JPH10102162A - Production of metal-ceramic composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a metal-ceramic composite material composed of a high strength perform by adding a specified amt. of a colloidal silica soln. to SiC powder, forming and firing them and impregnating a molten metal into the resultant preform. SOLUTION: A colloidal silica soln. as a binder is added to SiC or Al2 O3 powder of 1.0-100μm average particle diameter by 0.5-25wt.% (0.1-5.0% expressed in terms of silica) or a colloidal soln. of alumina hydrate is added by 1.0-30% (0.1-10% expressed in terms of alumina). The colloidal silica soln. contains water as a dispersive medium and Na<+> (0.05-0.4% expressed in terms of Na2 O) or NH<4+> as a stabilizer and has 5-50nm colloid size. The colloidal soln. of alumina hydrate contains Cl<-> , CH3 COO<-> or NO3 <-> as a stabilizer and has 1-1,000nm colloid size. They are then formed and fired at 800-1, 100 deg.C for 1-3hr. A molten metal such as a molten Al alloy is impregnated into the resultant perform at 700-1,000 deg.C and the objective metal-ceramic composite material is obtd.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite material comprising a metal and a reinforcing material, and more particularly to a method for producing a metal-ceramic composite material using ceramics as the reinforcing material.

[0002]

2. Description of the Related Art A metal-ceramic composite material reinforced with ceramic fibers or particles has both characteristics of a metal and a ceramic. For example, this composite material has rigidity, low thermal expansion property, abrasion resistance and the like. It has excellent properties of ceramics and excellent properties of metals such as ductility, high toughness, and high thermal conductivity. As described above, since it has both the characteristics of ceramics and metal, which have been considered difficult, it has been drawing attention as a next-generation material from industries such as mechanical device manufacturers.

[0003] Methods for producing this composite material, particularly a composite material using aluminum as a matrix as a metal, include powder metallurgy, pressure casting, and vacuum casting. Among these, in powder metallurgy, powdered metal is mixed with granular or whisker-like or fiber-like ceramics as a reinforcing material, molded and fired under non-pressurized or pressurized conditions. I was However, when the powder filling rate of the reinforcing material in the composite material produced by this method is high, in other words, when the reinforcing material increases, sintering becomes difficult, so the powder filling rate is whisker or fibrous fibrous. The maximum was about 25%, and the maximum was about 40% in the form of particles.

[0004] In the pressure casting method and vacuum casting method other than the powder metallurgy method, the molten metal is hard to wet the ceramic particles. Therefore, when the reinforcing material is increased, it is difficult to uniformly mix the reinforcing material. At the maximum was also about 40% at most. Thus, in the conventional method for producing a composite material, the content of the reinforcing material is low and the rigidity is small,
It has been difficult to use it for applications requiring high rigidity. Therefore, recently, in order to increase the powder filling rate of the reinforcing material, an impregnation method has been adopted in which a preform made of ceramic fibers or particles as the reinforcing material is prepared in advance, and the preform is impregnated with the metal as the base material. ing.

[0005]

However, even in this method, even when the powder filling ratio of the reinforcing material is increased to 60% or more, the strength of the preform is reduced to less than 1 MPa in bending strength, so that the metal is impregnated during the impregnation. Thus, there were problems such as cracks and cracks occurring in the preform, which did not form a composite, and incorporation of metal into the cracks, resulting in non-uniform composite formation. Attempts have also been made to increase the strength of the preform by changing the type and amount of the binder that binds the ceramic particles, but increasing the strength creates closed pores in the preform, hindering the impregnation of the metal, resulting in a composite. There was also a problem that it could not be done.

The present invention has been made in view of the problems of the above-described method for producing a metal-ceramic composite material by the impregnation method, and has as its object to provide a high powder filling rate and sufficient metal impregnation. An object of the present invention is to provide a method for producing a metal-ceramic composite material comprising a preform having strength.

[0007]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to achieve the above object, and as a result, colloidal silica liquid, colloid liquid of alumina hydrate, colloidal silica Mixed liquid of silica liquid and colloid liquid of alumina hydrate, fine powder Si
If C powder or fine powder of Al ₂ O ₃ powder is used, a preform having a high powder filling rate and sufficient strength for impregnating a metal can be obtained. A composite material can be obtained, and a metal having different levels of bending strength and fracture toughness can be obtained by selecting the type of the binder.
The present invention was completed based on the knowledge that a ceramic composite material was obtained. This will be described in detail below.

The ceramic powder used as a raw material for the preform was SiC or Al ₂ O ₃ powder having an average particle size of 1.0 to 100 μm. Other ceramic powders, for example, oxides such as silica and mullite, silicon nitride, nitrides such as aluminum nitride, titanium nitride, zirconium nitride, titanium carbide, carbides such as boron carbide, zirconium boride, titanium boride, etc. Borides and the like can also be used.
The composite using C powder has a coefficient of thermal expansion of 5 to 10 ^-6 / ° C and a thermal conductivity of 150 w / mK, which has both low thermal expansion and high thermal conductivity, making it a high value-added machine part. It depends. On the other hand, Al ₂ O ₃ powder is used because it is inexpensive, has high plasma resistance, and has excellent properties such as high strength. The reason for setting the particle diameter to 1.0 to 100 μm is that if the average particle diameter is smaller than 1.0 μm, the distance between the particles becomes narrow, impairing the impregnation of the metal,
If it is larger than 0 μm, the filling rate of ceramic particles is 55%
However, the strength of the preform decreases, which is not preferable.

Among the above ceramics, the SiC powder may be one usually used as an abrasive or as a raw material for a refractory, and an abrasive having a particle size of # 8000 or more is used. be able to. The type may be any type such as green and black. Also, Al ₂ O ₃ powder may be used as a raw material for abrasives and refractories similarly to SiC powder, and may be any type such as electrofused alumina, sintered alumina, and calcined alumina. It can be used, and among them, fused alumina is preferable because of high powder filling rate.

The above-mentioned SiC powder or Al ₂ O ₃ powder is added to the above-mentioned oxides such as silica and mullite, nitrides such as silicon nitride, aluminum nitride, titanium nitride and zirconium nitride, and carbides such as titanium carbide and boron carbide. Other powders such as borides such as zirconium boride and titanium boride may be added.
Low thermal expansion, high thermal conductivity, or low Young's modulus of iC, or if it is SiO ₂ , it reacts with the matrix to increase the production of Si or Mg ₂ Si in the matrix, resulting in brittleness and reduced fracture toughness However, 10% or more is not preferable because the properties of the composite are impaired.

As the binder for binding the ceramic particles, a colloidal silica liquid having water as a dispersion medium and a colloid containing Na ⁺ or NH ₄ ⁺ as a stabilizer and having a colloid size of 5 to 50 nm, or a stabilizer is used. the Cl ^-, CH ₃
COO ^- or NO ₃ ^- and the size of the colloid is 1
A colloidal solution of alumina hydrate of 1000 nm was used, and the amount of the colloidal silica solution was 0.5 to 25 wt% with respect to SiC or Al ₂ O ₃ powder (0.1 to 25 wt% as silica).
5.0 wt%), and 1.
0-30 wt% (0.1-10 wt% as alumina)
In addition, it was molded and fired. If the amount of the binder is too small, the strength of the preform is small and a problem occurs when the composite is formed.If the amount is too large, closed pores cannot be formed with the colloidal silica liquid and the compound cannot be formed. And the powder filling rate is low, which is not preferable.

The colloidal silica solution and the colloidal solution of alumina hydrate may be mixed and used, and the mixing ratio is such that the silica component is 10 to the alumina component.
80%, and the mixture is SiC or A
l ₂ O ₃ 1.0~30wt% to the powder (0.1 to 5.0% as the silica + alumina) was added and molding, it was firing. If the added amount of the mixed solution is too small, the strength of the preform becomes small and a problem occurs when forming a composite, and even if it is too large, the viscosity of the slurry becomes high and the powder filling rate decreases,
The strength of the preform is undesirably reduced.

In the case of a colloidal silica liquid containing Na ⁺ as a stabilizer among the above binders, the Na ⁺ concentration in the binder is 0.05 to 0.4 wt% in terms of Na ₂ O.
And If it is lower than 0.05 wt%, the effect is small,
If it exceeds 4% by weight, the properties of the composite, particularly the bending strength and the fracture toughness, decrease. This becomes higher Na ⁺ concentrations when Na ₂
O remains, the Al melt impregnated in the preform is easily oxidized, the matrix is partially converted to Al ₂ O ₃ , and the preform becomes high in strength, but the properties of the composite, particularly the bending strength and fracture toughness, are reduced. When the reinforcing material is alumina, the grain boundary of Al ₂ O ₃ is vitrified to form closed pores, which impairs the impregnation.

In the case of a colloidal solution of alumina hydrate with Cl ^{− as the} stabilizer, the crystal form of alumina hydrate in the binder was made amorphous and amorphous. The use of crystalline boehmite is not preferred because the strength of the preform is reduced.

Other binders other than those described above include:
Al ₂ O ₃ fine powder or SiC fine powder of 0 μm or less, and these powders are used as reinforcing material SiC powder or Al ₂
1 to 10 wt% was added to the O ₃ powder, and the mixture was molded and fired. When this binder is used, the effect is reduced if the particle size of the reinforcing material is too small, and therefore, a reinforcing material having an average particle size of 10 μm or more is preferable. If the amount of the binder is less than 1% by weight, the strength of the preform is decreased, and if it is more than 10% by weight, closed pores are generated, which impairs the impregnation of the metal, which is not preferable. In the case of this powder, it is desirable to add an organic binder such as glycerin, PVA, or acrylic so that the molded body can retain its shape during molding.

When the binder is a colloidal silica liquid, the compact is fired at 800 to 1100 ° C. for 1 to 3 hours at 800 to 1100 ° C.
Sintering is performed at 800 to 1200 ° C. for 1 to 3 hours with Al ₂ O ₃ powder, and when the binder is a colloidal solution of alumina hydrate, 800 to 1100 ° C. and 1 to 3 for SiC powder.
Time, 1300 to 1600 ° C. with Al ₂ O ₃ powder for 1 to 3 hours, and when the binder is a mixed liquid of colloidal silica liquid and colloid liquid of alumina hydrate,
800-1100 ° C. for 1-3 hours with SiC powder, Al ₂
Sintering is performed at 800 to 1200 ° C. for 1 to 3 hours with O ₃ powder, and when the binder is fine SiC or Al ₂ O ₃ powder, the binder is 900 to 1200 ° C. and 1 to 3 for SiC powder.
Calcination was performed at 1000 to 1500 ° C. for 1 to ₃ hours using Al ₂ O ₃ powder. If the sintering temperature or the sintering time at that temperature is lower or shorter than these ranges, the sintering is not sufficient because the sintering is not sufficiently performed.
The oxide layer on the surface of the C particles increases, and Mg ₂ Si generated by the reaction between the oxide layer and the molten Al does not remain on the SiC surface, but is also generated in a large amount in the matrix to deteriorate the mechanical properties, which is not preferable. On the other hand, in the case of Al ₂ O ₃ powder, sintering proceeds to form closed pores, which is not preferable.

As a method for impregnating the preform with a metal, an alloy mainly composed of aluminum is
The impregnation was performed at a temperature of 1000 ° C. The reason why the metal is made of aluminum alloy is that aluminum alloy has higher rigidity and lower specific gravity than materials such as cast iron, and therefore has high specific rigidity. In addition, when the reinforcing material is SiC powder, the wettability is particularly good and preferable. by. If the impregnation temperature of this alloy is lower than this range, the alloy will not melt, and if it is higher than this range, aluminum will react with the SiC powder to produce aluminum carbide, which is not preferable. The cooling after the impregnation may be rapid cooling for small components, but it is preferable to gradually cool large components because cracks and cracks are likely to occur. Further, in the case of an aluminum alloy containing a large amount of Si, Mg ₂ Si is generated during cooling, and the ductility is reduced by the Mg ₂ Si to lower the fracture toughness.
By gradually cooling g ₂ Si, it is easy to concentrate near the surface of the SiC particles, and by stopping near the surface of the SiC particles, it is possible to suppress a decrease in ductility.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The method for producing a metal-ceramic composite material of the present invention will be described.
A ceramic powder of SiC or Al ₂ O ₃ having an average particle diameter of 100 μm, or a powder containing 10 wt% or less of other powder is used. The ceramic powder may have a single particle size, but it is desirable to mix powders having two types of particle sizes since the filling rate increases and the strength of the compact increases. The molding method can be a conventional method such as a casting method, an injection method, a pressing method, etc., and an example of the casting method will be described below.

About 10 to 50% by weight of ion-exchanged water with respect to the ceramic powder, and the above-mentioned colloidal silica liquid and alumina hydrate colloid liquid as a binder;
A required amount of the mixed liquid or fine powder of SiC or Al ₂ O ₃ powder is blended, and if necessary, an antifoaming agent of 2 wt.
% Or less, and about 2 wt% or less of urea.

The obtained composition is mixed for about 1 hour or more using a pot mill or the like. When a ball is put in a pot mill, the reinforcing material is crushed by the ball, so that the mixing time is at most about 100 hours or less. The mixed slurry is subjected to sedimentation molding by applying vibration. The viscosity of the slurry is preferably 100 poise or less because the powder does not settle if the viscosity is high.
Normally a silicone rubber mold is used, but plastic,
A type such as aluminum may be used, and there is no particular limitation.
During the sedimentation of the particles, vibration is applied as much as possible to improve the filling. The obtained compact is frozen and demolded. Freezing is not limited as long as the water is frozen. The demolded molded body is fired in the air at the firing temperature in the above range for 1 to 3 hours to produce a preform.

The obtained preform is unpressurized or pressurized in a nitrogen stream at a temperature of 700 to 1000 ° C.
-Impregnating with a Si-Mg-based or Al-Mg-based aluminum alloy and then slowly cooling in a furnace to produce a metal-ceramic composite material.

If the metal-ceramic composite material is produced by the above method, a dense and rigid preform having a high powder filling rate and high strength can be obtained. If the preform is impregnated with an aluminum alloy, A metal-ceramic composite material free of cracks and cracks is obtained.

[0023]

EXAMPLES Hereinafter, the present invention will be described in more detail with reference to Examples of the present invention and Comparative Examples.

(Examples 1 to 3) (1) Formation of preform A colloid obtained by stabilizing 25 wt% of ion-exchanged water and a stabilizer of Table 1 with respect to a SiC powder having an average particle size of Table 1 as a reinforcing material. A colloidal silica liquid having a size of 10 to 20 nm (solid content in the silica liquid is 20%) was added in the amount shown in Table 1, and an antifoaming agent (Formaster V manufactured by Sannobuco) was added thereto.
L) was added in an amount of 1.2% by weight, and mixed in a pot mill without balls for 5 hours. 25 × 25 ×
Pour into a 180 mm silicone rubber mold, 4
The reinforcing material was settled by applying vibration for a time to form. After molding, the entire rubber mold was cooled to -25 ° C, frozen, and demolded. After demolding, the preform was fired at a heating rate of 50 ° C./h in the air atmosphere at the firing temperature and firing time shown in Table 1, and then cooled to room temperature at a cooling rate of 50 ° C./h to produce a preform.

(2) Preparation of Metal-Ceramic Composite Material An Al-14Si-2Mg alloy was placed on the obtained preform in the same amount as the preform, and placed in a nitrogen stream at 820 ° C. (2 l / min: furnace volume) 0.03 m ³ ) after impregnating the preform with the alloy at 100 ° C./h in a furnace.
It was cooled to 00 ° C., kept at that temperature for 5 hours, and then cooled again to room temperature at 100 ° C./h to produce a metal-ceramic composite material.

(3) Evaluation The bulk density of the obtained preform was measured by the Archimedes method to determine the powder filling rate of the preform.
The bending strength of the preform was determined by R1601. Further, the bending strength of the obtained composite material was measured according to JIS R1601.
, And further, a test piece having a chevron notch introduced therein was prepared, the bending strength was determined according to JIS R1601, and the fracture toughness value was determined from the value. The distance between the lower fulcrums was 100 mm. Table 1 shows the results.

(Examples 4 to 6) (1) Formation of preform As a reinforcing material, 28% by weight of ion-exchanged water and a stabilizer of Table 1 were stabilized with respect to Al ₂ O ₃ powder having an average particle diameter of Table 1. A colloidal silica liquid having a size of the formed colloid of 10 to 20 nm (solid content in the silica liquid is 20%) was added in the amount shown in Table 1, and an antifoaming agent (Formaster V manufactured by Sannobuco) was added thereto.
L) was added in an amount of 1.2% by weight, and mixed in a pot mill without balls for 5 hours. 25 × 25 ×
Pour into a 180 mm silicone rubber mold, 4
The reinforcing material was settled by applying vibration for a time to form. After molding, the entire rubber mold was cooled to -25 ° C, frozen, and demolded. After demolding, the preform was fired at a heating rate of 50 ° C./h in the air atmosphere at the firing temperature and firing time shown in Table 1, and then cooled to room temperature at a cooling rate of 50 ° C./h to produce a preform.

(2) Preparation of Metal-Ceramic Composite Material An Al-2Mg alloy was placed on the obtained preform in the same amount as the preform, and placed in a nitrogen gas stream at 860 ° C. (2 liters / min; 03m ³ ), the preform was impregnated with the alloy, cooled in a furnace at 100 ° C./h to 700 ° C., kept at that temperature for 5 hours, and then again at 100 ° C./h.
And cooled to room temperature to produce a metal-ceramic composite material.

(3) Evaluation The powder filling rate, bending strength, bending strength and fracture toughness value of the obtained preform were determined in the same manner as in Example 1.
Table 1 shows the results.

(Examples 7 to 9) (1) Formation of Preform Colloid stabilized with ion-exchanged water of 25 wt% and a stabilizer of Table 1 based on SiC powder having an average particle diameter of Table 1 as a reinforcing material Table 1 shows a colloidal solution of alumina hydrate having a size of 10 to 20 nm (solid concentration in the colloidal solution is 20%).
And an antifoaming agent (Fourmaster VL manufactured by Sannobuco) was added to the mixture in an amount of 1.2 wt%, followed by mixing for 5 hours in a pot mill without balls. 25 ×
The mixture was poured into a silicone rubber mold having a size of 25 × 180 mm, and vibrations were applied for 4 hours to settle the reinforcing material and to mold.
After molding, the entire rubber mold was cooled to -25 ° C, frozen, and demolded. After releasing from the mold, sintering was performed at a heating rate of 50 ° C./h in an air atmosphere at a sintering temperature and a sintering time shown in Table 1, and then at 50 ° C./h.
Then, the preform was cooled to room temperature at a temperature lowering rate.

(2) Preparation of Metal-Ceramic Composite Material An Al-12Si-1Mg alloy was placed on the obtained preform in the same amount as the preform, and placed in a nitrogen stream at 850 ° C. (2 l / min: furnace volume) 0.03 m ³ ) after impregnating the preform with the alloy at 100 ° C./h in a furnace.
It was cooled to 00 ° C., kept at that temperature for 5 hours, and then cooled again to room temperature at 100 ° C./h to produce a metal-ceramic composite material.

(3) Evaluation The powder filling ratio, bending strength, bending strength and fracture toughness of the obtained preform were determined in the same manner as in Example 1.
Table 1 shows the results.

(Examples 10 to 12) (1) Formation of preform As a reinforcing material, 30% by weight of ion-exchanged water was used with respect to Al ₂ O ₃ powder having an average particle diameter of Table 1 and stabilized with a stabilizer shown in Table 1. A colloid solution of alumina hydrate having a size of the formed colloid of 10 to 100 nm (solid content concentration in the colloid solution is 20%) was added in the amount shown in Table 1, and an antifoaming agent (Sannobuco Formaster VL) was added thereto. 1.2 wt% was added and mixed for 5 hours in a pot mill without balls. The resulting slurry is
The mixture was poured into a silicone rubber mold having a size of 5 × 25 × 180 mm, and vibration was applied for 4 hours to set the reinforcing material to settle and to mold. After molding, the entire rubber mold was cooled to -25 ° C, frozen, and demolded. After demolding, after firing at the temperature of 50 ° C./h in the air atmosphere at the firing temperature and firing time shown in Table 1, 50 ° C./h
A preform was produced by cooling to room temperature at a temperature lowering rate of h.

(2) Preparation of Metal-Ceramic Composite Material An Al-5Mg alloy was placed on the obtained preform in the same amount as the preform, and placed in a nitrogen stream at 820 ° C. (2 liters / min; 03m ³ ), the preform was impregnated with the alloy, cooled in a furnace at 100 ° C./h to 700 ° C., kept at that temperature for 5 hours, and then again at 100 ° C./h.
And cooled to room temperature to produce a metal-ceramic composite material.

(3) Evaluation The powder filling rate, bending strength, bending strength and fracture toughness value of the obtained preform were determined in the same manner as in Example 1.
Table 1 shows the results.

(Examples 13 to 15) (1) Formation of preform As a reinforcing material, 30 wt% of ion-exchanged water was added to SiC or Al ₂ O ₃ powder having an average particle diameter of Table 1, and SiC or Al of Table 1 was used. ₂ O ₃ fine powder was added in the amount shown in Table 1 and mixed in a pot mill without balls for 5 hours. The resulting slurry is
The mixture was poured into a silicone rubber mold having a size of 5 × 25 × 180 mm, and vibration was applied for 3 hours to set the reinforcing material to settle and to mold. After molding, the entire rubber mold was cooled to -25 ° C, frozen, and demolded. After demolding, after firing at the temperature of 50 ° C./h in the air atmosphere at the firing temperature and firing time shown in Table 1, 50 ° C./h
A preform was produced by cooling to room temperature at a temperature lowering rate of h.

(2) Production of Metal-Ceramic Composite Material On the obtained preform, an alloy of Al-14Si-5Mg is used when the reinforcing material is SiC powder, and an Al-Si alloy is used when the reinforcing material is Al ₂ O ₃ powder. 4Mg alloy was placed in the same amount as the preform, and the preform was impregnated with the alloy in a nitrogen stream at 850 ° C. (2 L / min: furnace volume 0.03 m ³ ).
It was cooled in a furnace at 100 ° C./h to 700 ° C., kept at that temperature for 5 hours, and then cooled again to room temperature at 100 ° C./h to produce a metal-ceramic composite material.

(3) Evaluation The powder filling ratio, bending strength, bending strength and fracture toughness of the obtained preform were determined in the same manner as in Example 1.
Table 1 shows the results.

(Comparative Example 1) (1) Formation of preform As a reinforcing material, an aluminum phosphate solution having 21% by weight of ion-exchanged water and a solid concentration of 30% was added to a green SiC powder having an average particle diameter of Table 2. 4 wt% was added and mixed for 4 hours in a pot mill without balls. The obtained slurry was poured into a silicone rubber mold having a size of 25 × 25 × 180 mm, and vibration was applied for 4 hours to set a reinforcing material and settle. After the molding, the whole rubber mold was cooled to -40 ° C, frozen, and demolded. After demolding, the resultant was fired at 1200 ° C. for 2 hours in an air atmosphere at a temperature rising rate of 70 ° C./h, and cooled to room temperature at a temperature decreasing rate of 50 ° C./h to produce a preform.

(2) Preparation of Metal-Ceramic Composite Material An Al-14Si-2Mg alloy was placed on the obtained preform in the same amount as the preform, and placed in a nitrogen stream at 820 ° C. (2 l / min: furnace volume) 0.03 m ³ ) after impregnating the preform with the alloy at 100 ° C./h in a furnace.
It was cooled to 00 ° C., kept at that temperature for 5 hours, and then cooled again to room temperature at 100 ° C./h to produce a metal-ceramic composite material.

(3) Evaluation The powder filling rate, bending strength, bending strength and fracture toughness value of the obtained preform were determined in the same manner as in Example 1.
Table 2 shows the results.

(Comparative Examples 2 to 4) In Comparative Example 2,
The Na ⁺ concentration to a concentration shown in Table 2, in Comparative Example 3, the sintering temperature and its time of Example 1 to a temperature and time shown in Table 2,
In Comparative Example 4, a preform was prepared and impregnated with an alloy in the same manner as in Example 1 except that the amount of the binder added in Example 2 was changed to Table 2, and the obtained composite material was evaluated. Table 2 shows the results.

(Comparative Examples 5 to 7) In Comparative Example 5, Example 4
The Na ⁺ concentration to a concentration shown in Table 2, in Comparative Example 6, the sintering temperature and its time of Example 4 and the temperature and time shown in Table 2,
In Comparative Example 7, a preform was prepared and impregnated with an alloy in the same manner as in Example 4 except that the amount of the binder added in Example 4 was changed to Table 2, and the obtained composite material was evaluated. Table 2 shows the results.

(Comparative Examples 8 to 10) In Comparative Example 8, the amount of the binder added in Example 7 is shown in Table 2, and in Comparative Example 9,
The firing temperature and time in Example 8 were set to the temperature and time in Table 2. In Comparative Example 10, except that the crystalline form of the alumina hydrate of Example 8 was changed to crystalline boehmite, the same procedure as in Example 8 was repeated. A reform was produced, the alloy was impregnated, and the obtained composite material was evaluated. Table 2 shows the results.

Comparative Examples 11 to 13 In Comparative Example 11, Table 2 shows the amounts of the binders added in Example 10 and Comparative Example 1
In Example 2, the firing temperature and time in Example 11 were set to the temperature and time in Table 2, and in Comparative Example 13, Example 1 was changed except that the crystalline form of the alumina hydrate in Example 11 was changed to crystalline boehmite.
A preform was prepared and impregnated with an alloy in the same manner as in Example 1, and the obtained composite material was evaluated. Table 2 shows the results.

(Comparative Examples 14 and 15) In Comparative Example 14, the firing temperature and time in Example 13 were set as the temperature and time in Table 2, and in Comparative Example 15, the firing temperature and time in Example 14 were compared in Table 2. A preform was prepared and impregnated with an alloy in the same manner as in Examples 13 and 14 except that the temperature and the time were set as described above, and the obtained composite material was evaluated. Table 2 shows the results.

[0047]

[Table 1]

[0048]

[Table 2]

As is clear from Table 1, in each of the examples, the powder filling ratio was about 60% or more, and the bending strength was more than 1.5 MPa, and the solid preform was solid. In addition, no cracks or cracks occurred in the metal-ceramic composite material using aluminum as a matrix produced from the preform.

On the other hand, in Comparative Example 1, the powder filling rate,
The flexural strength was similar to that of the example, but the mechanical properties of the composite material were deteriorated because it was not the binder of the present invention. In Comparative Examples 2 and 5, since the Na ⁺ concentration of the stabilizer was high, in Comparative Examples 3, 6, 9, 12, 14, and 15,
Since the calcination temperature and the calcination time are high, low, or long, in Comparative Examples 10 and 13, since the crystal form of the alumina hydrate of the binder is not amorphous but crystalline boehmite, both are complex. The mechanical properties of the material deteriorated, and impregnation with metal became impossible. Furthermore, in Comparative Examples 4, 7, 8, and 11, since the amount of the binder added was large, closed pores were formed, or the strength of the preform was low, and cracks were formed, so that the metal could not be impregnated.

[0051]

According to the above-mentioned method, a metal-ceramic composite material is produced, whereby a dense and rigid preform having a high powder filling rate and high strength can be obtained, and the preform can be impregnated with an aluminum alloy. For example, a metal-ceramic composite material free from cracks and cracks can be obtained.
In addition, if a preform powder type, a powder filling rate, and a binder type are selected and produced, a metal-ceramic composite material having a necessary strength and a fracture toughness value corresponding thereto is obtained. became. Thus, the required fracture toughness value and strength can be selected, which is sufficiently useful for designing mechanical parts.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Heishiro Takahashi 314-1 Matsudo Nitta, Matsudo City, Chiba Prefecture (72) Mutsui Hayashi 560 Omaki, Urawa City, Saitama Prefecture

Claims (10)

[Claims] 1. A method for producing a metal-ceramic composite material in which a preform is formed using ceramic fibers or particles as a reinforcing material, and the preform is impregnated with a metal as a base material. .0
Water is used as a binder as a binder for the SiC powder having an average particle size of about 100 μm, and Na ⁺ or NH _{4 is used.}
A colloidal silica liquid having a size of 5 to 50 nm with ⁺ as a stabilizer is added in an amount of 0.5 to 25% by weight (0.1 to 5.0% by weight as silica) and molded, and then the molded body is 800 to 1100%. Metal for 1 to 3 hours at a temperature of 700 ° C., and an alloy containing aluminum as a main component is impregnated in the formed preform at a temperature of 700 to 1000 ° C. Manufacturing method of ceramic composite material. 2. A method for producing a metal-ceramic composite material in which a preform is formed by using ceramic fibers or particles as a reinforcing material and the preform is impregnated with a metal serving as a base material, wherein the method for forming the preform is as follows. .0
For Al ₂ O ₃ powder having an average particle size of １００100 μm,
Water is used as a binder as a dispersion medium, and Na ⁺ or N
Colloid having H ₄ ⁺ as stabilizer is 5 to 50 nm in size
After adding 0.5 to 25% by weight (0.1 to 5.0% by weight of silica) of the colloidal silica liquid and molding, the molded body is fired at a temperature of 800 to 1200 ° C. for 1 to 3 hours. And a method of manufacturing a metal-ceramic composite material, wherein the formed preform is impregnated with an alloy containing aluminum as a main component at a temperature of 700 to 1000 ° C. 3. A method for producing a metal-ceramic composite material in which a preform is formed by using ceramic fibers or particles as a reinforcing material, and the preform is impregnated with a metal as a base material, wherein the preform is formed by the following method. .0
With respect to SiC powder having an average particle size of about 100 μm, water is used as a binder as a dispersion medium, and Cl ⁻ , CH ₃ COO ⁻
Alternatively, the size of the colloid using NO ₃ ^- as a stabilizer is 1
-1000 nm alumina hydrate colloid solution
After molding by adding ３０30 wt% (0.1 to 10 wt% as alumina), the formed body is fired at a temperature of 800 to 1100 ° C. for 1 to 3 hours, and aluminum is applied to the formed preform. A method for producing a metal-ceramic composite material, comprising impregnating an alloy as a main component at a temperature of 700 to 1000C. 4. A method for producing a metal-ceramic composite material in which a preform is formed by using ceramic fibers or particles as a reinforcing material, and the preform is impregnated with a metal as a base material, wherein the preform is formed by the following method. .0
For Al ₂ O ₃ powder having an average particle size of １００100 μm,
Using water as a dispersion medium as a binder, Cl ⁻ , CH ₃ COO
^- or NO ₃ ^- in the colloid stabilizing agent magnitude colloidal solution of alumina hydrate of 1 to 1,000 nm 1.
0-30 wt% (0.1-10 wt% as alumina)
After the addition and molding, the molded body is fired at a temperature of 1300 to 1600 ° C for 1 to 3 hours, and an alloy containing aluminum as a main component is formed on the formed preform at a temperature of 700 to 1000 ° C. A method for producing a metal-ceramic composite material, characterized in that the composite material is impregnated. 5. A method for producing a metal-ceramic composite material in which a preform is formed by using ceramic fibers or particles as a reinforcing material, and the preform is impregnated with a metal as a base material. .0
Water is used as a binder as a binder for the SiC powder having an average particle size of about 100 μm, and Na ⁺ or NH _{4 is used.}
⁺ A colloidal silica solution the size of 5~50nm colloid stabilizing agent, Cl ^-, CH ₃ COO ^- or NO ₃ ^- the size of the colloid stabilizing agent 1 to 100
A colloidal solution of 0 nm alumina hydrate is mixed with the silica component so that the silica component is 10 to 80% with respect to the alumina component, and the mixed solution is 1.0 to 30 wt% (0.1 to 5.0 wt% as silica + alumina). After the addition molding, the molded body is fired at a temperature of 800 to 1100 ° C. for 1 to 3 hours, and an alloy containing aluminum as a main component is formed on the formed preform at a temperature of 700 to 1000 ° C. A method for producing a metal-ceramic composite material, characterized by impregnating with a metal. 6. A method for producing a metal-ceramic composite material in which a preform is formed by using ceramic fibers or particles as a reinforcing material, and the preform is impregnated with a metal as a base material, wherein the preform is formed by the following method. .0
Water is used as a binder as a binder in Al ₂ O ₃ powder having an average particle size of about 100 μm, and Na ⁺ or NH ₄ ⁺
Colloidal silica solution 5~50nm the magnitude of the colloid stabilizing agent, Cl ^-, CH ₃ COO ^- or N
The size of the colloid having O ₃ ^- as a stabilizer is 1 to 1000
and a colloidal solution of alumina hydrate having a particle size of 10 nm to 80% with respect to the alumina component. After the addition molding, the molded body is fired at a temperature of 800 to 1200 ° C. for 1 to 3 hours, and an alloy containing aluminum as a main component is formed on the formed preform at a temperature of 700 to 1000 ° C. A method for producing a metal-ceramic composite material, characterized by impregnating with a metal. 7. Na ⁺ concentration in the binder was stabilizers the Na ⁺ is, 0.05～0.4Wt in terms of Na ₂ O
%. The method for producing a metal-ceramic composite material according to claim 1, 2, 5 or 6. 8. The metal-ceramic composite according to claim 3, wherein the crystal form of the alumina hydrate in the binder containing Cl ⁻ as a stabilizer is amorphous. Material manufacturing method. 9. A method for producing a metal-ceramic composite material in which a preform is formed by using ceramic fibers or particles as a reinforcing material, and the preform is impregnated with a metal as a base material, wherein the method for forming the preform comprises: ~
After adding 1.0 to 10 wt% of an Al ₂ O ₃ powder or an SiC powder having an average particle diameter of 1.0 μm or less to a SiC powder having an average particle diameter of 100 μm as a binder, and molding the resultant, 900 to 1200 The method is to bake at a temperature of 1 to 3 hours, and an alloy containing aluminum as a main component is 700 to 1 in the formed preform.
A method for producing a metal-ceramic composite material, comprising impregnating at a temperature of 000 ° C. 10. A method for producing a metal-ceramic composite material in which a preform is formed using ceramic fibers or particles as a reinforcing material, and the preform is impregnated with a metal serving as a base material.
For Al ₂ O ₃ powder having an average particle size of １００100 μm,
Al ₂ O ₃ having an average particle size of 1.0 μm or less as a binder
After adding 1.0 to 10 wt% of powder or SiC powder and molding, the molded body is heated at a temperature of 1000 to 1500 ° C. for 1 to 1%.
It is a method of firing for 3 hours, and an alloy containing aluminum as a main component is 700
A method for producing a metal-ceramic composite material, characterized in that the impregnation is performed at a temperature of from 1000 ° C to 1000 ° C.