JPH064161B2 - Method for manufacturing a designable metal plate - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing a metal plate (panel) having a high design property, which is used for an outer wall or an interior of a building, particularly a casting surface (cast sand pattern). And a method for producing a metal plate having a (texture of a metal casting) to which is transferred by hot working.

(Prior Art) In recent years, various materials are used for interior and exterior of general houses, buildings, etc., or so-called exterior products such as gate posts, fences, etc., and their design properties are competing. One of them is a metal plate (panel) having a cast surface pattern. This is because when iron, aluminum, etc. are cast, the surface in contact with the foundry sand has a heavy and astringent texture unique to the casting (hereinafter referred to as the casting surface pattern), so this is used for decoration. Is.

The above-mentioned metal plate having a casting surface pattern can be manufactured by casting one by one as long as it has a considerable thickness. However, the panel used for decoration is made as thin as possible to reduce the unit price,
In addition, it is required to reduce the weight. Therefore, for example, a stainless steel plate with a cast surface pattern has been manufactured by a method of forming a tube by a centrifugal casting method, cutting the tube in the longitudinal (longitudinal) direction, and pressing it into a flat plate.

The centrifugal casting method described above is more efficient than casting one plate at a time. However, when performing centrifugal casting, it is necessary to adhere molding sand to the inner wall of the mold, and after casting and solidification,
There is a process of cutting and pressing the pipe, which is by no means an efficient method. Also, in this method, there is a limit to the wall thickness of the pipe that can be cast, and the minimum thickness is approximately 4 mm.

Further, the plate produced by the casting method has a defect peculiar to the casting in terms of material properties, regardless of the surface design. That is,
Plastic working is restricted due to poor toughness. For example, a plate bent at 90 ° is required for covering the corner portion, but such bending is impossible with a casting. In addition, corrosion of the casting sand is impaired due to biting of sand (sand bite) and minute cracks in the surface layer.

Japanese Patent Application Laid-Open No. 55-10304 discloses a method for forming a metal plate in which a metal plate and a wire net are overlaid and rolled at the same time during rolling to form grooves or patterns on the surface of the metal plate. This method
By selecting the pattern of the wire mesh to be superimposed on the surface, a decorative plate can be manufactured.

However, in this method, the pattern formed on the surface is basically a mass-produced decorative plate with a selected wire mesh pattern, regardless of how the wire nets are stacked and how they are rolled. However, it is not possible to obtain a metal plate having a unique pattern for each product and, in some cases, having an excellent design that makes the product feel artistically.

(Problems to be Solved by the Invention) The present invention has as its problem to solve the above-mentioned problems associated with the production of a metal plate by a conventional casting method, and provides a metal plate having a casting surface pattern by a hot working method. The purpose is to provide a new method of manufacturing.

(Means for Solving the Problem) The gist of the present invention is to "hot-work an assembly in which a shaping material harder than the metal plates is sandwiched between two or more metal plates at a processing temperature, and then The method for producing a metal plate having a casting surface pattern characterized by separating two or more metal plates ".

FIG. 1 is a process schematic diagram illustrating an example of the method for manufacturing a metal plate of the present invention. In this example, two metal plates are used, but this may be three or more.

First, prepare metal plates 1 and 1 '(this is a plate separately manufactured by forging, rolling, etc.) (a in the figure), and join three sides by welding or the like with a predetermined gap between them. (B in the figure). Next, the gap is filled with the shaping material 3 from the remaining opening 2 (c in the figure).

The shaping material has a function of being pressed against the surface of the plate to give a predetermined pattern during the hot working in the next step.
Therefore, it should not be softer than the material metal plate in the processing temperature range. The most common type of profile is that of a particulate mineral such as foundry sand. By using this, a typical casting surface pattern almost the same as the conventional one can be obtained. In addition, as a shaping material for stainless steel plates, powdered or lumpy materials such as chromium nitride, metallic chromium, silica, various carbides can be used, and shapes for relatively soft plates such as copper and aluminum can be used. In addition to the above materials, powders of mild steel or stainless steel, chips, flakes, etc. can be used as the attachment material. In addition, if a shaping material that deforms slightly at the rolling temperature (for example, in the case of stainless steel plate, agglomerated electrolytic manganese or ferrochrome) is used, the plate surface has a new flow pattern different from the conventional casting surface. The pattern appears. The desirable particle size range of the above shaping material is
The maximum diameter (longest axial length) is 0.001 to 50 mm.
If the maximum particle size is less than 0.001 mm, it is too small to perform the function as a shaping material even during hot working.
On the other hand, if it exceeds 50 mm, holes may be opened in the metal plate during hot working.

As the method of using the shaping material, powder, granules, lumps, etc. may be individually filled, but the maximum diameter is 0.001 to 0.5 mm and 0.5 to 5
You may mix and fill with 0 mm grain or lump. Furthermore, select a combination of hardness, particle size distribution and mixing ratio,
A variety of different surface designs may be created. It is desirable to add a release agent such as Al ₂ O ₃ having a maximum particle size in the range of 0.001 to 0.01 mm to the shaping material so that it can be easily removed from the plate surface later.

After the filling of the shaping material is completed, the remaining opening is sealed by welding or the like so as not to spill out during processing (d in the figure). It is desirable to degas the gap before this sealing. In addition, it is preferable that the seal of the opening part should leave a gas vent hole in part. If completely sealed, there is a concern that the gas inside will expand and the plate will peel during heating before processing or during processing. The assembly thus obtained is heated to a suitable temperature, for example rolling rolls 4
Subject to hot working (e in the figure).

The hot working includes pressing, forging, rolling, etc., but a rolling method using a rolling roll in ordinary metal plate production is recommended in terms of production efficiency. For processing temperature, rolling reduction and other conditions,
Type of target metal plate, depth of pattern to be applied to the surface,
Set according to the type of shaping material. It is also a great advantage of the method of the present invention, which is not found in the casting method, that the pattern printed on the surface of the metal plate can be changed by changing the processing conditions such as the reduction rate. Needless to say, the thickness of the patterned metal plate to be the product can be freely changed by adjusting the reduction ratio.

When the processing is completed, the four sides are cut, the two plates are peeled off, and the shaping material is removed. The impression of the shaping material is printed on the surface of the metal plate (the surface that was inside the assembly),
The desired pattern appears. In addition, since it may be more excellent in designability that a part of the shaping material remains on the surface, removal of the shaping material is not always complete removal.

The metal plate thus obtained can be cut to an appropriate size and used as it is as a decorative panel. However, in order to improve the mechanical properties, heat treatment may be performed after the rolling is completed, before the separation, or after the separation. Further, resin coating or other surface treatment may be applied for coloring or improving corrosion resistance.

If the method of the present invention is carried out using three or more metal plate materials,
The board sandwiched in the middle has a pattern on both sides. Such a metal plate is also useful for some applications.

The example of using the two cutting plates shown in FIG. 1 has been described above. However, according to the method of the present invention, two or more continuous plates (coils) are used, a shaping material is supplied while running the plates, and heating and rolling are continuously performed to form a casting surface pattern. It is also possible to manufacture a metal plate.

In the method of the present invention, since a rolled material can be used as the metal plate, the plate thickness can be arbitrarily reduced. In addition, this metal plate has much better workability than cast metal, and it is easy to form a panel for a corner by bending 90 °. Furthermore, for example, when manufacturing a panel made of stainless steel, if a nitride such as chromium nitride is used as a shaping material, nitrogen (N) diffuses and permeates from the surface of the plate during the heating-working process, and N of the surface layer portion is penetrated. It also has the effect of increasing the content and improving the pitting corrosion resistance.

Hereinafter, examples of the present invention will be described with respect to the production of a design panel made of stainless steel, which has recently become popular due to its excellent material properties such as corrosion resistance and mechanical properties.

(Example) Using two hot-rolled sheets of austenitic stainless steel (JIS SUS 304) having a thickness of 10 mm, a length of 400 mm, and a width of 150 mm, the first
A plate with a cast surface pattern was manufactured by the method shown in the figure.

First, weld the two plates on the three sides with an interval of 4 mm,
The gap was filled with chromium nitride having a particle size of about 2 to 3 mm. For chromium nitride, 10 wt% particle size 10
Al ₂ O ₃ powder of 0 μm or less was mixed. After degassing the inside of the gap, the remaining one side was welded, leaving some openings.

The above assembled material was heated to 1100 ° C. and rolled by a two-stage hot rolling mill. The rolling reduction was 83%.

After rolling, softening annealing was performed at 1100 ° C. for 5 minutes, and four sides were cut to separate the two plates. When the shaping material (chromium nitride) attached to the surface was removed, a casting surface pattern almost the same as that obtained by the conventional centrifugal casting method was attached.

The mechanical properties and corrosion resistance (measurement of pitting potential in 0.5 mol NaCl, 40 ° C aqueous solution) of the thus obtained stainless steel sheet were examined. The results are shown in the table on the next page. In addition, the measurement results of the plate made of the same material manufactured by the conventional centrifugal casting method are also shown for reference.

FIG. 2 is a photomicrograph showing the metallographic structure of the cross section of the stainless steel design panel manufactured by the method of the present invention and the conventional centrifugal casting method. According to the method of the present invention of (a), the crystal grains are small and there is almost no residual δ-ferrite. In the cast material of (b), not only the crystal grains are large and δ-ferrite remains largely, but also the segregation of components is remarkable. The difference in mechanical properties shown in the table below is mainly due to the difference in the metallographic structure between the rolled material and the cast material.

As shown in the table, even if the same material (SUS 304) is used,
The product manufactured by the method of the present invention using a hot-rolled sheet has excellent mechanical properties and corrosion resistance as compared with conventional cast products. It is considered that the improvement of the corrosion resistance is contributed by the fact that there is no sand bite unlike the casting and the surface is homogenized, and that N is diffused and penetrated from the chromium nitride of the shaping material. In this example, the N content in the surface layer portion was increased by about 0.1%. The product of the example of the present invention having a large elongation and excellent toughness can be easily processed from a flat plate into various shapes.

(Effect of the Invention) According to the method of the present invention, not only a metal plate having a high design property can be efficiently manufactured, but the obtained metal plate is superior to conventional products in mechanical properties and corrosion resistance.
Moreover, unlike the cast product, the thickness of the product can be arbitrarily determined, and the plate can be processed into a box shape or the like.

Furthermore, according to the method of the present invention, since a pattern is formed with an irregular shaping material such as powder, one by one for each production,
It is possible to manufacture a metal plate having a unique pattern having a different surface pattern, which is rich in artistry and design.

INDUSTRIAL APPLICABILITY The present invention greatly contributes to further widespread use of a decorative decorative panel made of metal.

[Brief description of drawings]

FIG. 1 is a process schematic diagram illustrating an example of a method for manufacturing a designable metal plate of the present invention. FIG. 2 is a micrograph showing a metallographic structure of a cross section of a design stainless steel plate (a) manufactured by the method of the present invention and a steel plate (b) manufactured by a conventional centrifugal casting method.

Claims (3)

[Claims] 1. An assembly in which two or more metal plates are sandwiched with a shaping material that is harder than the metal plates at a processing temperature and is in the form of powder, particles, pieces or lumps, and then the two or more metal plates are hot-worked. A method of manufacturing a designable metal plate, which comprises separating the metal plate. 2. An assembly is made by sealing three sides of two or more metal plates with a gap between them and filling the gap with a shaping material from the unsealed opening. The method for producing a metal plate according to claim 1, wherein the metal plate is hot worked. 3. The method for producing a metal plate according to claim 1 or 2, wherein the metal plate is a stainless steel plate.