EP1594646A2 - Composants comprenant une couche de mousse metallique - Google Patents

Composants comprenant une couche de mousse metallique

Info

Publication number
EP1594646A2
EP1594646A2 EP04706125A EP04706125A EP1594646A2 EP 1594646 A2 EP1594646 A2 EP 1594646A2 EP 04706125 A EP04706125 A EP 04706125A EP 04706125 A EP04706125 A EP 04706125A EP 1594646 A2 EP1594646 A2 EP 1594646A2
Authority
EP
European Patent Office
Prior art keywords
foamed
semi
finished product
component
forming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04706125A
Other languages
German (de)
English (en)
Inventor
Winfried Bunsmann
Christoph Beichelt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wilhelm Karmann GmbH
Original Assignee
Wilhelm Karmann GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wilhelm Karmann GmbH filed Critical Wilhelm Karmann GmbH
Publication of EP1594646A2 publication Critical patent/EP1594646A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention relates to a method for producing components according to the preamble of claim 1 and a component according to the preamble of claim 11.
  • components or semi-finished products with at least one layer containing a blowing agent and a metallic powder these components are brought together from a powder consistency after their mixing to form a foamable composite.
  • Such components are particularly light and, at the same time, very stiff due to the foam content, so that they can be used very advantageously as body parts in mobile units, such as motor vehicles, and also for reducing the energy introduced in the event of an accident.
  • the same foam shapes can be used for different components. This enables a series to be split up without modifying the foaming furnaces. A costly retrofitting, in which the furnaces would first have to be shut down and then heated up again to the foaming temperature after the changeover, is thus avoided.
  • a form-fitting design of the furnace can be completely unnecessary if, for example, plane level Semi-finished products are foamed and are subjected to forming for the first time after foaming.
  • the cell structure of the component according to claim 11 in the foamed layer provides the possibility of being able to carry out the shaping only after the foaming, without having to carry out a subsequent recovery annealing.
  • Fig. 1 is an overall view of a for performing a method according to the invention trained press tool with inserted semi-finished product during the forming process
  • FIG. 2 shows a detailed view of the upper and lower molded part of the press with the foamed, planar semi-finished product held in between before the forming
  • FIG. 3 is a view similar to FIG. 2 with the onset of pressing and the beginning of forming
  • FIG. 4 is a view similar to FIG. 3 with continued pressing and forming
  • FIG. 5 is a view similar to FIG. 4 at the end of the pressing process
  • Deformation 9 shows the onset of compression and deformation
  • FIG. 13 shows a lower molded part for the production of a skateboard.
  • a powder mixture of one or more metallic powders for example an aluminum-silicon alloy, such as AlSi7 or A1SÜ2, or an aluminum-silicon-copper alloy, such as AlSi6Cu4, is first on the one hand, and one or more gas-releasing propellants, on the other hand, for example titanium hydride.
  • the powder components can be mixed in a mechanical mixer.
  • the powder layer formed in this way can be compacted, for example, by means of an extrusion process between two rollers or by means of pulse compression or other one-dimensional compression perpendicular to the extension of the powder layer, alone or with one or more solid metal cover layers 2, 3 to form a foamable semi-finished product.
  • solid metallic cover layers 2, 3 metallic bonds are formed between the or the top layer (s) 2, 3 and the powder layer.
  • the semifinished product can also be formed without cover layers 2, 3.
  • Such a semi-finished product can be cut to size and then either subjected to a first shaping, for example provided with features, as described in DE 196 12 781 Cl.
  • This reshaping can be carried out by known customary one-sided or two-sided reshaping processes, such as, for example, by a deep-drawing process, one end already receiving its final contour.
  • the semi-finished product can also remain in its generally plane shape.
  • the possibly formed semi-finished product is then placed in a mold which is adapted to the end-contoured side, so that during the subsequent foaming, expansion only takes place in the direction facing away from the end-contoured side.
  • Foaming takes place in this form in an oven at a temperature above the decomposition temperature of the blowing agent, at which this gas splits off, and can be limited or free, depending on requirements.
  • a semifinished product 4 to be processed is formed with at least one foamed layer 1.
  • a semifinished product 4 with double-sided solid metal sheets 2, 3 and a foamed layer 1 lying in between there are metallic bonds between the cell walls 7 of the foamed bubbles 8 and the solid metal cover sheets 2, 3 drawn in.
  • the semi-finished product 4 is parallel-walled, has a constant thickness over its entire course and has not been formed here before foaming.
  • a flat semifinished product 4 is thus present in the forming process shown in FIGS. 2 to 5. This is about ten millimeters thick.
  • the cover layers 2, 3 each have a thickness of approximately one millimeter.
  • the thickness of the cover layers 2, 3 should be sufficiently small to enable their deformation and to ensure a low weight afterwards in the component 14.
  • a cover layer 2, 3 should therefore take up less than about 15% of the thickness of the semi-finished product 4.
  • a pressing tool is used as the forming tool 9, which comprises an upper 10 and a lower molding 11. These have mutually facing surfaces 5, 6 which are parallel to one another both when the tool 9 is open and when it is closed and thus leave a parallel gap 12 between them when the tool 9 is closed, in which the semifinished product 4 has a constant thickness over its entire surface extent.
  • the height H of the parallel gap 12 remaining when the tool 9 is closed corresponds to the thickness D of the Semi-finished product 4 and the component 14 formed in the tool 9 by the deformation.
  • the surfaces 5, 6 are each self-contained and are thus in full contact with the cover layers 2, 3 of the component 14 at the end of the forming process.
  • the shaping parts 10, 11 do not have a minimum radius which is too narrow, since otherwise, as is shown in FIGS. 8 to 11, a significant proportion of cell webs 7 of the foam bubbles 8 tears and also in that there shown extremely small radius, the upper, compressed cover layer 2 is pressed in at points or in lines. The Parallelwandigkei t of the component 14 would be violated, the component unusable. If the component has a minimum thickness D of 5 mm, for example when using an AlMnl alloy for cold working, even at small forming angles of a few degrees, no radius occurring in the molded parts 10, 11 should be less than 20 mm.
  • the cell webs 7 are plastically deformed (buckling by Euler), but retain their supporting effect. Due to the large minimum radii, which are preferably also greater than 100 mm, the pressure is entered linearly into the semifinished product 4 only in the first phase of the deformation. In this phase, however, elastic deformation still takes place, so that this does not lead to destruction. Furthermore, when the plastic deformation has started, a flat pressure entry takes place.
  • FIG. 12 also shows a tearing of the lower cover layer 3, which is stretched in the forming shown here, which results from an excessively narrow radius of the forming parts 10, 11 and / or an excessively large forming angle of more than approximately 60 °.
  • the material expansion in the cover layer 3 must not lead to a thinning of the material if the stability of the component 14 is to be kept high throughout.
  • the foamed semi-finished product 4 is not clamped on the edge side during the shaping process described, unlike in deep drawing, so it can keep its parallel wall without thinning.
  • compressive stress is introduced through the upper molded part 10, through the lower 11 a tension.
  • the ratios can also be reversed.
  • the molded parts 10, 11 are designed so that they reshape the foamed semi-finished product 4 at several points at the same time. They can initiate partial tensile and partial compressive stresses.
  • the shape of the deformations can be different, for example linear or punctiform.
  • the forming can be carried out as cold forming in a particularly cost-effective manner. Hot forming is also possible. A high copper content in the starting mixture ensures good ductility of the foam layer 1 formed.
  • the component 14 produced and also claimed by the method according to the invention thus has at least one deformed region which deviates from a plane surface and is curved in such a way that part of the foamed layer 1 comprises a fiber which is neutral with respect to the curvature and in one relative to the neutral fiber narrower curved area cells 8a are reduced and cells 8b are expanded in a further curved area outer relative to the neutral fiber.
  • This widening or narrowing does not have to affect all the cells 8 located there, but a significant part visible in the micrograph.
  • the enlargement or reduction is primarily related to the direction of the neutral fiber. This results in a preferred extension of the cells 8 in the manner of a texture of metallic grain boundaries.
  • the component 14 can be processed further in various ways, for example pressed in at the edges to form flanges, drilled and polished and painted on the surfaces.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé pour produire un composant (14) comprenant au moins une couche expansée, constituée d'une ou de plusieurs sortes d'agent d'expansion et d'une ou de plusieurs sortes de poudre métallique, et au moins une couche de métal massif (2 ; 3). Pour former la couche expansée, une poudre comprenant plusieurs constituants est mélangée, puis le mélange (1) ainsi formé est soumis, avec la ou les couches de métal (2 ; 3), à au moins une opération de pression et il est ensuite expansé. Le procédé selon l'invention se caractérise en ce que le produit semi-fini (4) obtenu après l'expansion est introduit dans un outil de formage (9) en deux parties dans lequel il est soumis à une opération de formage.
EP04706125A 2003-01-31 2004-01-29 Composants comprenant une couche de mousse metallique Withdrawn EP1594646A2 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10304078 2003-01-31
DE10304078A DE10304078A1 (de) 2003-01-31 2003-01-31 Bauteile mit metallischer Schaumlage
PCT/DE2004/000129 WO2004067212A2 (fr) 2003-01-31 2004-01-29 Composants comprenant une couche de mousse metallique

Publications (1)

Publication Number Publication Date
EP1594646A2 true EP1594646A2 (fr) 2005-11-16

Family

ID=32747526

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04706125A Withdrawn EP1594646A2 (fr) 2003-01-31 2004-01-29 Composants comprenant une couche de mousse metallique

Country Status (3)

Country Link
EP (1) EP1594646A2 (fr)
DE (1) DE10304078A1 (fr)
WO (1) WO2004067212A2 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102004040888A1 (de) * 2004-08-24 2006-04-13 Wilhelm Karmann Gmbh Herstellung von Bauteilen mit zumindest einer metallischen Schaumlage
DE202005006240U1 (de) * 2005-04-18 2005-10-20 Seeliger, Hans-Wolfgang Metallschaum-Sandwichs

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19612781C1 (de) 1996-03-29 1997-08-21 Karmann Gmbh W Bauteil aus metallischem Schaumwerkstoff, Verfahren zum Endformen dieses Bauteils und Vorrichtung zur Ausführung des Verfahrens
SE0100232L (sv) 2001-01-26 2002-07-27 Bombardier Transp Gmbh Metod för tillverkning av ett krökt sandwichelement och ett krökt sandwichelement
ITMO20020041A1 (it) * 2002-02-19 2003-08-19 Tecnoform Spa Metodo per la produzione di componenti curvi da arredo, particolarmente ante per mobili e manufatto cosi' ottenibile

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2004067212A2 *

Also Published As

Publication number Publication date
WO2004067212A3 (fr) 2004-10-21
DE10304078A1 (de) 2004-08-26
WO2004067212A2 (fr) 2004-08-12

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