obtain a composite material that fully utilizes the characteristics of the metal material base material.

Furthermore, since the amount of base material used to satisfy the required performance can be avoided without reducing the amount of base material used, if the base material is expensive, product cost I. is reduced. T.

I can do it.

[Description of Fourth Invention] Below, a fourth invention that is a more specific version of the third invention will be described.

In the method for casting metal-based materials of the present invention, first, l
Alternatively, a base material made of one alloy is prepared (metal material preparation step).

Af or AI! The alloy is pure A/, A! -Mg alloy,
Af-Mg-8i alloy, Al2-Ca alloy, A7-
Metals such as Ni-based alloys and Al-Cu-based alloys are preferred, or other A1 alloys may be used.

Next, Af or A[A[alpha] is deposited on the surface of a metal base material made of an alloy by a physical vapor deposition method such as a sputtering method, a vacuum evaporation method, or an ion blating method. Forming a vapor deposited film made of a metal that has excellent wettability with alloys (vapor deposit film forming process).

Ajl? Among metals that have excellent wettability for Af-gold alloys, metals suitable for formation by the vapor deposition method of the present invention include gold (Au), silver (Ag), copper (Cu), and the like.

Among these, Au is one of the vapor deposited metals. .

It is preferred because it is widely used and has an excellent effect on improving wettability.

The thickness of the deposited film is preferably about 0.01 to 0605 μm. If the film thickness is less than 0.01 μm, the film thickness will become non-uniform, which is undesirable, and if it is thicker than 0.05 Ilrn, the wettability improvement effect will not be improved much.
In terms of cost, the above range is appropriate.

The method for forming this metal vapor deposited film is the same as that described in the vapor deposited film forming step of the second aspect of the invention.

Next, the vapor-deposited film-forming metal material is placed within a high-pressure casting value r, and a molten metal made of Af or A7 alloy is poured,
The molten metal is cast around the vapor-deposited film-forming metal material under a high-pressure atmosphere (casting step).

Pure Δl, Ai?, which is generally used in high-pressure casting methods, is used as the casting metal for the metal material base material having steam SM. -C
u-based alloy, Af-Cu-3i-based alloy, Al-3i-based alloy, A1-Mg-based alloy, Aj? -MgSi alloy etc. can be used. Among these, especially kl-Cu alloy and A! ! -Cu-3i alloy is preferable because it provides a cast body with high adhesion to the metal material base material having the vapor deposited film.

If the contact time between the Ai7 base material and the molten metal is too long, there is a risk that the A1 base material will melt and its properties will deteriorate, so the placement position of the Al base material and the timing of pouring should be carefully considered. It is preferable to shorten the contact time with the molten metal. In addition, if the pouring temperature of the casting metal is too high, it will deteriorate the properties of the Al base material for the same reason as mentioned above, and if it is too low, it will solidify before it sufficiently wets the deposited film, so the pouring temperature of the casting metal will deteriorate. It is preferably about 30 to 100°C higher than the solidification start temperature of the metal. The casting pressure is set at lO~ to prevent defects such as cavities from occurring in the cast body and to prevent deformation of the FRM.
Approximately 1000 atm is preferable. Further, a pressurizing time of about 30 seconds to -2 minutes is usually required until coagulation is completely completed. In this way, by optimizing the high-pressure casting conditions, a healthy cast body with good interfacial adhesion can be obtained.

〔Example〕

The present invention will be explained in detail below.

First Example First, Aj? A carbon fiber reinforced A [alloy (CFRM) base material with -5% Mg alloy as a matrix was produced.

Next, this CFRM base material was degreased by ultrasonic cleaning in ethyl alcohol to remove dirt such as oil. Next,
The prepared base material was placed in an ion sputtering device, an Au was attached as a target, and a 5 x 10"
After evacuating the inside of the apparatus to Torr, argon gas was
Au was deposited for 6 minutes at a sputtering current of 3 mA. From kneading, there is a uniform A on the surface of CFRM.
A plating film is formed with U vapor deposition, and the film thickness is approximately 0.03 mm.
It was confirmed that it was μm.

Next, the vapor-plated CFRM was fixed to a steel plate holder, attached to the upper punch of a vertical hydraulic booth using a magnet, and a high-pressure casting mold heated to about 250"C placed below. Fill the inside with Aj?-4% Cu alloy molten metal at 700°C, lower the upper punch, immerse the CFRM in the molten metal for a month, and pressurize the molten metal at a pressure of about 1000 atm for 1 minute to solidify it. As a result, the cast body of this example according to the present invention was obtained.

A performance evaluation test of the obtained cast body was conducted by a bending strength test and cross-sectional structure observation. First, the obtained cast body was cut, and a test piece with a length of about 60 mm and a thickness of 4 mm was cut out so as to be located in the center of the 3 mm wide CFRM. As a result of performing a three-point bending test on this cut-out test piece, it was found that CFRM and An? It broke at the interface of the alloy layer (casting layer), and the bending strength was about 140 MPa.

Next, the obtained cast body was cut, and CFRM and A1-
Observation of the casting interface (metallic structure) of the 5% Mg alloy using an optical microscope revealed that the adhesion state was good.

For comparison, CFRM with only the surface degreased was cast in the same manner as in the previous example, and CFRM and Aj? - As a result of observing the interfacial structure of the casting of the 5% Mg alloy, it was found that near the surface of the CFRM there were black linear traces of the oxide film that was on the surface of the CFRM before casting, and the adhesion state was poor. Met. Further, this part was easily peeled off, and the adhesive strength was zero.

2nd embodiment Aj? by high pressure casting method? A -5% Mg alloy was prepared, and the Δ1 alloy was subjected to the same cleaning treatment as in the first example.

Next, a film with a thickness of about 0.03 μm was applied to the surface of the cleaned AI alloy base material using the same method and conditions as in the first example.
An Au vapor-deposited plating film was formed.

Next, A77-7%Si-3 was applied to the aluminum alloy which had been subjected to Au vapor deposition plating treatment in the same manner as in the first embodiment.
% Cu alloy to obtain a cast body of this example according to the present invention.

As a result of observing the metal structure of the cross section of the casting interface of the obtained casting body, it was found that the aluminum alloy base material and Al-7%5i
No trace of the original interface was observed at the boundary of the -3% Cu alloy, and the adhesion state was good. In addition, a three-point bending test was conducted on a test piece cut out from the obtained cast body into a piece approximately 60 mm long x 4 mm thick, with the CFRM of three normal widths located in the center. It breaks at the interface between the base material and the casting layer, and the bending strength is approximately 100
It was MPa.

For comparison, an aluminum alloy whose surface was only degreased was cast in the same manner as in the above example.
As a result of observing the casting interface structure of the i-3% Cu alloy, a non-bonded area was observed in a part of the casting interface, and the adhesion state was poor. Further, this part was easily peeled off, and the adhesive strength was as low as 37 MPa.

Claims (1)

[Claims] (1) In a method in which a base material made of aluminum or an aluminum alloy, or a fiber-reinforced metal material obtained by reinforcing the material with fibers, is cast with a molten metal made of aluminum or an aluminum alloy, the surface of the base material is coated with aluminum or an aluminum alloy. A cast material made of a metal base material, characterized in that after forming a vapor deposited film made of a metal with excellent wettability, the vapor deposited film forming base material is cast by a high pressure casting method using a molten metal made of aluminum or an aluminum alloy. Method.