JPS61221341A - Production of single composite material - Google Patents

Abstract

PURPOSE:To produce a single composite reinforced material with high productiv ity by laminating plural preforms for the composite material via specific release materials then penetrating a molten metal therein to prepare a base material and separating the materials at the release material parts in the stage of produc ing the composite material consisting of reinforcing materials such as fibers and metal. CONSTITUTION:Plural pieces of the preforms 2 formed by mixing and drying the fibers and whiskers for reinforcement and surface active agent and molding the mixture to an intended shape are laminated by the release materials 3. The release materials formed by pressing or cutting the meshes consisting of the same material as the metal to be impregnated into the preforms 2 to form the composite material and molding such meshes are used for the release materials 3. The laminated body is put into a metallic mold 6 and a molten metal L is pressurized and injected from a nozzle 7 by a plunger 8 into the mold by which the molten metal is penetrated into the preforms and is solidified. The laminated body is taken out of the mold 6 and is cut along the planes of the materials 3, by which many pieces of the single composite reinforced materials are produced simultaneously and the productivity is improved.

Description

[Detailed Description of the Invention] [Industrial Field of Application] The present invention relates to a method for manufacturing a single composite material as a component unit formed of composite materials such as fiber-reinforced metal materials and whisker-reinforced composite materials. The present invention relates to a method for manufacturing a single composite material that can be manufactured from a base material made of a composite material with good manufacturability.

[Prior Art] In recent years, so-called composite materials, such as fiber reinforced metal (FRM) materials and whisker reinforced composite materials, have been developed.

Fiber-reinforced metal materials include carbon fibers and silicon carbide in the metal.
M, boron fiber, alumina fiber H, or other inorganic fiber material is embedded (Japanese Patent Application Laid-Open No. 55-24763 is an example of application to a rocker arm.). Whisker-reinforced composite materials are made by dispersing and mixing acicular single crystals such as silicon nitride and silicon carbide into metals (aluminum, magnesium, or their alloys, etc.), ceramics, plastics, etc. This material also aims to improve the material performance, and in particular, the material strength has been dramatically improved.

[Problems to be Solved by the Invention] Generally, casting is often used to obtain component materials in a desired shape from raw materials, but it is difficult to produce a large number of component materials one by one in a typical casting operation. is extremely difficult and has poor manufacturability. Therefore, as shown in Fig. 13, by extrusion molding, which is a method of plastic working, a base material a is molded to an indefinite length, and then component materials are cut out as necessary from this long base material a. It has excellent manufacturability.

However, when this method of manufacturing component materials is applied to the above-mentioned composite materials, there is a problem in that their increased strength results in poor cutting workability and reduced manufacturability.

On the other hand, there is the molten metal casting method as a manufacturing method used to manufacture component materials, in which a fairly large base material is molded and several component materials are cut out from it. There were similar problems in manufacturing methods when applied to composite materials.

[Purpose of the Invention] The present invention has been devised in view of the above-mentioned problems, and its purpose is to process a composite material such as a whisker-reinforced composite material or an IN-reinforced metal material as a component unit. An object of the present invention is to provide a method for manufacturing a single composite material that can efficiently manufacture the single composite material.

[Summary of the Invention] The present invention involves molding a preformed body to be constructed as a single composite material into a desired shape using fiber material or whiskers, and interposing a mold release material between these preformed bodies. After laminating and infiltrating the laminated preforms with a metal melt to integrally form a bonded composite material as a base material, a single composite material is separated from the bonded composite material using a mold release agent and molded. It is something.

[Example] A preferred embodiment of the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 shows a base material formed by integrating a preform 2 and a mold release material 3 immediately before individually molding a single composite material 1 as a component unit as a final product in the present invention. A bonded composite material 4 is shown and is manufactured by the following procedure.

First, as shown in FIG. 2, a preform 2 is produced and prepared as a unit, which will ultimately be formed individually from a bonded composite material 4 as a single composite material 1. Although not shown, this preformed body 2 is manufactured by mixing whiskers or 11M material in a surfactant liquid, pouring this mixed liquid into a formwork of a desired shape such as a mold, and then drying it. It is. This preformed body 2 has a large number of fine porous voids into which the metal melt will later penetrate.

On the other hand, the mold release material 3 is interposed between the preforms 2 that will be sequentially laminated later (and is molded along the outer shape of the surfaces of the preforms 2 to be overlapped).

In this embodiment, the mold release material 3 is made from a mesh 5 as shown in FIG. 3, which does not contain whiskers or fibers and is made of the same material as the metal that will later be infiltrated into the preform 2 as a melt. It is molded by pressing or cutting (Fig. 4).

And the preformed body 2 manufactured and prepared in advance in this way
As shown in FIG. 2, the preforms 2 are sequentially assembled in a laminated manner with a mold release material 3 interposed between each preform.

Thereafter, extrusion molding is performed on this assembled preform 2. The preformed body 2 assembled as shown in FIG. 5 is mounted on a mold 6, and the metal molten liquid (molten metal) L injected into the mold 6 from the nozzle 7 is pressurized by the plunger 8 to form the preformed body. As a result, as shown in FIG. 1, a bonded composite material 4 is formed in which a plurality of preforms 2 and a mold release material 3 are integrated. At this time, in this embodiment, since the mold release 03 is formed of the mesh 5, the metal molten liquid can smoothly penetrate into the preforms 2 stacked on top of each other.

By separating the bonded composite material 4 formed in the above manner using a mold release material 3, a single composite material 1 is molded as shown in FIG. 6. In this example, the single composite material 1 is obtained by cutting the release material 3 of the same quality once it has been impregnated into the preform 2 along its surface.

As explained above, in the present invention, when taking out parts, etc. as necessary from a base material whose strength has been increased by whiskers or fiber materials, the preform 2 and the laminate that become a single composite material 1 are prepared. A mold release material 3 that forms a separation part between these preforms 2 is laminated, and then a molten metal liquid is infiltrated into them to form an integral bonded composite material 4. This bonded composite material 4 is By separating the parts using the mold release material 3 which is not reinforced, it is possible to mass-produce the single composite material 1 efficiently while fully demonstrating good productivity in extrusion molding and the like. Therefore, reductions in material costs can be achieved.

FIGS. 7 to 12 show the case of using the molten metal casting method. As shown in Fig. 9, the molten metal casting method is a method in which the molten metal (metal molten liquid) L injected into the mold 6 is solidified under high pressure and molded. 3 is integrated to form a bonded composite material 4 (first
Figure 0). In the case of this method, the mold release material 3 is formed with an expanded locking piece 3a for holding it in the mold 6 (FIG. 7), which is overlapped between the preforms 2 and protrudes. (Figure 8). A single composite material 1 can be molded by separating the bonded composite material 4 formed by solidifying the molten metal liquid using a mold release material 3 as shown in FIG. 11 (FIG. 12).

[Effects of the Invention] In summary, the present invention exhibits the following excellent effects.

A preformed body of a desired shape is molded as a component unit using fiber material or whiskers, and a release material is interposed between the preformed bodies to form a separation part, and then the preformed bodies are laminated, and then a molten metal liquid is infiltrated into these preformed bodies. After forming an integral bonded composite material, the bonded composite material is separated by a non-reinforced mold release material to form a single composite material, so that a whisker-reinforced composite material or a fiber-reinforced metal material can be used as the base material. In manufacturing methods in which parts are extracted as needed, a single composite material can be efficiently mass-produced while fully utilizing the good productivity of extrusion molding methods, molten metal casting methods, etc.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing the formed bonded composite material according to the present invention, the second momme is a perspective view showing the laminated state of the preform and the release material, and FIG. 3 is the mesh used in the release material. FIG. 4 is a plan view showing the molding of the mold release material, FIG. 5 is a side view showing the penetration state of the metal melt (extrusion molding), and FIG.
The figure is a perspective view showing a single composite material, Figures 7 to 12 are explanatory views when the molten metal casting method is applied to the present invention, and Figure 13 is a perspective view showing a state in which component materials are cut out from the base material. It is. In the figure, 1 is a single composite material, 2 is a preform, 3 is a mold release material, 4 is a bonded composite material, 5 is a mesh, and 2 is a metal melt.

Claims (3)

[Claims] (1) Molding a preform into a desired shape using fiber material or whiskers, interposing a release material between these preforms and laminating them, and infiltrating the laminated preform with a metal melt. 1. A method for producing a single composite material, characterized in that after forming a bonded composite material, the bonded composite material is separated and molded into a single composite material using the mold release agent. (2) The method for manufacturing a single composite material according to claim 1, wherein the mold release material is formed of a mesh. (3) The method for producing a single composite material according to claim 1 or 2, wherein the mold release material is made of the same material as the metal of the metal melt.