JPS5974247A - Fiber reinforced metallic composite member and its production - Google Patents

Abstract

PURPOSE:To produce a composite material member of which the surface layer and inside have respective reinforced characteristics by sticking reinforcing fibers which are short fibers on the surface of a molding formed of reinforcing fibers which are long fibers, disposing the same in a casting mold and pouring the melt of a metal therein. CONSTITUTION:A fibrous molding having a prescribed shape, density and orientation is formed of reinforcing fibers which are long fibers having a large ratio of fiber length with respect to fiber diameters and are ceramic fibers of alumina, etc. Reinforcing fibers which are short fibers having a small ratio of fiber length with respect to fiber diameter and are ceramic fibers of alumina, etc. are stuck by means of an inorg. binder or the like on the surface thereof and are disposed in a casting mold. The melt of a matrix metal such as an aluminum alloy or the like is poured into said casting mold, and while the metal is pressurized in the mold, the metal is solidified. The fiber reinforced metallic composite member which has excellent specific strength and rigidity over the entire part of the member and is highly resistant to wear and heat in the surface layer is thus obtd.

Description

Detailed Description of the Invention The present invention relates to an m-fiber reinforced metal composite (Δ diagonal member, in which the surface layer is reinforced with short fibers or particles and the inside is reinforced with long fibers or short fibers). Pertains to composite material members.

Various components and members of automobiles, aircraft, etc. are often required to have special mechanical properties. For example, in automobile engines, as the demands for engine performance become higher, members such as pistons not only have excellent specific strength and rigidity, but also have excellent wear resistance. In addition, there is a strong demand for the top surface to have excellent heat resistance and heat insulation properties. One way to improve the specific strength, abrasion resistance, heat resistance, heat insulation, etc. of such members is to make them fiber-reinforced using various inorganic fibers as reinforcement materials and light metals such as aluminum alloys as a matrix. Attempts have been made to construct them using metal composite materials.

However, in conventional parts made of fiber-reinforced metal composite materials, only one type of reinforcing material is generally used, so the parts made of fiber-reinforced metal composite materials are There are disadvantages such as not being able to satisfy all the characteristics required for it, limiting its uses, and requiring other treatments to be applied to the component. For example, in order to improve the specific strength of a piston pin, if the piston pin is made of an aluminum alloy reinforced with long fibers such as Km Wt, the strength such as bending strength and shear strength can be improved. However, it is not possible to sufficiently improve the wear resistance of the sliding movement between the piston and the connecting rod, so the cylindrical outer peripheral surface of the piston pin may be thermally sprayed with molybdenum or its alloy, or Ni - It is necessary to perform a treatment such as plating such as P plating.

The present invention has been developed in view of the above-mentioned problems with conventional members made of fiber-reinforced metal composite materials, and in general, the surface layer of each weighing machine member has heat resistance (wear resistance). In view of the fact that the material as a whole is required to have excellent strength, the surface layer and interior of the material are each shortened according to the required characteristics. The object of the present invention is to provide a fiber-reinforced metal composite material member reinforced with fibers or particles, long fibers, or short fibers, and a method for producing the same.

According to the present invention, the present invention provides a fiber-reinforced metal composite material member, in which at least a part of the surface layer of the member is reinforced with reinforcing fibers having a small ratio of 5iutt length to fiber diameter; A fiber-reinforced metal composite material member in which at least a part of the inner part of the surface layer is reinforced with reinforcing fibers having a fiber length ratio of 4411 diameter to '1J larger than that of the first reinforcing fibers, and a fiber-reinforced metal composite material member. a metal composite material member, at least a part of the surface layer of the member is l1ff
At least a part of the inner side of the surface layer J of the member is reinforced with a first reinforcing fiber having a small ratio of fiber length to diameter, and at least a part of the inner side of the surface layer J of the member is reinforced with a first reinforcing fiber having a fiber length to diameter ratio of the first reinforcing fiber. A method for producing a fiber-reinforced metal composite material member reinforced with second reinforcing fibers larger than the reinforcing fibers, the method comprises forming a fiber molded article with a predetermined shape, density, and orientation using the second reinforcing fibers. , attaching the first reinforcing fiber to the surface of the fiber molded body, placing it in a mold, pouring a molten metal into the mold, and solidifying the molten metal while pressurizing it in the mold. This is achieved by a method for manufacturing a fiber-reinforced metal composite material member.

According to the present invention, at least a part of the surface layer of the member is reinforced with reinforcing fibers having a small ratio of fiber length to fiber diameter,
At least a part of the inner part of the surface layer of part 1 is reinforced with human reinforcing fibers in which the ratio of fiber length to fiber diameter is increased, so the member as a whole has excellent specific strength and rigidity. Moreover, in the surface layer, a member with excellent wear resistance and heat resistance can be obtained. That is, by appropriately selecting long fibers, short fibers or particles, and matrix metal according to the properties required for each part of the member, it is possible to obtain a member that has substantially all of the properties required for each part. I can do it. For example, manufacturing screws and piston pins according to the present invention.
If so, it is possible to avoid improving their specific strength and durability, and furthermore, it is possible to improve the performance of the engine.

In addition, the M&Treinforced metal composite material is generally used (5-The workpiece P1 is poor, so the wX miscellaneous reinforced metal composite material is ground into a member of a predetermined shape and size.) Although it is difficult, according to the present invention, the surface layer of the member is reinforced with short fibers and particles, so the entire member has high strength and high rigidity. long I
Compared to conventional fiber-reinforced metal composite material members reinforced with -C, it is easier to perform finishing processes such as grinding, and the finishing process of the IJ is also smoother.

Furthermore, according to the manufacturing method of the mm-reinforced metal composite material member according to the present invention, it is possible to easily and efficiently manufacture the 11-wire reinforced metal composite material member having excellent specific strength, durability, workability, etc. as described above. can.

According to one detailed feature of the invention, reinforcing fibers having a large fiber length to diameter ratio, i.e. long fibers or class 41
Fibers include ceramic fibers such as alumina fibers and silicon carbide fibers, various carbon fibers, metal fibers such as stainless steel wires and tungsten wires, ceramic short fibers such as alumina fibers and alumina-silica fibers, various carbon short fibers, and carbonized fibers. Reinforcing fibers, i.e., short fibers or particles, may be silicon, silicon nitride, alumina, potassium titanate, etc., and have a small ratio of fiber length to fiber diameter.
Ceramic short fibers such as lumina mechanical fibers and alumina-silica fibers, various short carbon fibers, and silicon carbide.

Voice power such as silicon nitride, alumina, potassium titanate, metal carbide particles such as titanium carbide, silicon carbide, vanadium RA, tungsten carbide, niobium carbide, chromium carbide, chromium oxide, alumina.

They may be metal oxide particles such as titanium oxide, zirconium oxide, and silicon oxide, metal nitride particles such as silicon nitride, titanium nitride, chromium nitride, and boron nitride, carbon particles and granulated molybdenum particles, and the matrix. The metal is a light alloy such as aluminum alloy or magnesium alloy.
, zinc alloy, lead alloy, copper alloy, tin alloy, etc.

Further, according to one detailed feature of the method for manufacturing a fiber-reinforced metal composite material member according to the present invention, in the step of attaching the first reinforcing fibers to the surface of the fiber molded article, the first reinforcing fibers are inorganic. It is attached to the surface of the fiber composition body using a binder.

The inorganic binder used in this case may be colloidal silica, alumina, zirconia, iso-helium oxide, cerium oxide, ferric oxide, zirconium silicate, antimony diluted, etc. The reinforcing fibers of the cylinder are attached to the fiber molded body, and the reinforcing fibers of the cylinder are then dried. However, in this case, prior to compounding with the matrix metal, the fiber molded body to which the first reinforcement!11ft was attached was fired and
It is necessary to remove some organic components contained in the binder.

According to another detailed feature of the method for manufacturing a fiber-reinforced metal composite material component according to the present invention, prior to pouring the molten 7-trix metal into the mold, a first reinforcing fiber is attached. The fiber molded body is heated to a temperature higher than the melting point of the matrix metal.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention will now be described in detail by way of example embodiments with reference to the accompanying drawings.

Example 1 Figure 1 shows a fiber-reinforced metal composite material 11 according to the present invention configured as a piston pin of an automobile diesel engine.
FIGS. 2 to 4 are illustrations showing the manufacturing process of the screws 1 to 1 shown in FIG. 1. FIGS.

In Figure 1, 1 is an aluminum alloy (A1-3%M (
1), the screw 1 to the pin 1 have a hollow structure with a hole 3 extending along an axis 2. The surface layer 4 (thickness approximately 0.5 mm) defining the cylindrical outer peripheral surface of the piston pin 1 is made of silicon carbide voice 5 (average fiber? M'0.2 μm, average si
#lt length 150 μm) - (reinforced, and the inner layer 6 radially inner than the surface layer 4 is made of carbon fibers I"7 spirally oriented around the axis 2 at a pitch angle θp-±70°.
(Trading card M40 (registered trademark) manufactured by Toshi Co., Ltd., fiber diameter 7
μm).

The screw 1->bottle constructed as described above was manufactured in the following manner using the method for manufacturing a fiber-reinforced metal composite material member by Akira Kibu (1).

First, stainless steel 11M (JIS standard SU) with outer diameter Bm+n
1 of carbon fiber 7 on the surface of rod 8 made of
7-n (number of fibers 3 'O'0 'O tree) as pitch angle θp
Axis 2 due to filament winding = ±70°
A rod 10 having an outer diameter of 21.5 mm as shown in FIG. 2 was formed by winding the rod helically around the rod. Next, this rod 10 was cut into a cylinder having a length of 75w+m.

Next, silica carbide VOISCA 5 was mixed with water-soluble silica sol 3'Q.
wt% solution, and the dispersion was applied to the cylindrical outer circumferential surface of the cylindrical body to a thickness of 1 mm by spraying, and this was dried at 120'C for 2 hours. A composite fiber molded body 11 as shown in FIG. 3 was formed.

Next, this composite fiber molded body 11 is heated for 80' in a preheating furnace.
It is preheated to 0°C, placed in a mold cavity 14 defined by an upper mold 12 and a lower mold 13 as shown in FIG. The melt field 16 of the aluminum alloy of
The pressurized state is maintained until the melt field 16 of the aluminum alloy is completely solidified. After the melt field 16 of the aluminum alloy is completely solidified, the upper mold 12 is separated from the lower mold 13. The solidified body formed as described above is taken out by knockout bottles 18 to 20, and the solidified body is subjected to machining such as cutting and drilling, and is strengthened with carbon fiber and silicon carbide voice force. Cut out only the part and perform grinding etc. on it to obtain an outer diameter of 22nm as shown in Fig. 1.
v.

A piston pin 1 with an inner diameter (3 mm) and a length of 72I1 m was formed.

Incidentally, the volume fraction of the silicon carbide whisker 5 and the carbon fiber 7 of the Ic piston pin 1 manufactured as described above is about 10% each.
, about 60%. Furthermore, when the thus manufactured piston pin 1 was cut along its @portion 2 and its 11th surface was observed, it was found that a portion of the silicon carbide 5 that strengthens the surface layer 4 had seeped into the spaces between the carbon fibers 7. It was observed that the surface layer 4 reinforced with carbon fiber whiskers 5, the inner layer reinforced with carbon fibers 7, and the portion 6 were firmly adhered to each other.

Furthermore, the piston pin 1 manufactured as described above is fixed to the piston by a pin, and is inserted into the connecting rod without using a bushing. It was installed in a pill engine (compression ratio +21.5, exhaust: 2198CG) and tested under the test conditions shown in Table 1 below.
The piston pin manufactured as described above was found to have sufficient strength and wear resistance.

Table 1 Fuel used 2 Diesel engine speed: 4 (3QQrpm (5% overrun) Engine load = full 1'' - Cooling water temperature: 100℃ Test time 20'O hours Example 2 Figure 5 shows the results of a diesel engine for an automobile. FIGS. 6 to 8 are partially cutaway perspective views showing another embodiment of the fiber-reinforced metal composite material member according to the present invention configured as a piston, and FIGS. It is an illustration showing a manufacturing process.

In Figure 5, 21 is an aluminum alloy (JISMAI
8AC8) shows a piston configured with i3.
The surface layer 23 (thickness approximately 1.5 mm+) of the piston head 22 of the piston 21 is made of Zirnia particles 2 with an average diameter of 3 μm.
4, screw 1-, surface layer 23J of head 22: 1-1 layer part 25 on the inner side of the rim (approximately 5 mm thick)
is suspended from alumina-silica short fibers 26 (average fiber diameter 3 μm, fiber length 5 to 13111 m). Also, the piston 21 side 8rl side 14^1 surface 27 1~tube brand 28 and 1~tube The part defining the 1 long iM 29 is alumina silino J')n [Nli < It has been strengthened here.

In addition, in FIG. 5, 30 is shown as pz l; (
, s+ indicates a hole for receiving a piston pin, and 31 and 32 indicate a ring groove for receiving a second 1 nong and an oil ring, respectively, which are not shown in the figure.

The screw 1-21 constructed as described above was manufactured as follows using the manufacturing method of the fiber-reinforced metal composite material member σ) according to the present invention.

First, the alumina-silica short fibers 26 are dispersed in water, and the dispersion is vacuum-formed into a shape having a diameter of 9 Q mm, a height of 2' Q mm, a thickness of the cylindrical side wall 33 of 8 mm, and a bottom wall as shown in FIG. 34 and a dish-shaped fiber molded body 35 with a thickness of 5 nm.
was formed.

Next, the zirconia particles 24 were dissolved in water-soluble zirconia sol 2Q.
The dispersions of U゛ and A dispersed in the wt% solution were added to the fiber molded body 3.
Using a brush, apply several threads to a thickness of about 1.5 mm on the surface 36 of the bottom wall 34 of No. 5 on the screw head side.
By drying at 0° C. for 2 hours, a composite fiber molded body 37 made of alumina-silica staple fibers 26 and zirconia particles 24 as shown in FIG. 7 was formed.

Next, this composite fiber molded body 37 is heated to about 80% in a preheating furnace.
'Preheat the bottom wall 3 of the lower mold 38 of the piston casting machine to 0°C.
9, pour the molten metal 40 containing aluminum and cum into the lower mold 38, and pour the molten metal into the upper mold 41 at 13'O'O.
The pressure was increased to kq/9, and the pressurized state was maintained until the molten aluminum alloy 40 was completely solidified.

After the molten aluminum alloy 40 is completely solidified, the thus formed solidified body is taken out from the lower mold 38 by the knockout bin 42, and the solidified body is subjected to machining such as cutting and grinding, as shown in FIG. A piston with a diameter of 9'Qmm and a length of 70mm was formed as shown in FIG.

The volume percentages of alumina-silica short fibers and zirconia particles in the piston 21 manufactured as described above are each about 7%.
, about 40%. Also, the screw 1-
The engine 21 was assembled into a 4-cylinder 4-recycle easel engine (compression ratio: 21.5, displacement 2198 CC), and a test run was conducted under the test conditions shown in Table 1.
- [As mentioned above, the piston 21 with IJit+7 has the strength of the piston as a whole, the wear resistance of the top ring groove 29, and the heat resistance and heat insulation properties of the screw head 22, compared to only aluminum alloys. It has been confirmed that the piston is far superior to the IC piston.

Further, when the piston 21 manufactured as described above was cut along the axis A and its cross section was observed, it was found that the adhesion between the surface layer 23 and the inner layer 25 inside the surface layer 23 was good.

Although the present invention has been explained above with reference to two embodiments, the present invention is not limited to these embodiments, and various embodiments are possible within the scope of the present invention. This will be clear to those skilled in the art.

[Brief explanation of drawings]

Figure 5 The figure shows the manufacturing process of the piston pin shown in Figure 1.
FIGS. 6 to 8 are perspective views, partially cut away, of another embodiment of the fiber-reinforced metal composite material member according to the present invention configured as a piston for a piston, and FIGS. It is an illustration showing a manufacturing process. 1... Piston pin, 2... Axis line, 3... Hole, 4
...Surface layer, 5...Silicon carbide voice force, 6...
Inner layer part, 7... Carbon fiber, 8... Rod, 10... Rod body, 11... Composite fiber molded body, 12... Upper mold, 13
... Lower mold, 14 ... Mold-1-Yaviti, 15
... runner, 16 ... molten aluminum alloy, 17
...Plunge p, 18-20...Knockout pin 8, 21...Bis 1-n, 22...Piston head, 23...Surface layer, 2/l...Zirconia particle, 2
5...Inner layer part, 26...Aluminaria J short fiber, 27...Side outer peripheral surface, 28...Top land, 2
9... Top ring groove, 30... Hole, 31.32.
...Ring groove, 33...Cylindrical side wall, 34...Bottom wall, 35...Fibre molded body, 36...Surface, 37...
Composite fiber molded body. 38... Lower mold, 39... Bottom wall, 40... Molten aluminum alloy, 41... Soil, mold, 42... Knockara 1-bin patent Applicant: Toyota Motor Corporation representative Person Patent Attorney Akashi Hatake No. 1
Figure 1 Figure 2 ρ0 Figure 3 Figure 4 - Figure 8

Claims (3)

[Claims] (1) A fiber-reinforced metal composite material member, in which at least a part of the surface layer of the member is reinforced with a first reinforcing fiber having a small ratio of fiber length to fiber diameter, and the surface layer of the member is A fiber-reinforced metal composite material member, wherein at least a portion of the inner portion is reinforced with a second reinforcing fiber having a fiber length to fiber diameter ratio greater than that of the first reinforcing IBM. (2) A II fiber-reinforced metal composite material member, at least a part of the surface layer of the member is reinforced with first reinforcing fibers having a small ratio of fiber length to fiber diameter; A method for producing a fiber-reinforced metal composite material member, wherein at least a part of the inner part of the surface layer is reinforced with second reinforcing fibers having a ratio of fiber length to fiber H diameter larger than that of the first reinforcing fibers. A fiber molded body having a predetermined shape, density, and orientation is formed using the second reinforcing Al fibers, the first reinforcing fibers are attached to the surface of the fiber molded body, and this is placed in a mold. A method for manufacturing a fiber-reinforced metal composite material member, comprising: pouring a molten matrix metal into the mold, and solidifying the molten metal while pressurizing the molten metal within the mold. (3) In the method for manufacturing a fiber-reinforced metal composite monthly member according to claim 2, in the step of attaching the first reinforcing fibers to the surface of the fiber molded body, the first A method for producing a fiber-reinforced metal composite material member, characterized in that the reinforcing fibers are attached to the surface of the M&composition shaped body using an inorganic binder.