JPS62149831A - Manufacture of fiber-reinforced metallic composite material - Google Patents

Abstract

PURPOSE:To manufacture a fiber-reinforced metallic composite material free from internal blowholes, by pouring a molten matrix metal into a metal mold, by placing a preheated fibrous reinforcement into the above, by applying gas pressure to the melt with evacuating the inside of the metal mold prior to the pressurization, and by cooling the metal mold from the outside so as to solidify the melt. CONSTITUTION:The mold of Al, Al alloy Pb, Zn, Sn, Cu, Mg, and alloys thereof to be a matrix is poured into the cylindrical metal mold 1, and the matrix metal is kept in a molten state. Then as a reinforcement, a bundle or preformed wires composed of carbon fiber, boron fiber, silicon carbide fiber, alumina fiber, metal fiber such as the one of stainless steel, Mo, Ta, etc., or matrix metal and fiber is stuffed into the melt. Subsequently, a cover 5 is attached to the mold 1, which is evacuated via a vacuum system and then pressurized by N2, Ar, etc., introduced via a pressurization system. Then water is poured into an outside a vessel 8 and the metal mold 1 is cooled gradually from the lower part toward the upper part to undergo solidification, so that fiber-reinforced metallic composite material free from blowholes and having various shapes such as round bar, square bar, etc., can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for producing a fiber-reinforced metal composite material.

(Conventional method) Composite materials made of fiber materials such as silicon carbide and metals such as aluminum as reinforcement materials, especially lightweight composite materials, have traditionally been suitable as materials for various materials such as vehicles, aircraft, rockets, and spacecraft. Various studies have been made since then, and various manufacturing methods have been proposed.

For example, solid phase diffusion bonding method (hot press method), high pressure solidification casting method, roll forming method, etc. are known.

(Problems to be solved by the invention) However, such fiber reinforced metal composite materials (FRM)
has the following problems: That is, according to the solid-phase diffusion bonding method, it is necessary to use high pressure of about 360 kgAm or more to manufacture FRMs, and for this reason, large-sized FRMs
It is difficult to manufacture, the equipment cost is high, and the molding time is long. In addition, in the high-pressure solidification casting method, the heat capacity of the mold is large, so the solidification rate is slow, and the fibers of the reinforcing material deteriorate during composite formation, resulting in low strength of the obtained FRM. Since a high molding pressure of 100 PC9/c or 2 to 1 ton/C is required, equipment costs are high. Furthermore, according to the roll forming method, it is possible to manufacture thin FRMs such as sheets, but it is difficult to manufacture thick FRMs such as round bars and square materials, and there are problems in that the equipment cost is high. . On the other hand, among these problems, it is possible to prevent the deterioration of reinforcing material fibers, and
JP-A-56-9256 and JP-A-56-11376 disclose a method of using ultrasonic waves to improve the intensity of R)l[.

(Means for Solving the Problems) The present invention solves the problems associated with the conventional method without using ultrasonic waves as described in the above-mentioned publication. A bundle of preheated reinforcing wires or fibers is placed in a preheated mold, the inside of the mold is evacuated, gas pressure is applied to the molten metal to infiltrate the molten metal into the gaps between the wires or fibers, and the molten metal is then removed from the mold. The present invention relates to a method for producing a fiber-reinforced metal composite material, which is characterized by cooling and solidifying the material from the outside.

The present invention will be explained below with reference to the drawings.

In producing the fiber-reinforced metal composite material according to the present invention, aluminum (Aj), aluminum alloy, lead (Pb), zinc (Zn), tin (Sn) is used as the matrix metal.
), copper (Ou), magnesium <Mg>, etc., carbon fiber, boron fiber, silicon carbide (Sin) fiber, alumina (ht2o, )lli fiber, metal fiber (stainless steel, molybdenum (MO), tantalum (Ta) as reinforcing materials) ) etc. and their preforms, e.g. silicon carbide/
ht * O/At + "Select wirex metals such as goa/A and reinforcing materials. Hereinafter, Aj will be used as the matrix metal, and Nicalon (silicon carbide continuous fiber, trade name, manufactured by Nippon Carbon Co., Ltd.) will be used as the reinforcing material.
/ An explanation will be given using an Al pre-7 ohm wire. A predetermined amount of Aj is placed in advance in a mold and maintained at, for example, 750° C. in a furnace. A bundle of preform wires having a diameter of 0.5111 is preheated to 800-850'C in a separate furnace. In the case of reinforcing fibers, it is usually preheated to 450°C. However, the temperature of the matrix metal and the preheating temperature of the reinforcing material are appropriately selected depending on the size of the mold. Note that if the preheating temperature of the wire or fiber is high, fiber deterioration will occur, and if it is low, unimpregnated areas will occur, so the lowest temperature at which no cavities are generated is adopted. The preheated pre-7 ohm wire 2 is then placed into the mold 1 after the mold is removed from the furnace. At this time, if the wire is directly inserted into the Al, the wire will float on top of the molten metal due to buoyancy, so see Figure 1a.
Preferably, a heated iron weight 8, for example, is placed on top of the wire as shown in FIG.

In order to ensure that the reinforcing wires or fibers (7) are unidirectional and the reinforcing wires or fibers (7) W@, the bundle is preferably bundled with matrix metal wire 4 or wrapped in netting as shown in FIG. 1a. Next, an inlet 6 and a pressurization system (not shown) communicating with a vacuum system (not shown) shown in FIG.
(not shown) is placed on the top of the mold, and in the illustrated example, the lid 5 is brought into close contact with the mold 1 using a press 10, and the inside of the mold 1 is vacuumed through the inlet 6. The degree of vacuum is preferably 31 II H or less, usually 2 to 8 m Hg.

Next, stop the vacuum and apply pressurized gas from the inlet lower, preferably 5
Nitrogen (N, ) gas, argon (Ar) gas, or air at a pressure of 9 Am" to 9 Am2 is introduced into the mold 1 to apply pressure within the molten metal. In this way, the pressure between each wire of the wire bundle is The molten metal penetrates sufficiently and each wire is completely covered with the molten metal.The mold 1 is then externally cooled and solidified, after which the formed FRM is taken out from the mold.

In addition, it is preferable to perform the above cooling from the bottom, as shown in Figure 1 (
As shown in b), when water 9 is injected into the container 8 in which the mold is placed and cooled from the bottom to solidify the FRM, no cavities are formed in the FRM part and the matrix is not reinforced by the wires above. Cavities are formed in areas where there is only metal or At.

FRM shown in FIG. 1(C) manufactured by the above method
ll has a diameter of 20n, a length of 1000mm, and a tensile strength of 70k.
g/cm”, bending strength 100-, fiber volume content (v
f) + 20%. Further, as a result of inspecting the inside of the FRM using soft X-ray transmission method and ultrasonic probe method, no defects were found at all.

A1 alloy (AO8) was used as the matrix metal in a similar manner.
A, JIS standard casting alloy), FRM using Sin/pure Al preform wire as reinforcing material (Vf = 20%)
Wotsukuri, CI7) F RM (!: , A CI
A (HT gold alloy for casting, 99.9% A) at various temperatures (
The bending strength (van'') in C) was measured and the results are shown in FIG.

In addition, A1 alloy (AC3 (3°J) is used as a matrix metal.
An FRM was made in the same manner as above using Si and 0/pure A knoble ohm wire as a reinforcing material, and the tensile strength of this FRM and AC4C at various temperatures (C) was kg// I-) is shown in Fig. 3.Furthermore, Fig. 4 shows the rotating bending fatigue characteristics of this FRM, AC8A-F, and AO8A-T6, and Fig. 5 shows the rotating bending fatigue characteristics of this FRM and AC40-T6. .

(Example) Next, the invention will be explained with reference to examples.

Example 1 A1 alloy (AC40) was placed in a carbon steel pipe mold having an outer diameter of 48.6 mm, an inner diameter of 88.4 mm, and a length of 500 Rml, and the mold was heated and maintained at 750°C. A Nicalon/pure Al preform wire with a diameter of Q and 51 m+ was preheated to 350"C, put into a mold, then covered with a lid and held at a vacuum level of 2 degrees H9 for 60 seconds, and then a nitrogen gas pressure of 15 vcm" After holding it for 70 seconds, it was cooled with water from the bottom to produce an FRM. The produced FRM has a tensile strength of 70 vCm” and a bending strength of 100
ψ-1Vf=20%. No defects such as cavities or voids were observed inside the FRH.

Example 2 Using a mold similar to that used in Example 1, Nicalon fiber (
In order to fix the bundle (diameter 15 μm) in one direction, the fibers were wrapped in an aluminum net, which was preheated to 500°C, and pure Al (99,991) was placed in the mold and heated and held at 750°C. The bicalole fiber was placed in a mold.Then, the inside of the mold was maintained at 2 tm Hg for 60 seconds, and then a nitrogen gas pressure of 15
kgAm! ' After holding for 30 seconds, cool with water from the bottom, and
RM was manufactured. Generated F RM ``J'') Strong 110 vlIK'', song strong 140 chant - 1Vf = 5
It was 0chi.

(Effects of the Invention) As explained above, the method for producing a fiber-reinforced metal composite material of the present invention is as follows: (1) After placing a preheated reinforcing material into a mold containing molten IJ sock metal, After creating a vacuum inside the molten metal, gas pressure is applied to the molten metal to allow the molten metal to penetrate into the gaps between the wires or fibers, and then the mold is cooled from the outside to solidify. Effects can be obtained.

(a) Because the molding time is short, there is no reaction between the fibers and the matrix during compositing.

(b) There are no nests or voids inside the FRM, it is dense and has high strength.

(c) It is possible to manufacture irregularly shaped FRM such as round bars, square bars, H-type, 1-type, etc., and partial reinforcement is also possible.

It can be used in parts for automobiles, aircraft, rockets, spacecraft, etc., such as piston pins, connecting rods, piston heads, etc., and in fields that require light weight and high strength.

b) Equipment costs are relatively low.

(e) Relatively high productivity.

(f) The impregnating metal type may be the same type as the matrix of the pre-7 ohm wire, or a different type of metal or alloy type having the desired performance can be selected.

(g) It is possible to perform a VF hunt roll.

(The above FRM can also be used as a billet for extrusion rolling.

[Brief explanation of drawings]

Figure 1 (~ shows the inside of the mold where the preheated preform wire is heated) A perspective view of the pre-7 ohm wire and the mold before it enters the molten metal, Figure 1) shows the pre-7 ohm wire Figure 1 (C) is a perspective view of the formed FRM, Figure 2 is a reinforced A7 alloy (A18A) as the matrix metal. Sin/[1
FRM, A (31
A. Song m showing the relationship between temperature and bending strength of 99.9 tipano
Figure 8 shows alloy 1 (AC40) as the matrix metal,
A curve diagram showing the relationship between temperature and tensile strength of FRM AC4c formed using Sio/Pure 1 preform wire T- as a reinforcing material.
A curve diagram showing the rotating bending fatigue characteristics of O8A, Fig. 4
It is a curve diagram showing the rotating bending fatigue characteristics of (7) FRM and AC40-T6 as in the figure. 1... Mold 2... Preform wire 3... Weight 5... Mold lid 8...
Container 9...Water 10...Press 11...FRM Figure 1 (a) (b) (C) Figure 2 Blade hole % (°C゛) 〼, 7! (°C) Figure 4 Figure 5 + Tentative li'N (Cyde) Procedure Amendment Written February 10, 1985 Director General of the Patent Office Mr. Michibu Uga 1, Indication of Case Patent Application No. 1985 No. 280387 2, Title of invention Method for producing fiber-reinforced metal composite material 3, ? ffl Relationship with the person making the correction Patent applicant Nippon Carbon Co., Ltd. 4, Agent 5, Subject of amendment "Claims" in the specification "Detailed description of the invention" 1, Specification page 1, No. 4 The claims in lines 11 to 11 are amended as follows. ``2. Claim 1: A preheated reinforcing wire or fiber bundle is placed in a mold containing molten matrix metal, the pressure inside the mold is reduced, and then gas pressure is applied to the molten metal. A method for manufacturing a fiber-reinforced metal composite material, characterized by infiltrating molten metal into the gaps between wires or fibers, and then cooling a mold from the outside to solidify it.'' 2, page 8, line 1 of the specification, ``Special ``Kaisho'' has been amended to ``Tokukosho,'' and in lines 17-18 of the same page, ``Magnesium (Mri), etc.'' has been amended to ``Magnesium (Mg), etc. and its alloys.'' 3. Correct page 5, lines 8 to 11 as follows. [Reducing the pressure inside the mold 1 through the port 6, preferably with a degree of vacuum of 20
11mH9 or less. Next, stop the vacuum pump and apply pressurized gas from the inlet lower, preferably 1 kgAm"G~80
Nitrogen (N2) gas at a pressure of kg/C, 2G, A''.
1 Alloy (A (38A) ) Figure 5

Claims (1)

[Claims] 1. Place a bundle of preheated reinforcing wires or fibers into a mold containing molten matrix metal, create a vacuum inside the mold, and then apply gas pressure to the molten metal to fill the gaps between the wires or fibers. A method for manufacturing a fiber-reinforced metal composite material, characterized by infiltrating molten metal, then cooling a mold from the outside, and solidifying it.