JPH1192841A - Production of parts made of metallic composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the production cost of parts made of composite materials, in such a manner that the fibers of plural fiber-reinforced composite materials obtd. from fibers for reinforcing orientated in one direction are orientated in an optional direction, by largely laminating the composite materials to form into a laminated body, charging a die having a curved face with the laminated body, subjecting it to heating and pressurizing and executing integrated forming. SOLUTION: As for bending as representative plastic working for long fibrous composite materials, the draft (e) to certain bending R is expressed by e=1/2R in proportion to the sheet thickness (t), and a thin sheet material is small in the degree (e) compared to that in a thick sheet material. Thus, in the case of the same draft, bending with small R is made possible in the thin sheet material compared to the case of the thick sheet material. Thus, the thin sheet laminated materials (to mm × (n) pieces = (t) mm) can be formed to the draft (1/n of bending R) higher (n) times than the case of the integrated sheet material (t mm) with the same thickness outwardly, and by integrating the laminated materials after the forming, the applying range of a compound-shape imparting process can remarkably be extended.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a fiber reinforced metal composite material part having an uneven shape.

[0002]

2. Description of the Related Art Fiber-reinforced metal composite materials are classified into long fiber type and short fiber type (including particle type) according to the length of the fibers used. It is manufactured by a processing method.

(1) Long-fiber-based composite material: Since long-fiber-based material is inferior in both plastic workability and machinability, parts are manufactured by using plastic working method and machining method after manufacturing the composite material. It is difficult, and the preform stage before compounding (for example, “lamination of metal foil and fiber”, “fiber coated with matrix material”, “sheets with matrix material sprayed on unidirectionally arranged fibers” etc.) ), A predetermined component shape is given, and then compounded to manufacture a metal composite material component. That is, a "shape-composite process" in which the composite is formed after the shape is applied is employed.

[0004] (2) Short fiber composite material: The same component manufacturing method as that of the metal material is basically applied to the short fiber material, and a net shape processing such as casting or powder HIP is performed. A method is used in which a metal composite material is manufactured by a molten metal method or a powder method, and then a part is manufactured by plastic working (extrusion, forging, rolling, etc.) or mechanical processing. Among them, the part (or shaped material) manufacturing method by plastic working is capable of orienting the fiber in the working direction (extrusion direction, rolling direction), and is used as a method for improving strength characteristics at the same time as shaping. ing.

[0005]

The above-mentioned conventional method of manufacturing a fiber-reinforced metal composite component has the following problems.

[0006] (1) Long fiber composite material: In the "shaping-compositing process" currently used for manufacturing parts, it takes a lot of man-hours for the shaping step, and the manufacturing cost of parts is extremely high. There are drawbacks. For example, when a laminate of a metal foil and a fiber is used as a preform, it is necessary to individually form dozens of metal foils in the shape-imparting step. It becomes molding. In addition, although the method of performing filament winding using a matrix metal-coated fiber as a preform is a relatively inexpensive shape-imparting method, parts to which this method can be applied are limited to some axially symmetric parts.
"Composite-shape-imparting process" in which a simple-shaped composite material such as a flat plate or a square bar is manufactured and then shaped by plastic working.
Can be applied to form a single step, thereby enabling a significant cost reduction. However, the plastic workability of long fiber composites is very poor, and the shape of parts to which such a process can be applied is extremely limited.

(2) Short fiber composite material: Among the processing methods for short fiber material, in a part manufacturing process using plastic working, it is possible to improve the strength characteristics by orienting fibers by plastic working. This is a great advantage in using metal composites. For example, a unidirectionally reinforced plate having high strength in the rolling direction can be produced by unidirectional rolling, and a plate having low strength anisotropy can be produced by cross rolling. However, since the fiber orientation given by plastic working is uniquely determined by the working direction (extrusion direction, rolling direction, etc.), it is not possible to arbitrarily control the fiber orientation when plastic working to a desired shape This is a major problem in the processing technology of this material. For example, when a cylinder subjected to internal or external pressure is manufactured by extrusion, an axial orientation completely opposite to a fiber orientation (circumferential orientation) desired for a product is given.

Another problem common to long fiber and short fiber composite materials is that large parts cannot be manufactured due to restrictions on the size of the material that can be manufactured.

The present invention has been made in view of the above-mentioned state of the art, and has as its object to provide a method for manufacturing a component made of a long-fiber-based metal composite material and a component made of a short-fiber-based metal composite material, which does not have the disadvantages of the above-described conventional method. .

[0010]

In order to reduce the first problem of "manufacturing cost of a long-fiber composite material part", the conventional "shaping-compositing process" is replaced with a complex forming process. An effective means is to use a “composite-shaping process” in which a shape is later formed by plastic working. Based on this, we considered expanding the range of applicable part shapes for this process, which is currently extremely limited due to the limitations of the processing limits of composite materials, and reducing the manufacturing cost of parts. As a means for expanding the applicable range, Instead of “integral composite material” (for example, thick plate), use “lamination of composite material” (for example, laminate of thin plate), perform plastic working and then reheat and integrate after cooling in the same heating process. Thought about doing it.

Regarding the second problem, "there is no freedom in controlling the fiber orientation of the short fiber composite material", materials having fiber orientation imparted by extrusion, rolling and the like are prepared, and these materials are prepared. It was conceived that the fibers were laminated in such a manner that the fiber orientation direction of the components matched the fiber orientation required for the component, and the laminate was integrated by heating / pressing.

Regarding the third problem, that is, "Large parts cannot be manufactured", it was considered to manufacture large parts by combining small materials and integrating them.

That is, the present invention provides (1) a plurality of block-like or plate-like fiber-reinforced metal composites in which reinforcing fibers are oriented in one direction, and the fibers of the composites are oriented in an arbitrary direction. A fiber-reinforced metal composite material component characterized in that a large number of the composite materials are laminated to form a laminate, and the laminate is loaded into a mold having a curved surface, and heated and pressed to be integrally molded. Manufacturing method, (2) producing a plurality of block-shaped or plate-shaped fiber-reinforced metal composite materials in which reinforcing fibers are oriented in one direction, and forming each of the composite materials into a desired shape having a curved surface; Manufacturing a fiber-reinforced metal composite material component, comprising laminating a large number of the applied composite materials to form a laminate, loading the laminate in a mold having a curved surface, and heating and pressing to integrally mold the laminate. Method and (3) Laminating a large number of composite materials Wherein a fiber powder, a metal powder, or a foil used for the composite material is inserted between the composite materials, wherein the method for producing a fiber-reinforced metal composite part according to the above (1) or (2) is performed. It is.

(Function) In the "compositing-shaping process" effective for reducing the cost of long fiber composite material, using "composite laminate" instead of "integral composite material" has the following effects. Have. In bending forming, which is a typical plastic working of long fiber composite materials, the degree of work (e) for a constant bending R (R) is expressed as e = t / 2R in proportion to the plate thickness (t), A thin plate material has a smaller workability than a thick plate material. Therefore, at the same degree of processing, a thinner sheet material can be bent with a smaller radius. From this, the laminated sheet material (t ₀ mm × n sheets = t
mm) can be formed to an apparently n-fold greater working ratio (1 / n bending R) than an integrated plate material (tmm) of the same thickness. By integrating the laminated material after forming,
The scope of the “composite-shaping process” is greatly expanded.

The process of laminating and integrating the fiber orientation materials of the short fiber composite material has the following effects. At the stage of laminating the metal composite material, materials having fiber orientation can be combined in an arbitrary direction, so that an arbitrary fiber orientation that cannot be provided by the conventional plastic working method can be provided. Thereby, the optimum fiber orientation required for the component can be easily realized without being restricted by the component shape.

[0016] Regardless of the long fiber type or the short fiber type, the process of integrating the laminate into a part has an effect of enabling a large member by combining small members.

The reinforcing fibers of the present invention are generally Si
C fibers, SiC whiskers and the like, and metal materials include Ti, Al, TiAl and the like.

[0018]

EXAMPLES The effects of the present invention will be clarified below with reference to specific examples of the present invention.

(Example 1) An example of a process for manufacturing a blade using SiC / Ti, which is a typical long-fiber composite material, will be described with reference to FIG. In the conventional “shaping-compositing process” shown in FIG. 1A, first, a titanium alloy foil (about 100 μm) serving as a matrix: 50 to 10
0 sheets are individually preformed and SiC fibers (diameter of about 100 μm) are arranged between the sheets to form a preform (laminated body of titanium alloy foil and SiC fibers), which is heated to a temperature around 900 ° C. Compression is performed by applying pressure. Here, the forming of the titanium alloy foil is hot forming, and since the number is large,
It is a very expensive process.

In the "composite-shaping process" of the embodiment of the present invention shown in FIG. 1B for the purpose of cost reduction, since the composite is performed by a simple shape such as a flat plate or a square bar, The forming of the titanium alloy foil is unnecessary, and the heating requires only two processes, namely, a composite process and a plastic working process of the composite material, so that the cost can be significantly reduced.

However, the critical working ratio (amount of strain that can be subjected to plastic working without causing a decrease in strength due to fiber breakage) of the long fiber composite material is only a few percent in the fiber orientation direction, and the thickness of the composite material is small. When it is thick, the formable bend R is limited to a rather large range. Machining limit is matrix material,
It varies depending on the fiber content and processing conditions, but if it is 3%
And the plate thickness is 10 mm and the radius of curvature in the longitudinal direction is 100 m
Considering the case of forming a blade of m
When the composite material plate is molded with a radius of curvature of 100 mm, the amount of strain on the surface becomes about 5%, and a decrease in strength due to fiber breakage cannot be avoided. On the other hand, when two sheets of a material having a thickness of 5 mm are laminated and the laminated body is formed, the amount of strain on the surface is about 2.5% in either plate, so that sound molding is possible. If the two plates are joined and integrated, a blade can be manufactured without impairing the strength characteristics of the composite material. If a smaller radius of curvature is required, the thickness of the composite material can be reduced to increase the number of laminated plates. Since the outer surface of the long-fiber composite material is covered with matrix metal, diffusion bonding without insert material is basically used for bonding between laminates. A material may be inserted for diffusion bonding or brazing. The joining (integration processing) of the laminates is most efficiently performed continuously in the same heating step as the plastic working (bending), and the cost is low. It is also possible to use a separate step.

(Example 2) A cylinder receiving internal pressure or external pressure, such as a flying object or a body of an underwater vehicle, is made of SiCw / Al (SiCw is a whisker of SiC) which is a typical short fiber composite material. Will be described with reference to FIGS. Conventional SiC shown in FIG.
Extrusion is considered to be the most common processing technique for producing w / Al cylinders (tubes). However, in a cylinder produced by extrusion, fibers (SiCw) are oriented in the axial direction (extrusion direction). Therefore, it is not suitable as a method for manufacturing a pressure cylinder. That is, in a pressure cylinder, since the Hoop stress is twice the axial stress, it is desirable to orient the fibers in the circumferential direction. As a method of realizing the fiber orientation in the circumferential direction by plastic working, it is conceivable to ring-roll a small-diameter cylinder into a large-diameter cylinder.In this case, too, the small-diameter cylinder to be rolled is manufactured by extrusion. Since the fibers are oriented in the axial direction, it is considered that unidirectional orientation in the circumferential direction is not obtained even after ring rolling.

On the other hand, in the manufacturing process according to the present invention shown in FIG. 2B, a thin plate in which fibers are oriented in one direction by extrusion, rolling, or the like is used as a material, and after a predetermined curvature is given in the fiber orientation direction. Are laminated in a container having a predetermined shape to form a cylindrical shape, and an integrated cylinder is manufactured by a HIP method or the like. At this time, if the long thin plate can be wound in a coil shape, the seam of the material is eliminated and the strength characteristics are most preferable, but even in the case of a short unidirectionally oriented material, the seam of the material is not concentrated at one point on the circumference. To form a cylindrical shape. In the case of short-fiber composite materials, the outer surface of the plate is rarely covered with matrix metal, and the matrix metal is often an aluminum alloy that is difficult to bond by diffusion. Is diffusion bonding or brazing using an insert material. When a gap is generated between the laminated members, a matrix powder and fibers of the composite material are filled in addition to the insert material for joining, and the composite material is formed in the integration process.

[0024]

As described above, according to the present invention, a long-fiber-based composite material can be applied to a low-cost "composite-shaping process" using plastic working. (This effect is due to an increase in the apparent workability by reducing the thickness of the plate to be formed.) This is the biggest problem in applying this material. Provide an effective solution to "high cost". Further, the short fiber composite material has an effect of enabling the orientation to be controlled in an arbitrary direction, which has been impossible so far, and the performance of the product is improved.

Furthermore, the metal composite material parts have heretofore been limited to small parts due to restrictions on the size of the material that can be manufactured, but the present invention provides means for manufacturing large parts made of metal composite materials. It also has an effect and greatly improves the applicability of the metal composite material.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a comparison between a blade manufacturing method (b) according to one embodiment of the present invention and a conventional blade manufacturing method (a) according to one embodiment.

FIG. 2 is an explanatory diagram showing a comparison between a method (b) for manufacturing a pressure-resistant cylinder according to one embodiment of the present invention and a method (a) for manufacturing a pressure-resistant cylinder according to a conventional mode.

Claims (3)

[Claims] 1. A plurality of block-shaped or plate-shaped fiber-reinforced metal composites each having a reinforcing fiber oriented in one direction are manufactured, and the composite is oriented so that the fibers of the composite are oriented in an arbitrary direction. A method for producing a component made of a fiber-reinforced metal composite material, comprising laminating a large number into a laminate, loading the laminate in a mold having a curved surface, and applying heat and pressure to integrally mold the laminate. 2. A plurality of block-shaped or plate-shaped fiber-reinforced metal composites in which reinforcing fibers are oriented in one direction are manufactured, and each of the composites is formed into a desired shape having a curved surface, and then a shape is imparted. A method for producing a fiber-reinforced metal composite part, comprising laminating a large number of composite materials into a laminate, loading the laminate in a mold having a curved surface, and heating and pressing to integrally mold the laminate. . 3. When laminating a large number of composite materials to form a laminate,
The method for producing a fiber-reinforced metal composite part according to claim 1 or 2, wherein a fiber powder, a metal powder, or a foil used for the composite material is inserted between the composite materials.