JP5653154B2 - Metal-ceramic composite material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a metal-ceramic composite material and a method for producing the same.

  According to the pressure infiltration method, which is one of the methods for producing ceramic powder or a composite material of ceramic fiber and metal, the metal such as aluminum melted into the ceramic powder or fiber or the ceramic molded body is infiltrated under pressure. (See Patent Document 1).

  According to this method, it is necessary to remove excess metal that covers the metal-ceramic composite material created by infiltrating aluminum into a ceramic molded body or the like.

JP 2010-083715 A

  However, when removing excess metal together with the surface portion of the composite material, it is difficult to work with cemented carbide tools due to the high ceramic filling rate in the compact, and the removal work takes a long time with expensive diamond tools. Need to be In addition, depending on the shape of the composite material, it is necessary to remove a part of the composite material with the diamond tool after the excess metal is removed with the carbide tool. For this reason, the problem of an increase in work cost due to tool breakage and extension of work time occurs.

  Then, an object of this invention is to provide the method etc. which manufacture the metal-ceramic composite material which can aim at the removal operation | work of the surplus metal which covers a metal-ceramic composite material easily.

  The manufacturing method of the metal-ceramic composite material of the present invention for solving the above-described problems is obtained by applying a slurry containing plate-like particles or plate crystals as a release material on the surface of a porous ceramic molded body, and then applying the slurry. The mold release material is adhered to the surface of the ceramic molded body by drying, and the metal-ceramic composite material covered with surplus metal is cooled by pressurizing and injecting molten metal into the ceramic molded body. The excess metal is removed from the metal-ceramic composite material together with the release material.

  According to the method of the present invention, since the plate-like particles interposed between the composite material and the surplus metal serve as a release material, the surplus metal can be easily removed from the surface of the composite material.

According to the knowledge obtained by the present inventors, when the amount of the release material (plate-like particles) applied to the ceramic molded body is less than 0.005 [g / cm ² ], coating unevenness occurs, and the plate-like particles The mold release effect due to is impaired. On the other hand, when the amount of the release material (plate-like particles) applied to the ceramic molded body exceeds 0.05 [g / cm ² ], the plate-shaped particles hinder the penetration of the molten metal into the ceramic molded body.

Therefore, it is preferable to adjust the amount of the release material applied to the ceramic molded body within a range of 0.005 to 0.05 [g / cm ² ]. In particular, when it is in the range of 0.01 to 0.03 [g / cm ² ], a situation such as non-penetration of aluminum or insufficient effect of the release material does not occur, and the releasability is stably expressed.

  The overall porosity of the release material attached to the ceramic molded body is 55 to 70%, the pore diameter distribution is 0.01 to 1 [μm] as the first range, and 10 to 100 as the second range. In each [μm], one peak is shown, and among the total porosity, pores belonging to the first range occupy 30 to 70 [%], while pores belonging to the second range are 5 to 35 It is preferable to apply the mold release material to the surface of the ceramic molded body so as to occupy [%].

BRIEF DESCRIPTION OF THE DRAWINGS Outline explanatory drawing of the manufacturing method of the metal-ceramics composite material of this invention.

  The metal-ceramic composite material and the manufacturing method thereof as one embodiment of the present invention will be described.

  First, as shown in FIG. 1 (a), a slurry 2 'containing plate-like particles (or tabular crystals) 2 is applied to the surface of the ceramic molded body 1'. In addition to applying the slurry 2 'to the surface of the ceramic molded body 1' with a brush, the slurry 2 'may be sprayed toward the surface of the ceramic molded body 1'.

  Subsequently, the slurry 2 'is dried. During the drying process, the plate-like particles 2 are oriented so that the longitudinal direction thereof is parallel to the surface of the ceramic molded body 1'. As a result, for example, as shown in FIG. 1 (b), the plates are oriented (layered) in a state in which the upper and lower surfaces are oriented so as to be parallel to the surface of the ceramic molded body 1 ′ and stacked in the vertical direction. The shaped particles 2 adhere to the surface of the ceramic molded body 1 ′.

  Subsequently, as shown in FIG. 1 (c), the molten metal 3 ′ is pressed and infiltrated into the ceramic formed body 1 ′ through the gap between the plate-like particles 2 (see the downward arrow). At this time, since the vertical gap of the plate-like particles 2 is narrow, the molten metal 3 ′ hardly enters the gap. Thereafter, the molten metal 3 ′ and the molded body 1 ′ are cooled to obtain the composite material 1 covered with the surplus metal 3 as an intermediate product.

  And as FIG.1 (d) shows, the surplus metal 3 is removed from the surface of the composite material 1 with the plate-shaped particle | grains 2 as a mold release material (refer upward arrow), As final product A metal-ceramic composite material 1 is obtained.

(Example)
(First embodiment)
(Ceramic compact)
A ceramic molded body was prepared using two types of SiC powder as ceramic powder. One is a commercially available # 180 SiC powder having a median diameter of 81 [μm] measured by a laser scattering method. The other is a commercially available # 500 SiC powder having a median diameter of 28 [μm] measured by a laser scattering method. These two types of Si powders were mixed at a weight ratio of # 180: # 500 = 7: 3 and mixed with water and a binder (silica sol). The mixing time can be set to any time in the range of 10 to 20 [hr].

  After the slurry-like SiC was poured into the mold and the moisture was removed, the preformed body removed from the mold was heat-treated at 1000 [° C.] in the atmosphere to produce a ceramic molded body. The heat treatment temperature should just be adjusted in the range of 10-30 [degreeC].

As the ceramic raw material, Al ₂ O ₃ , AlN or the like may be used in addition to SiC.

  The shape of the molded body is arbitrary, but is a rectangular parallelepiped (for example, height 70 [mm]) on one side of a rectangular parallelepiped (for example, height 100 [mm], width 700 [mm], length 400 [mm]). , A compact having a recess having a width of 360 [mm] and a width of 110 [mm] was formed.

(Release material)
Mica powder (manufactured by Yamaguchi Mica Kogyo Co., Ltd., average particle size (meaning the size in the longitudinal direction of the plate crystal; the same applies hereinafter) 16 [μm]) is used as the release material, and slurried with isopropyl alcohol as the solvent. It was done. In addition, ethanol etc. may be used as a solvent. The coating amount of the plate-like particles (release material) on the ceramic molded body was adjusted to 0.005 [g / cm ² ].

  The overall porosity of the release material attached to the ceramic molded body is in the range of 55 to 70%. In addition, the pore size distribution of the release material shows a peak in each of 0.01 to 1 [μm] as the first range and 10 to 100 [μm] as the second range. Further, among the total porosity of the release material, the pores belonging to the first range account for 39 [%], and the pores belonging to the second range account for 11 [%]. The pore size distribution was measured by mercury porosimetry.

  The pores belonging to the first range (0.01 to 1 μm) are derived from the gap C1 in the overlapping direction of the plate-like particles 2 (see FIG. 1B). The pores belonging to the second range (10 to 100 μm) of the pore diameter distribution are derived from the lateral gap C2 between the plate-like particles 2 (see FIG. 1B). The range of distribution is affected by the particle size and aspect ratio (vertical / horizontal ratio) of the plate-like particles 2.

(Pressure penetration)
An AC3A alloy (Si component: 10 to 13%), which is an aluminum alloy for casting as a metal, was infiltrated into the ceramic molded body in a molten state. The osmotic pressure was 10 [MPa]. In place of the aluminum alloy, aluminum may be infiltrated.

(Aluminum removal)
The aluminum covering the composite material excluding the recesses was removed by a cemented carbide tool (for example, a cutting machine) so that a thickness of about 1 to 5 [mm] remained. Further, the aluminum was further removed by manual work using a tool having a flat tip such as chisel. About the aluminum in a recessed part, after the screw hole was cut, the volt | bolt was inserted there and it was removed by hand so that aluminum might be extracted from a recessed part using a volt | bolt as a clue.

(Second embodiment)
The amount of the release material applied to the ceramic molded body was adjusted to 0.02 [g / cm ² ]. Of the entire porosity of the release material adhering to the surface of the ceramic molded body, the pores belonging to the first range account for 51 [%], and the pores belonging to the second range account for 19 [%]. . Except for this, the composite material was manufactured under the same conditions as in the first example.

(Third embodiment)
The amount of the release material applied to the ceramic molded body was adjusted to 0.03 [g / cm ² ]. Of the entire porosity of the release material adhering to the surface of the ceramic molded body, the pores belonging to the first range account for 43 [%], and the pores belonging to the second range account for 25 [%]. . The osmotic pressure with respect to the ceramic molded body of the aluminum alloy was adjusted to 20 [MPa]. Except for this, the composite material was manufactured under the same conditions as in the first example.

(Fourth embodiment)
The amount of the release material applied to the ceramic molded body was adjusted to 0.04 [g / cm ² ]. Of the entire porosity of the release material adhering to the surface of the ceramic molded body, the pores belonging to the first range account for 58 [%], and the pores belonging to the second range account for 29 [%]. . The osmotic pressure with respect to the ceramic molded body of the aluminum alloy was adjusted to 20 [MPa]. Except for this, the composite material was manufactured under the same conditions as in the first example.

(5th Example)
Boron nitride powder (manufactured by Electrochemical Co., Ltd., average particle size 9 [μm]) was used as the release material (plate-like particles). The amount of the release material applied to the ceramic molded body was adjusted to 0.01 [g / cm ² ]. Of the total porosity of the release material adhering to the surface of the ceramic molded body, the pores belonging to the first range account for 55 [%], and the pores belonging to the second range account for 9 [%]. . Except for this, the composite material was manufactured under the same conditions as in the first example.

(Sixth embodiment)
The amount of the release material applied to the ceramic molded body was adjusted to 0.02 [g / cm ² ]. Of the total porosity of the release material adhering to the surface of the ceramic molded body, the pores belonging to the first range account for 49 [%], and the pores belonging to the second range account for 14 [%]. . Except for this, a composite material was manufactured under the same conditions as in the fifth example.

(Seventh embodiment)
The amount of the release material applied to the ceramic molded body was adjusted to 0.03 [g / cm ² ]. Of the entire porosity of the release material adhering to the surface of the ceramic molded body, the pores belonging to the first range account for 61 [%], and the pores belonging to the second range account for 20 [%]. . The osmotic pressure of the aluminum alloy with respect to the ceramic molded body was adjusted to 40 [MPa]. Except for this, a composite material was manufactured under the same conditions as in the fifth example.

(Eighth embodiment)
The amount of the release material applied to the ceramic molded body was adjusted to 0.05 [g / cm ² ]. Of the entire porosity of the release material adhering to the surface of the ceramic molded body, the pores belonging to the first range account for 59 [%], and the pores belonging to the second range account for 31 [%]. . The osmotic pressure of the aluminum alloy with respect to the ceramic molded body was adjusted to 40 [MPa]. Except for this, a composite material was manufactured under the same conditions as in the fifth example.

  Table 1 summarizes the manufacturing conditions of the metal-ceramic composite materials of the first to eighth examples. “◯” in the “Releasability” column means that the aluminum in the five ribs could be removed manually.

(Comparative example)
(First comparative example)
A composite material was produced under the same conditions as in Example 1 except that no release agent was used.

(Second comparative example)
The amount of the release material applied to the ceramic molded body was adjusted to 0.001 [g / cm ² ]. The overall porosity of the release material exceeds 70%. Except for this, the composite material was manufactured under the same conditions as in the first example.

(Third comparative example)
The amount of the release material applied to the ceramic molded body was adjusted to 0.08 [g / cm ² ]. The overall porosity of the release material is less than 55%. Except for this, the composite material was manufactured under the same conditions as in the first example.

(Fourth comparative example)
The release agent was made of SiC particles that are not plate-like but granular, and the coating amount was adjusted to 0.05 [g / cm ² ]. The overall porosity of the release material is less than 55%. In the pore size distribution of the SiC particles, the pores belonging to the first range occupy 69 [%] and the pores belonging to the second range occupy 2 [%] of the entire porosity of the release material. Except for this, the composite material was manufactured under the same conditions as in the first example.

(Fifth comparative example)
The release agent was made of SiC particles that are not plate-like but granular, and the coating amount was adjusted to 0.05 [g / cm ² ]. The overall porosity of the release material is less than 55%. In the pore size distribution of the SiC particles, the pores belonging to the first range occupy 10 [%] and the pores belonging to the second range occupy 49 [%] of the entire porosity of the release material. Except for this, the composite material was manufactured under the same conditions as in the first example.

(Sixth comparative example)
The amount of the release material applied to the ceramic molded body was adjusted to 0.04 [g / cm ² ]. However, plate-like particles having a particle size different from that of the fourth example were used. In this pore size distribution, the pores belonging to the first range occupy 57 [%] and the pores belonging to the second range occupy 7 [%] of the entire porosity of the release material. The overall porosity of the plate-like particles is 54%. Except for this, the composite material was manufactured under the same conditions as in the first example.

(Seventh comparative example)
The amount of the release material applied to the ceramic molded body was adjusted to 0.04 [g / cm ² ]. However, plate-like particles having a particle diameter different from those in the fourth example and the sixth comparative example were used. In this pore size distribution, the pores belonging to the first range account for 43 [%] and the pores belonging to the second range account for 15 [%] of the total porosity of the release material. The overall porosity of the plate-like particles is 76%. Except for this, the composite material was manufactured under the same conditions as in the first example.

  Table 2 summarizes the manufacturing conditions for the metal-ceramic composite materials of the first to seventh comparative examples. “X” in the column of “Releasability” means that the aluminum in the five ribs could not be removed manually, the aluminum was broken in the middle, and the like. Further, non-penetrating means that a portion where aluminum did not permeate the composite material after permeation was observed.

  According to the method of the present invention, since the plate-like particles 2 interposed between the composite material 1 and the surplus metal 3 serve as a mold release material, the surplus metal 3 is easily removed from the surface of the composite material 1. Yes (see FIG. 1 (d)).

  When the molten metal 3 ′ is infiltrated, the infiltration state is affected by the infiltration pressure and the size of the gap between the plate-like particles 2. When this gap is small (when the ratio of the small pore size distribution is large), the molten metal 3 'will not sufficiently penetrate into the compact 1' unless the osmotic pressure is increased. On the other hand, when this gap is large (when the ratio of the large pore diameter distribution is large), sufficient penetration can be achieved even if the osmotic pressure is low.

  From this point of view, the entire porosity and pore size distribution of the release material 2 attached to the ceramic molded body 1 ′ are adjusted so as to have the above-described form. As a result, the molten metal 3 ′ penetrates into the molded body 1 ′ at a portion having a large pore diameter, but hardly penetrates between the plate-like particles 2. For this reason, the surplus metal 3 can be easily removed from the surface of the composite material 1.

  Moreover, the trace from which the plate-like particle 2 is peeled appears in the surface roughness of the composite material 1. That is, the surface roughness Ra of the composite material 1 is in the range of 1 to 10 [μm]. This means that the composite material 1 was produced as a result of the excess metal 3 being easily removed according to the method described above.

  In the first comparative example, since the release material is not applied, aluminum cannot be released from the composite material. In the second comparative example, since the amount of the release material applied is excessively small, aluminum cannot be released from the composite material. In the third comparative example, since the amount of the release material applied is excessively large, the penetration of aluminum is inhibited, and a portion where the aluminum does not penetrate is generated. In the fourth comparative example, the amount of pore distribution in the first range (0.01 to 1 [μm]) is large, whereas the amount of pore distribution in the second range (10 to 100 [μm]) is small. However, aluminum becomes difficult to penetrate and non-penetration occurs. In the fifth comparative example, the amount of pore distribution in the first range is small, while the amount of pore distribution in the second range is large, so that the release of aluminum cannot be performed. In the sixth comparative example, since the overall porosity is small, it is difficult for aluminum to penetrate and non-penetration occurs. In the seventh comparative example, since the whole porosity is large, it is not possible to release aluminum.

DESCRIPTION OF SYMBOLS 1 ... Metal-ceramics composite material, 1 '... Ceramic compact, 2 ... Plate-like particle, 2' ... Slurry, 3 ... Surplus metal, 3 '... Molten metal.

Claims (3)

A method for producing a metal-ceramic composite material, comprising:
The slurry containing plate-like particles or tabular crystals as a mold release material is applied to the surface of the porous ceramic molded body, and then the slurry is dried to attach the mold release material to the surface of the ceramic molded body.
A metal-ceramic composite material covered with surplus metal was obtained by cooling the molten metal after pressure infiltrating the molten metal into the ceramic molded body,
Removing the excess metal from the metal-ceramic composite material together with the release material. The method according to claim 1, wherein an amount of the release material applied to the ceramic formed body is adjusted within a range of 0.005 to 0.05 [g / cm ² ].   3. The method according to claim 1, wherein an overall porosity of the release material in a state of adhering to the ceramic formed body is 55 to 70 [%], and a pore diameter distribution is 0.01 to 1 as a first range. In each of [μm] and 10 to 100 [μm] as the second range, and the total porosity, the pores belonging to the first range account for 30 to 70 [%], The method, wherein the release material is applied to the surface of the ceramic molded body so that the pores belonging to the second range occupy 5 to 35 [%].

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