JPS6283438A - Metal combined with ceramic fiber and its manufacture - Google Patents

Abstract

PURPOSE:To manufacture a metal combined with ceramic fibers and having superior mechanical strength and wear resistance by melt-bonding and joining the mutual contact points of ceramic fibers to each other with frit in a preform and filling Al, and Al alloy, Mg or an Mg alloy into the voids in the resulting preform. CONSTITUTION:A preform consisting of 4.5-34wt% frit, 8-10wt% org. binder and the balance ceramic fibers is heat treated to vanish the binder and the balance ceramic fibers is heat treated to vanish the binder by burning and to melt-bond and joint the mutual contact points of the ceramic fibers to each other with the frit, so a preform having 75-95% void volume is obtd. Al, an Al alloy, Mg or an Mg alloy is melted and filled into the preform to manufacture a metal combined with ceramic fibers.

Description

[Detailed description of the invention] [Field of industrial protection] The present invention relates to a ceramic fiber composite metal having excellent friction, wear characteristics, elastic modulus, and strength, and a method for manufacturing the same. Piston, construction machine 4
It can be used for 4 etc.

[Prior art and problems to be solved by the invention] Conventionally, silica/alumina ceramics and kutsuitei bars were combined with gold scraps as reinforcing materials to improve the strength, heat resistance, abrasion resistance, etc. of the metal scraps. is known.

A method for manufacturing such a fiber composite metal is to form it into a predetermined shape in advance, and then use #A! After placing a Me compact (hereinafter referred to as an intermediate compact) into the jgr stereotactic image of a bath-extruded forging die, pressure is applied to elute the metal.
'E person's method is generally done 1)JrT's one book. At this time, if the strength of the intermediate molded product is not sufficiently high, there will be a problem that the intermediate molded product will be deformed during the elution injection, and the fibers will not be composited in the predetermined position and shape.

Conventionally, ceramic fiber molded bodies have been known to be made by using an inorganic binder such as silica sol, alumina sol, clay, or an organic binder such as latex alone or in combination. It is obtained by suctioning and overmolding a slurry of fibers and then drying it. The strength of the first molded body obtained in this way may be insufficient, or the strength of the molded body may be due to migration, which is a phenomenon in which binders such as silica sol and alumina sol move to Table 1m flu during drying and become concentrated. becomes significantly non-uniform, so the intermediate region te of the composite metal
When used as a body, problems arise in that deformation and damage occur when molten metal is injected. In order to eliminate these problems,
If migration is prevented by gelling with a binder or by increasing the content of binder 111, the viscosity of the slurry will increase, making suction molding extremely difficult, and the dry solidification of the binder will cause the molded product to deteriorate. One problem is that drying shrinkage occurs, making it extremely difficult to obtain a molded product with low bulk and a porosity of over 90%.

As a method to solve this problem, Japanese Patent Application Laid-Open No. 59-11
No. 8189 discloses a method for producing a molded reinforcing material for producing composite materials. However, in this method, a slurry of silica sol and ceramic fibers is suction molded, the resulting molded body is impregnated with sodium silicate, and then further dried. The problem is that it has to go through many complicated processes such as grinding.

[Means for solving problems]

The object of the present invention is to provide a composite metal having excellent strength, heat resistance, wear resistance, etc. by filling a molded product with a metal such as aluminum, which improves the above J11 defects, and the ceramic fiber described in the claims. The object of the present invention is to provide a composite metal jacket and a method for manufacturing the same.

Ceramic fiber is generally made into fibers by electrically melting approximately equal amounts of silica and alumina of mellow purity and blowing the resulting stream with high-pressure air. Unlike fiber, 85
It does not crystallize unless it reaches 0"0 or higher, and has excellent fire resistance that can withstand high temperatures of 1000°C or higher.

In addition, in the gaps where the above-mentioned rivulet is turned into a fibers, there are shots that are not turned into MIl fibers, shots that remain attached to the tips of the fibers, shots that have escaped from the delicate tips of the fibers, and so on. The size of this shot is fiberized from the beginning.
Those without l are generally coarse and often have a particle size of 150μ or more3, and those at the tip of the MA strip or those that are expelled from it are generally fine and often have a particle size of about 44 to 100μ. accounting for the majority of the total. -ni-'t
Ceramic fibers produced using Method F typically contain 50% shot with a particle size of 44 microns or more. Such shot impairs the machinability of composite metals and makes weaving difficult, so the content should be kept below 20%! 14 years old.

A method for obtaining ceramic fibers having a shot content of 20 or less for use in the present invention will be described.

Commercially available ceramic fibers are placed in water and stirred to create a ceramic fiber slurry. Next, this slurry is gradually introduced into an inward container, and at the same time pressurized water is sent from the side wall of this container to generate a thin flow, and the ceramic fibers are loosened in the thin flow. A slurry of disentangled ceramic fibers is sequentially flowed out from the center of the eddy stream, and the interwoven fibers are collected on a moving endless screen.

Next, the frit used in the present invention will be explained.

The frit used in the present invention is made by bonding the contact points of the ceramic fibers together in the ceramic fiber intermediate molded body before injecting the metal molten metal. , to prevent damage, the melting point of metals such as aluminum is 800'C.
Materials 1. that soften and melt in the vicinity have no effect, and ceramic fibers that become thick (deteriorate due to crystallization)
Materials that do not fuse unless the temperature exceeds 0°C cannot be used in the present invention. For these reasons, the frit used in the present invention is preferably borosilicate-based, calcium borate-based, calcium silicate-based, sodium silicate-based, or the like.

The present invention produces a molded body using ceramic fibers, fibers, throat, and an organic binder such as latex that is completely burned out at a temperature of 800°C or higher, and heat-treats this molded body to bond the organic bond. At the same time as the agent is burnt out, the contact points between the ceramic fibers are fused and bonded using 7 lifts, and a uniform and high-strength 111 compact is filled with metal such as aluminum.

Next, the reason for limiting the mixing ratio of each material used when manufacturing the ceramic fiber composite metal of the present invention will be explained. If the frit is less than 4.5 wt%, the strength of the intermediate molded product will be insufficient, and if it exceeds 4 wt%, it will result in poor penetration of the metal k (k), so it is necessary to keep it within the range of 4.5 to 134 wt%. If the organic binder is less than 9 wt%, the strength of the molded product before firing will be insufficient, causing problems in its handling, and if it exceeds 9 wt%, the time required for the binder to burn out will be longer. Since the problem arises, 3~lQwt
Must be within the range of %.

Next, a method for manufacturing the ceramic fiber composite metal of the present invention will be explained. First, ceramic fibers, frit, and organic binder are poured into water and thoroughly rubbed, stirred, and mixed to create a slurry. A commercially available #collecting agent is added to this slurry, stirred, mixed, suction filtered, molded, and dried to produce a molded body. Next, this molded body is heat-treated at a temperature of 800 to 1000°C to burn out the organic binder, thereby producing an intermediate molded body made of ceramic fiber and frit with a porosity of 75 to 95%.

This intermediate molded body is fixed at a predetermined position in a metal mold for molding, and pressure is applied to the gold to inject and solidify the void of the intermediate molding fh≦molten field.

[Action and effect]

The ceramic fiber composite metal of the present invention uses frit as a binder for a ceramic fiber intermediate molded body before metal melting, and has the following effects.

The particle size of frit is from several microns to several tens of microns, which is larger than conventionally used binders such as silica sol and alumina sol, so migration occurs when the binder is transferred to the surface layer by drying after suction filtration and molding. It does not occur and is uniformly dispersed in the molded product.

Further, the frit used in the present invention is heat-treated to fuse and join the delicate contact points of the molten lamic fibers. For this reason, the ceramic 7 eyeper intermediate molded body conveniently used in the production of the composite metal of the present invention has high strength and is uniform in strength.
It is possible to obtain a composite gold side with a predetermined shape (spear) without causing deformation or #Fi scratches even when the gold-molten field is inserted. This is to fuse and bond the contact points of the ceramic fibers together by heat treatment, and there is no bonding effect before the heat treatment is performed. Therefore, in the present invention, it is possible to easily produce an intermediate molded body with a high porosity, which was extremely difficult to obtain when using a binder such as silica sol or alumina sol that produces a binding effect by drying and solidifying. It has the characteristic that it is possible to obtain a composite gold side with a small value.

〔Example〕

Next, the present invention will be explained with reference to examples.

Example 1 Commercially available ceramic fiber 189&, calcium silicate frit 7g, acrylonitrile butadiene yarn latex (solid content 40%) 11mff were mixed with 19500+ne
of water and thoroughly stirred and mixed. To this slurry, add 751 parts of acrylamide yarn flocculant 0.0% aqueous solution and 1% aqueous solution of sulfuric acid (baml) and stir and mix thoroughly. After making the paper using a machine and drying it, it was heated to 900℃ for 80 minutes.
An intermediate molded body having a size of 1/150 x 15 (IIM), a thickness of 10 mm, and a porosity of 75% was obtained. This intermediate molded body was placed in a mold for melting. Inject 750"C aluminum #'41JA into !~q,
(Al2 in the intermediate j & shape at a pressure of 100 kQ/d
The ceramic fiber composite metal of the present invention was obtained by filling and solidifying aluminum.

Example 2 Commercially available ceramic fibers were put into water to make a slurry, and the song DL! At the same time, the slurry is gradually introduced into the inward container, and water is added from the side wall of the container to generate a thin stream. (removal show) Ti-containing band 1
t% ceramic fibers were obtained.

In this way? Ujko ceramic fiber 44y1
Calcium silicate frit 14y, acrylonitrile butadiene yarn latex (40% of same type Lana) 8rJ, acrylamide yarn flocculant 0.05% water K (liquid 811+ne
, sulfuric acid buff 110% aqueous solution 20Ine, water 7800m7
! 150 x 150 m in the same manner as in Example 1.

An intermediate molded body having a thickness of 10 mm and a porosity of 9% was obtained. Using this intermediate compact, a ceramic fiber composite metal of the present invention was obtained in the same manner as in Example 1.

Example 8 Actual m11 shot content 1% obtained by the same method as Example 2
Ceramic fiber 38g, calcium borate thread frit 201/, acrylonitrile butadiene cured latex (solid content 40%) l (imd, acrylamide thread flocculant 0.05% water soluble 3Qm/, sulfate band 10% aqueous solution 20ME, water 78 (10rr1#'l! using the same method as Example 1, 160 x 160 size, thickness lO small,
An intermediate molded body having a porosity of 90% was obtained. This intermediate molded body was used for convenience 17, and a ceramic fiber composite metal of the present invention was obtained in the same manner as in Example 1.

Example 4 Ceramic fiber 189N with a shot content of 0.1% obtained by the method of Example 2 and ll-1], 7 g of calcium borate yarn frit, and acrylonitrile pig (1
B) Diene yarn latex (solid content 40@;) 19m/acrylamide yarn #collecting agent 0.06 filtrate/water soluble/1 75m1!
, sulfuric acid buff 110% water soluble% 57 me1 water 19500
15 (IX
An intermediate molded body with a porosity of 75% was obtained using a ceramic fiber composite metal of the present invention (41 mm) in the same manner as in Example 1. .

Example 5 The same method as in Example 2 was used. The shot fi content was 0.
28g of 1% ceramic fiber, 69g of calcium borate frit. Acrylonitrile butadiene latex (solid content 40%) 4me1 acrylamide flocculant 15me, sulfate band 10% aqueous solution IQtn/, water 40
001ne was used to obtain an intermediate molded body of 150×16ON, thickness 10×, and porosity of 95% using method D. Using this intermediate molded body, a main molding was performed in the same manner as in Example 1. The ceramic fiber composite metal of the invention was obtained.

Example 6 Shot content obtained in the same manner as in Example 2 (LID 0.1% ceramic fiber 19g, calcium borate frit 10f1 acrylonitrile butadiene latex (solid content 40%) 4 to (4 , acrylamide thread M collection agent 15mL sulfate band 10% aqueous solution tom
1 in the same manner as in Example 1 using 400Qme of water.
An intermediate molded body having a size of 50×150 mm, a thickness of 10 mm, and a porosity of 95% was obtained. Using this intermediate compact, a ceramic fiber composite gold layer of the present invention q) was obtained in the same manner as in Example 1.

When the ceramic fiber composite gold of Examples 1 to 6 obtained in this manner was cut and the cross section was observed, it was found that the ceramic fibers were composited in a predetermined shape, and the deformation of the intermediate molded body due to filling with molten metal was confirmed. Couldn't see it:.

Furthermore, the ceramic-kutsaibar composite metal of the present invention was excellent in mechanical strength and abrasion resistance.

Claims (1)

[Claims] 1. A porosity of 75 to 85 wt% frit, the remainder being ceramic fiber, and the contact points of the ceramic fibers are fused and joined by the frit.
A ceramic fiber composite metal in which 95% of the voids in the molded body are filled with one metal selected from aluminum, aluminum alloy, magnesium, and magnesium alloy. 2. The frit is one or more types selected from borosilicate-based, calcium borate-based, calcium silicate-based, and sodium silicate thread frits. Ceramic fiber composite metal according to item 1. 3. The ceramic fiber composite metal according to claim 1 or 2, wherein the ceramic fiber has a shot content of 20 wt% or less. 4. Frit 4.5-34wt%, organic binder 3-10
wt%, the remainder of the molded body is made of ceramic fibers, and the organic binder is burnt out, and the points of contact between the ceramic fibers are fused and joined by a frit to form a molded body with a porosity of 75 to 95%. 1. A method for producing a ceramic fiber composite metal, the method comprising: filling the voids of the molded body with any one metal selected from molten aluminum, aluminum alloy, magnesium, and magnesium alloy. 5. The frit is one or more types selected from borosilicate-based, calcium borate-based, calcium silicate-based, and sodium silicate-based frits. 4. The method for producing a ceramic fiber composite metal according to item 4. 6. The ceramic fiber has a shot content of 20 wt% or less, which is obtained by dispersing commercially available ceramic fibers in water to form a slurry, turning the slurry into an eddy flow, and separating and removing large shots by centrifugal force. A method for manufacturing a ceramic fiber composite metal according to claim 4 or 5, characterized in that: 7. The method for manufacturing a ceramic fiber composite metal according to any one of claims 4 to 6, wherein the heat treatment is performed at a temperature within a range of 800 to 1000°C.