JPH11770A - Aluminum honeycomb and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an aluminum honeycomb superior in high temperature strength, heat resistance, corrosion resistance, etc., by diffusion welding in which magnesium vaporized by pressurizing and heating removes by reduction the oxide film on the texture of an aluminum alloy foil. SOLUTION: An aluminum honeycomb is manufactured using an Mg containing aluminum alloy foil AL as the base material for the cell wall. The cell wall is formed by joining in striation the aluminum alloy foil AL, the base material for the cell wall, by diffusion welding. In other words, using the Mg containing aluminum alloy foil AL as the cell wall base material, the oxide film 3 on the texture 2 surface is removed by reduction through pressurizing and heating, with the cell walls diffusion-welded to each other in striation. With a release agent arranged on the base material at a specific width and pitch, diffusion welding is performed on the texture in contact left in striation between the release agent. Thus, the cell walls are diffusion-welded to each other without using an adhesive or a filler metal.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to an aluminum honeycomb and a method for manufacturing the same. That is, the present invention relates to an aluminum honeycomb formed of a planar aggregate of a large number of hollow columnar cells and using an aluminum alloy foil as a base material, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Aluminum honeycombs, like other general honeycomb cores, have conventionally been manufactured by a stretching method or a corrugating method, and the striations between cell walls are bonded by bonding or brazing. I was In the stretching method, first, an adhesive or brazing material is applied to an aluminum alloy foil as a base material in a linear manner, and then a large number of sheets are shifted by half a pitch of the adhesive or brazing material applied in a linear manner. The blocks are stacked in a relationship, and then the blocks are glued or brazed by applying pressure and heat, and then stretched by applying a tensile force in the stacking direction. Thereby, the aluminum alloy foil that has been glued or brazed and stretched linearly is used as a cell wall, and is a planar aggregate of a large number of hollow columnar cells defined by such a cell wall. Manufacture of aluminum honeycomb. On the other hand, in the corrugated method, first, after forming an aluminum alloy foil as a base material into a corrugated sheet, a large number of sheets are displaced by half a pitch of a wave so that a valley portion and a top portion are aligned, while maintaining a space. After stacking, the members are bonded or brazed with each other with an applied or interposed adhesive or brazing material by applying pressure and heating. Thereby, the corrugated sheet which is glued or brazed in a line shape and stacked together is used as a cell wall, and an aluminum honeycomb, which is a planar aggregate of a large number of hollow columnar cells partitioned and formed by the cell wall, is formed. Had been manufactured.

[0003]

The following problems have been pointed out in such a conventional example. First,
The following first, second, and third problems have been pointed out with respect to aluminum honeycombs that are bonded in a strip shape using an adhesive and that are manufactured by a stretching method or a corrugating method. First, a problem has been pointed out that the performance of the aluminum honeycomb is affected by the performance of the adhesive. That is,
The overall high-temperature strength, heat resistance, corrosion resistance, etc. of the manufactured aluminum honeycomb is determined by the high-temperature strength, heat resistance, corrosion resistance, etc. of the adhesive used for partial striation bonding between cell walls.
Domination, had been decided. As described above, the conventional aluminum honeycomb using the adhesive has the basic performance of the aluminum alloy foil as the base material, that is, aluminum, regardless of whether it is of the expansion type or the corrugation type, that is, excellent high-temperature strength, heat resistance, It was not pointed out that corrosion resistance and the like were not utilized, and difficulties were pointed out in performance aspects such as high-temperature strength, heat resistance, and corrosion resistance. Second
In addition, a problem has been pointed out that when an aluminum honeycomb is used outdoors, the adhesive is deteriorated by ultraviolet rays. That is, in the manufactured aluminum honeycomb, the cell walls are partially adhered to each other in the form of striations. However, when the honeycomb is used outdoors, the adhesive for the adhesion is exposed to ultraviolet rays contained in sunlight. It was easy to deteriorate. As described above, the conventional aluminum honeycomb using the adhesive easily deteriorates regardless of the expansion system and the corrugation system, and a problem has been pointed out on the quality maintaining surface such as the shape. Third, in manufacturing,
First, it was necessary to pretreat and wash the aluminum alloy foil as a base material with a highly toxic and harmful organic solvent, alkali, strong acid or the like. In other words, in order to prepare for subsequent bonding, highly toxic harmful substances must be used in order to remove oils and fats and dust on the surface of the aluminum alloy foil as a base material in advance. The problem was pointed out.
In addition, toxic gas is generated from the adhesive which is melted and hardened during the striation by pressurizing and heating during production, and this aspect also involves danger in production, and problems have been pointed out in terms of safety. As described above, the conventional aluminum honeycomb using the adhesive has a problem in terms of safety at the time of manufacturing, regardless of whether it is of the expansion type or the corrugated type.

[0004] With regard to the conventional aluminum honeycomb cores which are adhered in a strip shape using an adhesive and which are manufactured by a stretching method or a corrugated method, the first, second, and second aluminum honeycomb cores are thus obtained.
A third problem was pointed out. Next, the conventional aluminum honeycomb core manufactured by the brazing method or the corrugated method while being brazed in a strip shape using a brazing material is described in the following fourth, fifth, sixth, and sixth aspects. Seven problems were pointed out.

Fourthly, in this aluminum honeycomb, the cell walls are brazed by using a brazing material. At the time of brazing, an erosion phenomenon and an intermetallic compound layer are easily generated.
The problem was pointed out. In other words, when brazing wire by pressurization and heating during manufacturing, an erosion phenomenon occurs in the aluminum alloy foil, corrugated plate, and cell wall as the base material to be brazed, and mechanical delamination, erosion, Holes and the like were easily generated. Furthermore, at the time of brazing, a brittle intermetallic compound layer in which the aluminum alloy foil and the brazing material were melted was easily formed between the aluminum alloy foil, the corrugated sheet, and the cell walls to be brazed. As described above, the conventional aluminum honeycomb using the brazing material, regardless of whether it is of the expansion type or the corrugated type, has the problem of erosion phenomenon and embrittlement due to the formation of an intermetallic compound layer at the cell wall during manufacturing. There was a problem of quality, and it was easy to have difficulties in quality. Fifth, in order to suppress such an erosion phenomenon and the formation of an intermetallic compound layer, brazing by pressurizing and heating must be performed in an extremely short time. However, brazing tends to be incomplete, and especially when manufacturing an aluminum honeycomb by the stretching method, when the aluminum alloy foil as a base material stacked in a block shape at the time of pressurization and heating, the center of the block is In some cases, the temperature does not reach the brazing temperature and the brazing is stopped. As described above, the aluminum honeycomb using the brazing material is liable to cause poor brazing and joining failure between the cell walls, and from this aspect, a problem has been pointed out in terms of quality.

Sixth, as a brazing material, a powdery or paste-like brazing material is often used, and such a brazing material is applied to an aluminum alloy foil or a corrugated sheet as a base material to be brazed. It has been pointed out that it is not easy to control the amount of application and the positioning in the form of a stripe when applying. In particular, paste-type brazing materials are often used, especially when manufacturing by the stretch method, but such paste-like brazing materials are easy to flow, and are precisely applied to the aluminum alloy foil as the base material in a linear manner. It is not easy to perform the positioning, and it is also not easy to hold the positioning in the form of a stripe. In the case of manufacturing by a corrugation method, a powdery or paste-like brazing material is accurately and uniformly applied to a brazing target portion of a corrugated sheet made of aluminum alloy foil, that is, a valley portion or a top portion in a linear manner. It was not easy to apply. As described above, in the conventional aluminum honeycomb using the powdery or paste-like brazing material, it is difficult to accurately control the line of the brazing material and to control the amount of application, and the quality tends to be unstable. Seventh, if there is a corrugated manufacturing method using brazing material there,
In place of such a powdery or paste-like brazing material, a brazing sheet, that is, a brazing filler previously made into a plate-like shape, may be used. However, a brazing sheet having a thickness of 100 μm or less is difficult to obtain at present, and is heavy. Therefore, it has been difficult to reduce the weight of aluminum honeycombs manufactured by the corrugation method using such a brazing sheet as a brazing material, and a problem in terms of weight has been pointed out. The conventional aluminum honeycomb manufactured by the brazing method and the corrugating method while being brazed in a strip shape using the brazing material has the fourth, fifth, sixth, and seventh problems as described above. Was pointed out. In addition, regarding the conventional aluminum honeycomb using the brazing material as described above, in addition to the above, a problem has been pointed out with respect to the corrosion resistance according to the above-described first. In other words, the aluminum alloy foil and the brazing material are made of different kinds of metal materials, but the cell wall made of the aluminum alloy foil as a base material and the brazing material, which is a different kind of metal, are in contact with each other at the line brazing portion. For this reason, there has been a problem in corrosion resistance. That is, the corrosion resistance, which is one example of the excellent basic performance of the aluminum alloy foil as the base material, was not utilized in the aluminum honeycomb, and a problem was pointed out in the corrosion resistance.

The present invention has been made in view of such circumstances, and has been made in order to solve the above-mentioned problems of the prior art. An aluminum alloy foil containing magnesium is used as a base material of a cell wall, and the pressure and pressure are reduced. By heating, the oxide film on the ground surface of the aluminum alloy foil is reduced and removed, and diffusion bonding is performed between the cell walls in a linear fashion, that is, the space between the cell walls is used without using an adhesive or brazing material. The purpose of the following is achieved by connecting the striations. That is,
First, it has excellent high-temperature strength, heat resistance, corrosion resistance, etc. Second,
Thirdly, it does not deteriorate even when used outdoors. Thirdly, it does not use harmful substances and produces no toxic gas during production. Fourthly, it does not generate erosion phenomenon or brittle intermetallic compound layer. Defects are prevented, sixth, quality is stable, seventh, weight saving is promoted, eighth, cost is excellent, and ninth, pressurization and
An object of the present invention is to propose an aluminum honeycomb and a method for manufacturing the same, in which heating can be performed easily and easily at relatively low pressure, low temperature, and short time.

[0008]

The technical means of the present invention for solving such a problem is as follows. First, claim 1 is as follows. That is, this claim 1
Is composed of a planar aggregate of a large number of hollow columnar cells defined by cell walls joined in a stripe shape. As a base material of the cell wall, an aluminum alloy foil containing magnesium is used, and the cell wall is formed by joining an aluminum alloy foil as a base material in a striped manner by diffusion bonding. The magnesium vaporized by pressurizing and heating reduces and removes an oxide film on the ground surface of the aluminum alloy foil;
Is performed by the following.

Next, claim 2 is as follows. That is, in the method for manufacturing an aluminum honeycomb according to the second aspect, first, a release agent is applied to an aluminum alloy foil as a base material containing magnesium at a predetermined interval while leaving the ground in a line shape at a constant width and pitch. And arrange them. Then, after stacking a plurality of the aluminum alloy foils in a positional relationship in which the background left in the form of a stripe is shifted by a half pitch,
By pressurizing and heating, the aluminum alloy foils are diffusion-bonded to each other at the ground in contact with the mold release agent, which remains in the form of striations between the release agents. Then, each aluminum alloy foil is bent along the edge of the streak-shaped diffusion bonding portion by applying a tensile force in the stacking direction and expanded, and portions other than the diffusion bonding portion are separated. , Separated. Thus, such an aluminum alloy foil is used as a cell wall, and an aluminum honeycomb, which is a planar aggregate of a large number of hollow columnar cells defined by the cell wall, is obtained.

[0010] Claim 3 is as follows. That is, in the method for manufacturing an aluminum honeycomb according to the third aspect, first, an aluminum alloy foil serving as a base material containing magnesium is corrugated into a corrugated sheet in which corrugations are continuously bent. Then, a plurality of the corrugated sheets are displaced by half a pitch of the wave and stacked in a positional relationship of matching the valley and the top, and then pressurized and heated so that the corrugated valleys of the corrugated sheets are brought into contact. And diffusion bonding between the top and the background. Thus, the corrugated sheet diffused and bonded in the form of a stripe is used as a cell wall, and an aluminum honeycomb, which is a planar aggregate of a large number of hollow columnar cells defined by the cell wall, is obtained. .

[0011] Claim 4 is as follows. That is, the method for manufacturing an aluminum honeycomb according to a fourth aspect of the present invention is the following in the method for manufacturing an aluminum honeycomb according to the second or third aspect. That is, the magnesium is contained in the aluminum alloy foil in an amount of 0.1% by weight or more, and the diffusion bonding is performed in a low oxygen concentration atmosphere such as a vacuum or an inert gas atmosphere and at 400 ° C.
The method is characterized in that the magnesium vaporized by heating as described above reduces and removes an oxide film on the ground surface of the aluminum alloy foil.

The aluminum honeycomb and the method for manufacturing the same are configured as described above, and are as follows.
That is, the aluminum alloy foil containing magnesium is used as a base material, and is stacked while using a release agent in the stretching method, and is stacked after corrugating in the corrugated method.
Then, by pressurization and heating, magnesium is vaporized,
It reacts with the oxide film that has firmly and stably covered the surface of the aluminum alloy foil, and reduces, removes, destroys, and disperses it. Then, the aluminum of the aluminum alloy foil is exposed and contacts in a solid state, and diffusion bonding proceeds. In the corrugated method, this is performed, and in the expanded method, further expansion is performed afterwards, so that an aluminum alloy foil (and a corrugated sheet) is used as a cell wall, and a planar aggregate of a large number of hollow columnar cells defined by the cell wall. A barrel, aluminum honeycomb is obtained. And this aluminum honeycomb,
Without using an adhesive or a brazing filler metal, the cell walls are connected by a strip line by diffusion bonding.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail based on embodiments of the invention shown in the drawings. FIG. 1, FIG. 2,
3 and 4 are provided for explaining the embodiment of the present invention. FIG. 1 is a perspective explanatory view for explaining an example of application to the stretching method as one example. FIG. 1A shows a state in which an aluminum alloy foil is provided, and FIG. 1B shows a state in which a release agent is provided. And (3)
The figure shows the cut state, and the figure (4) shows the stacked state.
FIG. 5 (5) shows a state of diffusion bonding, and FIG. 6 (6) shows an expanded state. FIG. 2 is a front view for explaining an example of application to a corrugated method as another example. (1) FIG. 2 shows an aluminum alloy foil, (2) FIG.
FIG. 3 (3) shows a formed corrugated sheet, and FIG. 4 (4) shows a corrugated sheet which has been stacked and diffusion bonded. FIG. 3 is a perspective view of the obtained aluminum honeycomb. FIGS. 4A and 4B are explanatory diagrams showing the principle of diffusion bonding. FIG. 4A shows a pair of aluminum alloy foils to be bonded, FIG. 4B shows a heated state thereof, and FIG. FIG. 4D shows a state of diffusion bonding, in which the state is reduced and removed.

First, the manufacturing method of the present invention will be described with reference to an example of the stretching method shown in FIG. In the method for manufacturing the aluminum honeycomb 1 by the stretching method, first, as shown in FIG. 1A, an aluminum alloy foil as a base material containing magnesium Mg (see FIG. 4A). AL is prepared. That is, this aluminum alloy foil AL
In addition to containing 0.1% by weight or more of magnesium Mg,
Silicon Si, iron Fe, copper Cu, manganese Mn, chromium Cr, zinc Zn, titanium Ti, etc. are selectively or entirely contained. And this aluminum alloy foil AL
Is in the form of a sheet, thin plate, or strip as it is rolled,
Thickness of 1 mm or less is usually used,
m or more can be used, typically 0.13 m
m is used. Then, FIG.
(2) As shown in the figures, this aluminum alloy foil A
An oxide film 3 is firmly and stably formed on the surface of the background 2 of L. That is, the surface 2 of the base 2 of the aluminum alloy foil AL is usually covered with the oxide film 3, and even if it is polished mechanically or chemically, it is immediately oxidized to form the oxide film 3, and the oxide film 3 is formed. Is known as alumina AL ₂ O ₃ .

Next, in this manufacturing method, as shown in FIG. 1 (2), the release agent 4 is applied to such an aluminum alloy foil AL in a striped manner at a constant width and pitch. 2 are arranged at predetermined intervals while leaving 2. That is, the release agent 4
In the illustrated example, is disposed at a constant pitch with a small interval so as to leave the ground 2 in a striped shape with a narrow constant width and a pitch on one side of the aluminum alloy foil AL, for example, by coating or the like. Examples of the release agent 4 include ceramic powder spray, boron nitride powder, and others in a narrow sense, as well as vinyl tape, adhesive tape, oil-based ink,
Volatile inks, carbon paper, and other broadly used masking agents can also be used.

Then, in this manufacturing method, the aluminum alloy foil AL in which the release agent 4 is provided and the ground surface 2 is left in the form of a stripe as shown in FIG. ,
It is cut from the band at regular intervals. Then, as shown in FIG. 1 (4), a plurality of aluminum alloy foils AL cut in this way, for example, a large number of aluminum alloy foils AL have They are stacked in a block shape with a positional relationship shifted by half a pitch. That is, in the multiple aluminum alloy foils AL, the ground surface 2 left in a streak shape on one side is vertically stacked in a block shape in a positional relationship shifted by a half pitch from side to side from top to bottom.

Thereafter, in this manufacturing method, as shown in FIG. 1 (5), by applying pressure and heating,
Between the aluminum alloy foils AL stacked in a block shape,
Diffusion bonding is performed at the ground 2 that remains in contact between the release agents 4 in the form of striations. This diffusion bonding is performed in a low oxygen concentration atmosphere such as a vacuum or an inert gas atmosphere.
As shown in FIG. 4, (1), (2), (3), (4), etc., magnesium Mg vaporized by heating at 400 ° C. or more forms the surface of the aluminum alloy foil AL. This is performed by reducing and removing the oxide film 3 on the surface 2.

The diffusion bonding and the like will be described in more detail. First, in each of the aluminum alloy foils AL in the illustrated example, a release agent 4 is disposed on one surface (for example, the surface) thereof, and
Is streaked, while the other side (for example, the back side)
In this case, the release agent 4 is not provided, and the entire surface remains as the ground surface 2. Therefore, the stacked aluminum alloy foil AL
Between each other, the linear background 2 on one side and the entire surface 2 on the other side are in direct contact and close contact with each other, and are thus diffusion-bonded at the linear background 2. Diffusion bonding is performed as follows. First, as shown in FIG. 4A, magnesium M contained in the vicinity of the ground 2 of the aluminum alloy foil AL
As shown in FIG. 4 (2), g is vaporized by heating, gathers on the surface of the background 2, and reacts with the oxide film 3 covering the surface of the background 2. In other words, magnesium Mg has a higher vapor pressure than aluminum (it easily evaporates even if the pressure is high).
It is a metal with high activity and has a strong affinity for oxygen, so it is oxidized to reduce the oxide film 3 made of AL ₂ O ₃ ,
Thus, as shown in FIG. 4 (3), a product 5 made of MgAL ₂ O ₄ is produced. In this manner, the oxide film 3 on the surface 2 of the aluminum alloy foil AL becomes the product 5 and is reduced, removed, destroyed, and dispersed. Therefore, for the background 2 of the aluminum alloy foil AL,
As shown in FIG. 4 (4), the aluminum is exposed in a solid state, and the aluminum alloy foil AL having the aluminum exposed as described above is diffused by contact and adhesion by pressing. Joining is performed to form a striped diffusion joining portion 6. That is, the atoms are densely bonded between the ground 2 of the aluminum alloy foil AL by diffusion and movement of the atoms at the grain boundaries.

Such diffusion bonding is performed in a furnace or the like under the following conditions of temperature, pressure, time, atmosphere, and the like. First, the temperature condition is set to 400 ° C. or higher. That is, when the heating is lower than 400 ° C., the vaporization of magnesium Mg in the aluminum alloy foil AL, which is a premise of the diffusion bonding, becomes insufficient or unsatisfactory, and the oxide film 3 is not reduced and removed. Next, the pressure condition, that is, the load, is preferably 1 gf / mm ² or more. That is, if the pressure is less than 1 gf / mm ² , contact and adhesion between the aluminum alloy foils AL required for diffusion bonding cannot be obtained. Further, the time condition, that is, the pressurization and heat treatment time is set in the range of about 5 minutes to about 10 hours in consideration of the other conditions. In any case, if the treatment time is too short, for example, less than 5 minutes, the vaporization of magnesium Mg in the aluminum alloy foil AL, which is a prerequisite for diffusion bonding, becomes insufficient or unsatisfactory, and the oxide film 3 is reduced. Insufficient removal. On the other hand, if it is too long, for example, more than 10 hours, magnesium Mg will be excessively vaporized from the aluminum alloy foil AL, and the strength of the aluminum alloy foil AL will be reduced afterwards. That is,
Magnesium M contained in aluminum alloy foil AL
g functions to improve the strength of aluminum as is well known, so it is necessary that all of them remain in an appropriate amount without being vaporized, and when magnesium Mg is excessively removed, the aluminum alloy foil AL is used as a base material. The strength of the damaged cell wall is reduced. Next, as an atmospheric condition, the process is performed in a vacuum or a low oxygen concentration atmosphere such as an inert gas atmosphere while paying attention to overall prevention of oxidation. Preferably, the oxygen content is 1,000 ppm or less and the water content is 80 p.
pm or less. Under such conditions of temperature, pressure, time, atmosphere, etc., aluminum alloy foil AL
Diffusion bonding between them is performed. Specific values for each condition are determined as appropriate. Next, three specific examples will be described.

First, an example of the case where the aluminum alloy foil AL having a thickness of 0.13 mm and having a weight ratio constitution shown in Table 1 and having a JIS standard No. 6951 is used is as follows. In this example, the temperature is 600 ° C,
The pressure was set to 3 gf / mm ² , the time was set to 20 minutes, the atmosphere was set to nitrogen gas having an oxygen concentration of 50 ppm, and boron nitride powder was used as the release agent 4. Next, as the aluminum alloy foil AL, the thickness is 0.13 m.
In the case where m is the same as the weight ratio configuration shown in Table 1 and the JIS standard No. 6951 is used, another example is as follows. In another example, the temperature is between 450 ° C and 58 ° C.
0 ° C., pressure is 1 gf / mm ² to 5 gf / mm ² ,
The time was set to 30 minutes to 1 hour, the atmosphere was set to a vacuum of 10 ⁻³ torr to 10 ⁻⁵ torr, and a boron nitride powder was used as the release agent 4. An example of the case where the aluminum alloy foil AL having a thickness of 0.13 mm and having a weight ratio configuration shown in Table 2 and having a JIS standard name of 5052 is used is as follows. In this example, the temperature is 550 ° C. and the pressure is 3 gf / m
m ² , the time was 30 minutes, the atmosphere was set to a vacuum of about 10 ⁻³ torr, and a boron nitride powder was used as the release agent 4.

[0021]

[Table 1]

[0022]

[Table 2]

Now, in this manufacturing method,
Aluminum alloy foil A as a base material stacked in a block shape
As for L, diffusion bonding is performed as shown in FIG. 1 (5). Thereafter, in this manufacturing method, expansion is performed as shown in FIG. 1 (6). That is,
By applying a tensile force in the stacking direction and expanding, the stacked aluminum alloy foils AL are folded along the edges of the linear diffusion bonding portions 6 (see also FIG. 4 (4)). While being bent, portions other than the diffusion bonding portion 6 are separated and separated. That is, the aluminum alloy foils AL stacked in a block shape and diffusion-bonded in a strip shape as described above
Is stretched by applying a tensile force upward and downward along the direction of stacking up and down as indicated by the arrow. Therefore, each aluminum alloy foil AL
Are bent up and down along the edge of the striped diffusion bonding portion 6, and portions other than the diffusion bonding portion 6 are vertically separated and separated.

In the manufacturing method of the stretching system shown in FIG. 1, the aluminum honeycomb 1 is manufactured by following these steps. That is, as shown in FIG. 3, the aluminum honeycomb 1 serving as a planar aggregate of a large number of hollow columnar cells 8 formed by the aluminum alloy foil AL as the cell walls 7 and formed by the cell walls 7 is obtained. The expansion method in FIG. 1 is as described above.

Next, a manufacturing method based on the corrugated method shown in FIG. 2 will be described. In this manufacturing method using the corrugated method, first, FIG. 2 (1), FIG.
(3) As shown in the figures and the like, the aluminum alloy foil AL as a base material containing magnesium Mg (see FIG. 4 (1)) is a corrugated sheet in which corrugations are continuously bent. 9
Is corrugated.

These will be described in more detail. First, FIG.
As shown in FIG. 1A, the aluminum alloy foil AL containing magnesium Mg prepared as a base material is the same as that described in the production method of the stretching method shown in FIG. . Then, the aluminum alloy foil AL prepared as described above is, as shown in FIG. 2 (2), a corrugating apparatus provided with a jig 10 such as a rack and a rack, a gear and a gear, and a gear and a rack. Supplied. Then, by applying pressure and heating, as shown in FIG. 2 (3), the irregularities of the waveform are linearly parallel to the short direction and continuously repeated in the long direction at a predetermined pitch and height. Is corrugated. The cross-sectional shape of the corrugations of the corrugated plate 9 is not limited to the trapezoidal shape shown, but may be substantially triangular, substantially square,
Other various shapes are also conceivable.

Then, in this manufacturing method, as shown in FIG. 2D, a plurality of corrugated sheets 9 are shifted by a half pitch of the wave and stacked in a positional relationship where the valley and the top are aligned. Then, by pressurizing and heating, diffusion bonding is performed between the valley portion and the top surface 2 where the corrugated plate 9 is brought into contact with the corrugated plate 9.

These will be described in more detail. That is, referring to FIG. 4 together with FIG. 2 (4), the corrugated sheet 9 made of the aluminum alloy foil AL containing magnesium Mg, which has been formed by corrugating as described above, is first used. It is cut every predetermined length. then,
A plurality of, for example, a large number of corrugated sheets 9 are sequentially shifted left and right by half a pitch of a wave between upper and lower corrugated sheets 9 so that a valley of the upper corrugated sheet 9 and a top of the lower corrugated sheet 9 are sequentially aligned. They are stacked one on top of the other in a positional relationship, and have a laminated block shape with a space as a whole. Thereafter, the corrugated sheets 9 stacked in this manner are pressed from above and below while being heated in a furnace or the like, so that the corrugated sheets 2 of the corrugated sheets 9 are brought into contact with each other. Are diffusion bonded. That is, magnesium Mg contained in the aluminum alloy foil AL as the base material of the corrugated sheet 9 is:
The surface of the aluminum alloy foil AL which is vaporized by heating 2
The oxide film 3 on the surface is reduced and removed, and the oxide film 3 covering the combined valley and top surface of the ground 2 is reduced and removed,
It is dispersed. In this way, the corrugated plate 9, that is, the combined valley and top of the aluminum alloy foil AL,
The aluminum is exposed in a solid state, and is contacted and adhered while being pressurized, whereby diffusion bonding is performed, and a linear diffusion bonding portion 6 is formed. The details of such diffusion bonding are the same as those described above with reference to FIG. 4 in the manufacturing method using the stretching method in FIG. 1, and thus description thereof is omitted. Regardless of the illustrated example, in this corrugated manufacturing method, a flat and flat aluminum alloy foil AL (see FIG. 2A) is further provided between the corrugated plates 9. It may be interposed. That is,
In some cases, a flat aluminum alloy foil AL, also called a bisect sheet, is interposed between the corrugated sheets 9 stacked as described above, and diffusion bonding is performed between the corrugated sheets 9 in some cases.

In the corrugated manufacturing method shown in FIG. 2, the aluminum honeycomb 1 is manufactured by following these steps. That is, as shown in FIG. 3, the corrugated sheet 9 diffused and joined in the form of a stripe is used as the cell wall 7, and a plurality of hollow column-shaped cells 8 defined by the cell wall 7, which is an aluminum planar assembly, The honeycomb 1 is obtained. This is the case with the corrugated system shown in FIG.

Now, the aluminum honeycomb 1 obtained by such a stretching method or a corrugating method is as follows. That is, as shown in FIG. 3, the aluminum honeycomb 1 is formed of a planar aggregate of a large number of hollow columnar cells 8 defined by cell walls 7 joined in a striped manner.
As a base material of the cell wall 7, an aluminum alloy foil AL containing magnesium Mg is used, and the cell wall 7 is formed such that the base material of the aluminum alloy foil AL is lined at a diffusion bonding portion 6 by diffusion bonding. Are joined together. The diffusion bonding at the diffusion bonding portion 6 is performed by applying pressure,
Magnesium Mg vaporized by heating reduces and removes the oxide film 3 on the surface 2 of the base 2 of the aluminum alloy foil AL. The cross-sectional shape of the cell wall 7 and the cell 8 is typically a regular hexagonal shape as shown in the figure. However, the cross-sectional shape is not limited to this, and may be a vertically long or horizontally long hexagonal shape, a trapezoidal shape, a substantially square shape, or various other shapes. Things are also possible.
The aluminum honeycomb 1, like a general honeycomb core, has excellent weight ratio strength, is lightweight, has high rigidity and strength, and has excellent rectifying effect, flatness accuracy, heat insulation, and sound insulation. It has properties such as a large surface area per unit volume and is widely used as various structural materials.
Normally, a surface plate is bonded to the cell end surface, which is the opening end surface, by bonding, brazing, diffusion bonding, or the like, and is provided for use as a honeycomb sandwich panel.
The aluminum honeycomb 1 is configured as described above.

The present invention is configured as described above. Then, it becomes as follows. This aluminum honeycomb 1
In the manufacturing method thereof, an aluminum alloy foil AL containing magnesium Mg is used as a base material of the cell wall 7, and in the stretching method shown in FIG. In the corrugated method shown in FIG. 2, such aluminum alloy foil AL is formed into a corrugated sheet 9 and then stacked. Then, in both the stretching method and the corrugating method, by applying pressure and heating, as shown in FIG. 4, the magnesium Mg contained in the aluminum alloy foil AL as the base material is vaporized, and the background of the aluminum alloy foil AL is vaporized. 2 Reacts with the oxide film 3 that has firmly and stably covered the surface,
Is reduced, destroyed, and dispersed, so that the aluminum of the aluminum alloy foil AL is exposed and contacts in a solid state.

As a result, the diffusion bonding progresses, and the gap between the bases 2 of the aluminum alloy foil AL as the base material and the base 2 of the corrugated plate 9
Diffusion bonding is performed in the form of striations, thereby forming diffusion bonding portions 6 in the form of striations. Therefore, by performing the expansion in the corrugated method and the subsequent expansion in the expansion method, as shown in FIG. 3, the aluminum alloy foil AL (and the corrugated sheet 9) is used as the cell wall 7, and the cell wall 7 is used. The aluminum honeycomb 1, which is a planar assembly of a large number of hollow column-shaped cells 8 partitioned by 7, is obtained. Then, in the aluminum honeycomb 1 obtained by such a manufacturing method of the expansion method or the corrugation method, the following first, second, third, and third are described.
The fourth, fifth, sixth, seventh, eighth, and ninth are obtained.

First, in the aluminum honeycomb 1, the cell walls 7 are joined by diffusion bonding by diffusion bonding. That is,
It is composed of only the aluminum alloy foil AL as a base material, and does not use any other dissimilar metals, resins or the like. Therefore, the aluminum honeycomb 1 has the basic performance of the aluminum alloy foil AL as the base material, that is, the aluminum as a whole as it is, and has excellent high-temperature strength, heat resistance, corrosion resistance, and the like.

Secondly, similarly, the aluminum honeycomb 1 is formed by only the aluminum alloy foil AL serving as a base material, in which the cell walls 7 are joined in a line by diffusion bonding. Therefore, even when this aluminum honeycomb 1 is used outdoors, the diffusion bonding portion 6 is exposed to the ultraviolet rays contained in the sunlight.
There is no deterioration.

Third, the aluminum honeycomb 1 is manufactured by the stratified wire bonding between the cell walls 7 by diffusion bonding, and by the above-described stretching method shown in FIG. 1 and the corrugated method shown in FIG. Then, an aluminum alloy foil A as a base material of the cell wall 7
L is used in a rolled state without the need for performing a pretreatment cleaning using a harmful substance in advance in preparation for diffusion bonding at the time of use. Diffusion bonding is performed by pressurizing and heating the aluminum alloy foil AL as the base material, and no toxic gas is generated at this time.

Fourth, in the aluminum honeycomb 1, the cell walls 7 are joined by a wire by diffusion bonding, and are manufactured by a stretching method or a corrugating method. As described above, this aluminum honeycomb 1 is manufactured using only the aluminum alloy foil AL as the base material, and no other metal is interposed.
The erosion phenomenon and the formation of a brittle intermetallic compound layer do not occur during diffusion bonding and striation bonding by pressurization and heating.

Fifth, since there is no erosion phenomenon and no formation of an intermetallic compound layer, pressurization and heating for diffusion bonding and striation bonding are limited to a very short time in order to suppress this phenomenon. , No need to set. That is, this aluminum honeycomb 1 can perform diffusion bonding and streak bonding between the cell walls 7 over a necessary and sufficient time. In particular, when manufacturing the aluminum honeycomb 1 by the stretching method (see FIG. 1 (5)), for each aluminum alloy foil AL as a base material stacked in a block shape, the central portion of the block is heated for a short time. Therefore, there is no possibility that the temperature does not reach the predetermined temperature and that the bonding is not finally ended. That is, it is possible to reliably prevent the aluminum honeycomb 1 manufactured by diffusion bonding and striation bonding to the center of the block from having defective bonding between the cell walls 7.

Sixth, in the aluminum honeycomb 1, the cell walls 7 are joined by diffusion bonding by diffusion bonding. Therefore, when manufacturing by the stretching method shown in FIG. 1, the release agent 4 is used to leave the ground 2 in the form of a stripe with a constant width and pitch as expected, and to perform the subsequent pressurization and heating. The aluminum alloy foils AL can be easily and easily and accurately diffusion-bonded between the aluminum alloy foils AL. Also, when manufacturing by the corrugated method shown in FIG. 2, simply applying pressure and heating to a portion to be joined of the corrugated sheet 9 using the aluminum alloy foil AL as a base material, that is, a valley and a top of the corrugated sheet 9, is simple. Diffusion bonding and striation bonding can be performed easily, accurately and uniformly. As described above, regardless of whether it is the expansion type or the corrugated type, this aluminum honeycomb 1
By adopting the diffusion bonding, the cell walls 7 can be easily, easily, accurately, and uniformly bonded as desired.

Seventh, the aluminum honeycomb 1 is formed such that the cell walls 7 are strip-bonded by diffusion bonding, and is formed using only the aluminum alloy foil AL as a base material.
As described above, since the aluminum honeycomb 1 does not use any metal or resin other than the base material, the weight is reduced by that much.

Eighth, similarly, this aluminum honeycomb 1
The cell walls 7 are strip-wire bonded by diffusion bonding, and are constituted only by the aluminum alloy foil AL as a base material.
That is, this aluminum honeycomb 1 employs diffusion bonding,
Since no metal or resin other than the base material is used for the strip wire joining, the cost is reduced accordingly.

Ninth, the aluminum honeycomb 1 is strip-wire bonded by diffusion bonding while using an aluminum alloy foil AL containing a predetermined amount of magnesium Mg as a base material of the cell wall 7. As described above, since the magnesium Mg is contained in a predetermined amount, the oxide film 3 that has firmly and stably covered the surface 2 of the aluminum alloy foil AL is reduced, removed, destroyed, and dispersed by the vaporized magnesium Mg. Accordingly, the aluminum of the aluminum alloy foil AL is exposed in a solid state, and diffusion bonding between the aluminum alloy foils AL proceeds easily, easily and extremely smoothly. Therefore, it is not necessary to set such a high degree of condition as to temperature, pressure, time, atmosphere and the like. Specifically, as described above, extremely high temperature, high pressure, long time, high vacuum, etc. are not required as essential conditions, but relatively low temperature, low pressure, short time, low degree vacuum, etc. Diffusion bonding is performed by applying pressure and heating below. Thus, this aluminum honeycomb 1
Is that, by using an aluminum alloy foil AL containing a predetermined amount of magnesium Mg as a base material, diffusion bonding and line bonding between cell walls 7 can be easily performed irrespective of the expansion method or the corrugation method. Be joined.

[0042]

As described above, the aluminum honeycomb and the method for manufacturing the same according to the present invention use an aluminum alloy foil containing magnesium as a base material of a cell wall.
By applying pressure and heating, the oxide film on the ground surface of the aluminum alloy foil is reduced and removed, and diffusion bonding is performed between the cell walls in the form of striations, that is, without using an adhesive or brazing material. The following effects are exhibited by connecting the walls between the lines.

First, an aluminum honeycomb excellent in high-temperature strength, heat resistance, corrosion resistance and the like can be obtained. That is, in this aluminum honeycomb, the cell walls are bonded by diffusion bonding by diffusion bonding, and the cell walls are not bonded by bonding or brazing as in the above-described conventional example. . As described above, this aluminum honeycomb is made of only an aluminum alloy foil as a base material without using any adhesive having inferior high-temperature strength, heat resistance, corrosion resistance, or the like, or a brazing material as a dissimilar metal. The basic performance of the alloy foil, ie, aluminum, is fully utilized, and it has excellent high-temperature strength, heat resistance, corrosion resistance, etc., and is excellent in performance.

Second, there is no deterioration even when used outdoors. In other words, in this aluminum honeycomb, the cell walls are joined by the striations by diffusion bonding, and are not necessarily joined by the adhesion as in the above-described conventional example. As described above, since the aluminum honeycomb is formed only of the aluminum alloy foil as a base material, even when used outdoors, it is unlikely that the aluminum honeycomb is deteriorated by ultraviolet rays like the adhesive of this type in the related art. And excellent in quality maintaining surface such as shape.

Third, no harmful substances are used during production, and no toxic gas is generated. In other words, in this aluminum honeycomb, the cell walls are joined by the striations by diffusion bonding, and are not necessarily joined by the adhesion as in the above-described conventional example. Therefore, the aluminum alloy foil used as a base material in the production does not need to remove oils and fats and dusts on the surface in preparation for bonding as in the conventional example of this type, and toxic substances such as highly toxic organic solvents, alkalis and strong acids are required. Does not require pre-treatment cleaning of the aluminum alloy foil. In addition, when joining striations by pressing and heating during manufacturing,
No toxic gas is generated from the adhesive as in the conventional example of this type. As described above, this aluminum honeycomb does not use harmful substances at the time of manufacturing, does not generate toxic gas, avoids danger, and is excellent in safety during manufacturing.

Fourth, there is no occurrence of an erosion phenomenon or a brittle intermetallic compound layer. That is, in this aluminum honeycomb, the cell walls are striation-bonded by diffusion bonding, and are not necessarily striation-bonded by brazing as in the above-described conventional example. Therefore, in the case of wire joining by pressurization and heating at the time of manufacturing, the erosion phenomenon does not occur on the aluminum alloy foil, corrugated plate, and cell wall of the base material to be joined unlike the conventional example of this type, and the surface is mechanically attached. No debris separation, erosion, holes, etc. occur. In addition, when joining the striations, the base material aluminum alloy foil,
A brittle intermetallic compound layer is not formed on the corrugated plate and the cell wall unlike the conventional example of this type. As described above, this aluminum honeycomb avoids the problem of the erosion phenomenon and the problem of embrittlement due to the intermetallic compound layer, and is excellent in quality.

Fifth, poor bonding is also prevented. In other words, in this aluminum honeycomb, the cell walls are joined in a strip line by diffusion joining.
It does not mean that the wires are joined by brazing. Therefore, it is not necessary to limit and set the pressure and the heating to a very short time in order to suppress the above-mentioned erosion phenomenon and the generation of the intermetallic compound layer, as in the conventional example of this type, and the strip line joining becomes incomplete. Nothing happens. In particular, when manufacturing by the stretching method, the center portion of each aluminum alloy foil as a base material stacked in a block shape does not cause poor bonding due to insufficient heating unlike the conventional example of this type, Diffusion bonding is ensured up to the part. As described above, in the aluminum honeycomb, the cell walls are surely diffusion bonded, the bonding failure is prevented, and the quality is excellent in this aspect as well.

Sixth, the quality is stable. That is,
In this aluminum honeycomb, the cell walls are striation-bonded by diffusion bonding, and are not necessarily striation-bonded using a powdery or paste-like brazing material as in the above-described conventional example of this type. Therefore, as in the case of manufacturing by the spreading method using a powdery or paste-like brazing material, it is difficult to accurately apply the wire to the aluminum alloy foil as the base material, or the wire is positioned as it is. It is not necessary to pay special attention to the holding, and the use of the release agent allows easy, easy and accurate diffusion bonding and striation bonding. Also, as in the case of manufacturing by a corrugation method using a powdery or paste-like brazing material, it is difficult to apply the corrugated sheet to the valleys and apex of the corrugated sheet accurately and uniformly in a linear manner. A situation in which control was not easy does not occur, and accurate and uniform diffusion bonding and striation bonding can be easily and easily realized. As described above, in the aluminum honeycomb, the cell walls are accurately and uniformly diffusion-bonded and line-bonded, and the quality is extremely stable from this aspect as well.

Seventh, weight reduction is promoted. That is,
In this aluminum honeycomb, the cell walls are joined by a wire by diffusion bonding, and are not joined by bonding or brazing as in the above-described conventional example. Therefore, weight reduction is promoted by the use of no adhesive or brazing material, and in particular, the weight is significantly reduced as compared with the case of manufacturing by the corrugated method using the above-mentioned brazing sheet. As described above, the aluminum honeycomb is excellent in weight, for example, the weight reduction is promoted.

Eighth, it is excellent in cost. In other words, in this aluminum honeycomb, the cell walls are joined in a strip line by diffusion joining.
It does not mean that the wires are joined by bonding or brazing. Therefore, the aluminum honeycomb can be manufactured with excellent cost regardless of whether it is a stretched type or a corrugated type. For example, the cost is reduced by the use of no adhesive or brazing material.

Ninth, pressurization and heating are also relatively low pressure, low temperature,
It is easily and easily implemented in a short time. That is, this aluminum honeycomb uses an aluminum alloy foil containing a predetermined amount of magnesium as a base material of the cell wall.
Then, the oxide film on the surface of the aluminum alloy foil is reduced and removed, destroyed and dispersed by the vaporized magnesium, and the aluminum is exposed in a solid state, so that diffusion bonding can easily and easily proceed. Therefore, as in the case of diffusion bonding which has been generally performed for nickel, stainless steel, and the like, extremely high temperature, high pressure, and long time (several tens of
It can be easily and easily diffused by applying pressure and heating under conditions of relatively low temperature, low pressure, short time, low vacuum, etc., without requiring high vacuum etc. as essential conditions. Joining is performed. As described above, this aluminum honeycomb can be easily and easily manufactured, though diffusion bonding is used.
As described above, the effects exhibited by the present invention are remarkable and large, for example, all the problems existing in this type of conventional example are solved.

[Brief description of the drawings]

FIG. 1 is a perspective explanatory view for explaining an example of an embodiment of an aluminum honeycomb and a method for manufacturing the same according to the present invention. FIG.
(2) Fig. 2 shows a state in which a release agent is provided, (3) Fig. 3 shows a cut state, (4) Fig. 4 shows a stacked state, and (5) Fig. 5 shows a state of diffusion bonding. , (6) show the expanded state.

FIG. 2 is an explanatory front view for explaining another example of the embodiment of the present invention, in which (1) FIG.
(2) shows a corrugated sheet forming process, (3) shows a formed corrugated sheet, and (4) shows a corrugated and diffusion-bonded corrugated sheet.

FIG. 3 is a perspective view of an aluminum honeycomb for explaining the embodiment of the present invention.

FIG. 4 is a diagram for explaining the principle of diffusion bonding for explaining the embodiment of the present invention. FIG. 4A shows a pair of aluminum alloy foils to be bonded, and FIG. ,
(3) Fig. 4 shows the reduced state of the oxide film, and (4) Fig.
This shows the state of diffusion bonding.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Aluminum honeycomb 2 Background 3 Oxide film 4 Release agent 5 Product 6 Diffusion bonding part 7 Cell wall 8 Cell 9 Corrugated plate 10 Jig AL Aluminum alloy foil Mg Magnesium

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI // B23K 101: 02 103: 10

Claims (4)

[Claims] An aluminum alloy containing magnesium as a base material of a plurality of hollow columnar cells defined by cell walls joined in a stripe shape. A foil is used, and the cell wall is formed by joining an aluminum alloy foil, which is a base material, in a stripe shape by diffusion bonding. An aluminum honeycomb, characterized in that it is carried out by reducing and removing an oxide film on the base surface of the alloy foil. 2. First, a release agent is disposed at predetermined intervals on an aluminum alloy foil serving as a base material containing magnesium while leaving a ground line in a constant width and at a constant pitch. After stacking a plurality of the aluminum alloy foils in a positional relationship in which the background left in the form of a stripe is shifted by half a pitch, the aluminum alloy foils are pressurized and heated to separate the aluminum alloy foils between the aluminum alloy foils. The aluminum alloy foil is diffused and bonded at the ground contacted while being left in the form of striations, and then expanded by applying tensile force in the direction of stacking, whereby each of the aluminum alloy foils forms In addition to being bent along the edge, portions other than the diffusion bonding portion are separated and separated, so that the aluminum alloy foil is used as a cell wall, and a large number of hollow columns formed by the cell wall are defined. Aluminum honeycomb, which is a planar assembly of cells A method for manufacturing an aluminum honeycomb. 3. An aluminum alloy foil serving as a base material containing magnesium is corrugated into a corrugated sheet in which corrugations are continuously bent, and then a plurality of corrugated sheets are formed. After stacking in a positional relationship where the valley and the top are shifted by the pitch, and then pressurized and heated, the corrugated plate is diffused and joined between the valleys and the ground of the top that are brought into contact with each other. The corrugated sheet diffused and bonded in a linear shape is used as a cell wall,
A method for manufacturing an aluminum honeycomb, comprising obtaining an aluminum honeycomb, which is a planar assembly of a large number of hollow columnar cells defined by the cell walls. 4. The method for manufacturing an aluminum honeycomb according to claim 2, wherein the magnesium is contained in the aluminum alloy foil in an amount of 0.1% by weight or more, and the diffusion bonding includes: It is performed in a low oxygen concentration atmosphere such as vacuum or inert gas atmosphere,
A method for producing an aluminum honeycomb, wherein the magnesium vaporized by heating at a temperature of at least 00 ° C. is reduced by removing an oxide film on the background surface of the aluminum alloy foil.