JPS61250132A - Manufacture of composite member - Google Patents

Abstract

PURPOSE:To obtain a composite member having characteristics such as light weight and high density, by compacting a fiber compact made of two layers having different fiber densities, arranging the compact so that high density layer is positioned at surface side of product and pouring a cast-in material. CONSTITUTION:Linear fibers A and curled fibers B are piled in layered state, compacted and sintered to prepare the fiber compact 3 made of layers having different fiber densities. The sintered compact 3 is arranged so that a layer 3a of the fibers A is brought to contact with the surface of a cavity 4a in a mold 4, and a layer 3b of the fibers B is positioned inside the cavity 4a. The cast-in material 5 such as molten Al alloy is poured into the cavity 4a and these are pressed. Poured molten metal is impregnated into the compact 3 to fill the material 5 into pores therein, and the composite member 6 having a prescribed shape is obtd. In the member 6, the surface part where the layer 3a is positioned is reinforced. The compact 3 is cast-in with high joining strength.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a composite member in which a fiber molded body is cast.

(Prior art) Traditionally, a composite member has been provided by partially casting a fiber molded body into a metal base material, and the properties of the fiber molded body have been utilized to partially improve wear resistance, mechanical strength, etc. The technology used is known.

However, conventionally, a single-density fiber molded body is cast, so when a fiber molded body with a high fiber density is cast, there is a problem that the bonding strength between the fiber molded body and the casting material is insufficient. .

In other words, in order to obtain sufficient mechanical and physical properties, it is necessary to increase the fiber density by increasing the amount of fiber inserts in the casting, but a fiber molded product with high fiber density has small pores. As a result, it is difficult for the casting material to penetrate inside during casting, and when the casting material comes into contact with the fibers, its temperature decreases and fluidity decreases, resulting in insufficient pressurization and the filling amount. If the bonding strength between the two is insufficient, there is a risk that the fiber molded article may fall off. and,
If the fiber molded body is made larger than necessary to increase the bonding surface area and thereby improve the bondability,
In addition to the problem of filling properties, the amount of fiber used increases, leading to an increase in manufacturing costs.

(Object of the Invention) In view of the above circumstances, an object of the present invention is to provide a method for manufacturing a composite member that obtains high bonding strength and is easy to manufacture even when a fiber molded article with a high fiber density is cast. It is something.

(Structure of the Invention) The manufacturing method of the present invention involves stacking straight fibers and curled fibers, filling them into a mold, and then compressing them to form a fiber molded article having fiber layers with different densities. Then, a fiber layer with high fiber density is placed on the mold side, the pores of the fiber molded body are filled with a casting material, and the fiber molded body is cast with the casting material. It is.

The above-mentioned fiber molded article uses metal fibers such as stainless steel fibers and cast iron fibers, or ceramic fibers, etc., and prepares straight fibers and curled fibers such as cutting waste. ! The I fibers are laminated in layers, filled into a mold, and then compression molded.

The compressed density of straight fibers is high, and the compressed density of curled fibers is low, so that a fiber molded article having fiber layers with two levels of fiber densities is formed.

In this IIN molded article, the fibers on both sides are intertwined and bonded at the boundary between the straight fiber layer and the curled fiber layer. When the fiber molded body is a metal fiber, it may be sintered and bonded by heating.

The above-mentioned integrated fiber molded product is placed in the mold so that the portion with high fiber density is placed on the cavity surface side of the mold, that is, the portion made of linear fibers with high fiber density is located on the surface side of the product. After placing it in the mold, a casting material such as aluminum alloy or cast iron is injected in a molten state into the mold, and the pores of the fiber molded body are filled with the casting material.
A composite member is manufactured by encasing the fiber molded body in a casting material.

(Effects of the Invention) According to the present invention, 118N having layers with different fiber densities
By forming a fiber compact, arranging this fiber compact so that the portion with high fiber density is located on the surface side of the product, and encasing it in a casting material to manufacture a composite member. The part with high fiber density fully demonstrates the characteristics of the fiber and improves wear resistance, mechanical strength, etc., while the part with low fiber density makes it easier to fill the inside of the fiber with casting material.
It is possible to improve bonding properties in areas with high fiber density and prevent peeling and falling off. In other words, compared to the direct bonding strength between the fiber molded body with high fiber density and the casting material, the bonding strength between the high fiber density part and the low fiber density part is greater because the fibers of both parts bond with each other. Moreover, the casting material sufficiently flows and fills the pores inside the fiber molded body from the areas with low fiber density, and the lack of pressure applied to the areas with high fiber density can be resolved, and the fiber molded body and the casting material can be separated. It is possible to obtain sufficient bonding properties. This results in
Composite members with features such as light weight, high strength, and high modulus of elasticity, as well as excellent heat resistance, can be manufactured with high productivity even in complex shapes.

Furthermore, simply by compression-molding fibers with different shapes, straight and curled, at the same time, the fiber molded body having fiber layers with different densities can be easily molded in a single step.

In particular, curled fibers intertwine with straight fibers and have good bonding properties between the two, and the curled fiber molded product has a high porosity, so it has good bonding properties with the base material.

(Example) The present invention will be explained in detail below.

First, as shown in FIG. 1, straight fibers A and curled fibers 1B are charged into a press mold 1 and stacked in layers.

In this case, the linear fiber A is made of spheroidal graphite cast iron (FCD50), has a diameter of 100μ, and a length of 1011
The curled mMB is made of chromium molybdenum steel (80M435) and has a diameter of 100μ.
, the length of which is 1011Il.

Subsequently, compression molding is performed with a punch 2.2 at a pressure of 100 kg/am2 to form a straight fiber layer 3a and a curled IJAH layer 3b with different fiber densities, and the fibers on both sides are intertwined at the joint of both layers. A fiber molded body 3 is formed by joining and integrally molding the fibers in this manner. Due to this compression molding, the straight fibers A are arranged with few gaps between the fibers, so the straight fiber layer 3a is formed with a high density of 1.5g1013, while the curled fibers B have a small gap between the fibers. By remaining in large numbers, the curled III fibers 113b are formed with a low density of 0.8 Ω/c1.

Next, the fiber molded body 3 is
The fiber molded body 3 was obtained by heating at .degree. C. for 1 hour and sintering to bond each III to each other and maintain the shape, thereby obtaining a fiber molded body 3 in which layers having different fiber densities were laminated together.

As shown in FIG.
It is arranged in a mold 4 so that the curled fiber layer 3b side is in contact with the surface and located inside the cavity 4a, and a molten metal of the casting material 5 (aluminum alloy) is injected into the cavity 4a using the molten metal forging method. The pressing force at this time was 1000 k (
1/cm2.

The injected molten metal penetrates into the fiber molded body 3 from the low-density curled fiber layer 3b side to the boundary between both layers, fills the pores of the fiber molded body 3 with the casting material 5, and A composite member 6 having a predetermined shape is obtained by casting a 1liN molded body 3 in a predetermined position of a material 5.

In this composite member 6, the part where the fiber molded body 3 is cast, especially the surface part where the linear fiber layer 3a is located, is reinforced, and the mechanical strength and physical properties are improved, and the wear resistance etc. At the same time, the fiber molded body 3 is cast-wrapped with high bonding strength.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing the state of molding of an mm molded body using a mold, and FIG. 2 is a cross-sectional view showing a state of casting with a casting mold. 1...Molding mold 3...1i
iIflIt shape 3a... linear fiber layer 3b
......Curled lH layer 4...Mold
5... Casting material 6... Composite member A... Straight fiber B... Curled MAR

Claims (1)

[Claims] (1) Straight fibers and curled fibers are laminated and filled into a mold, and then compression molded to form a fiber molded body having fiber layers with different densities. A method for producing a composite member, comprising arranging a layer on the mold side and filling the pores of the fiber molded body with a casting material, and also casting the fiber molded body with the casting material.