JPS6046237A - Ceramics-metal composite material and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a ceramic-metal composite and a method for producing the same, and more particularly to a ceramic in which a part of the ceramic is impregnated with a casting metal.

Conventionally, ceramics have been used in fields that require properties that combine the characteristics of both ceramics and metals, such as wear-resistant rollers where the strength is insufficient when ceramic molded bodies alone are used, and hot-worked steel conveyor rollers that require heat insulation on the surface. Metal composites are used.

To explain in more detail, as shown in FIG. 1, the outer layer ft is made of a molded body of metal carbide, boride, oxide, silicide, nitride, etc. (hereinafter referred to as a ceramic molded body).
There is a cylindrical ceramic-metal composite consisting of an inner layer (2) made of a metal material, and in the production of this, conventionally, a cylindrical ceramic molded body is set in a mold and metal is placed inside the mold. A composite was obtained by casting and welding the two together.

However, at the boundary between the two, the bonding state between the two is not good due to differences in the properties of the ceramic molded body and the metal, problems with the wettability of the ceramic to the metal, and the like.

Therefore, there have been problems with cracking when the metal shrinks, or peeling due to stress concentration at the boundaries in the finished product.

The present invention has been made to solve the above problems, and its purpose is to create a high-quality ceramic-metal composite material that has a good bond between ceramic and metal, has a long lifespan, and has no fear of peeling between the two. The purpose of the present invention is to provide a ceramic-metal composite material having an outer layer formed of a ceramic material, and a ceramic material of the outer layer that is continuous with the ceramic material of the outer layer. The manufacturing method of the present invention consists of a sintered ceramic material and a permeation layer having a metal casting material in the sintered particle voids. Using a cylindrical ceramic composite material consisting of an outer layer and a pre-infiltration layer made of a ceramic material with high porosity that is continuously sintered with the ceramic material of the outer layer,
A metal casting material is cast therein by centrifugal force casting, and a permeation layer is formed in which the metal casting material is infiltrated into the sintered particle voids of the pre-penetration layer. Regarding the third invention, the ceramic-metal composite material of the present invention comprises the outer layer and the permeation layer of the composite material of the first invention, and, in addition to these, the same type or metallurgically continuous metal casting material of the permeation layer. and an inner layer formed of different types of metal casting materials.Further, regarding the fourth invention, the manufacturing method of the present invention includes, in the manufacturing method of the second invention,
In addition to centrifugally casting a metal casting material to form a permeation layer, an inner layer that is metallurgically continuous with the metal casting material of the permeation layer and made of the metal casting material is formed; Regarding the fifth invention, the manufacturing method of the present invention uses the cylindrical ceramic composite material according to the second invention, and casts a metal casting material with good permeability inside it by centrifugal force casting, and at least the sintering of the pre-penetration layer. The method consists in forming a permeation layer in which the metal casting material is infiltrated into the particle voids, and then casting a different type of metal casting material having properties required for the inner layer.

The present invention will be explained in detail below.

First, the composite material of the present invention will be explained based on an example shown in FIG.

FIG. 2 is an example in which the composite material of the present invention is applied to a cylindrical ceramic-metal composite material (3). (4) is the outer layer, which is made of a densely fired ceramic layer. The type of ceramic material depends on the intended use, for example, Tie,
SiC%AI! Q03, ZrO2, Boo%TiN
, Si3N4 and other metal carbides, borides, oxides, silicides, and nitrides.

(5) is a permeation layer, which is a ceramic material that is continuously sintered with the ceramic of the outer layer (4), and the metal casting material permeates into the sintered particle voids. The permeable layer (5
) is preferably 1 to 5 thick. Below 11M,
The metal permeation layer becomes thinner, and the material changes rapidly from the dense outer layer (4) to the inner layer (6), which will be described later, resulting in poor boundary peeling resistance. This is undesirable because it creates areas where penetration is insufficient, resulting in material deterioration. Further, it is desirable that the porosity of the ceramic material before the metal penetrates is between 15 and 80 q&, and increases toward the inner layer (6) side.

If it is less than 15 inches, the penetration will be insufficient, and the material properties of the penetration layer (5) and the inner layer (6), which is a metal layer, will change rapidly.
When it exceeds 0, the material changes rapidly at the boundary between the outer layer (4) and the permeable layer (6), making it easy for both to peel off. (6) is the inner layer, which has metallurgical continuity and is made of the same material as the metal casting material of the permeation layer (5), and is made of iron material such as high-grade cast iron, ductile cast iron, cast steel, etc. depending on the desired mechanical properties. Alternatively, non-ferrous metals such as aluminum, copper, etc., and alloys thereof can be selected as appropriate.

Next, the manufacturing method of the present invention will be explained based on the case of the cylindrical ceramic-metal composite material (3). First, as shown in FIG. an outer layer (8) consisting of a ceramic layer;
It is a ceramic layer with a high porosity that is continuously sintered with the ceramic of the outer layer (8), and has a thickness of 1 to 5 m + 1.0 m as described above. A cylindrical ceramic composite material 17) consisting of a pre-penetration layer (9) with a porosity of 15 to 80 is manufactured.

This manufacturing method involves increasing the mixing ratio of thermoplastic binder in the ceramic particles in the pre-infiltration layer, increasing the particle size of the ceramic particles, and molding pressure during powder compaction compared to the area corresponding to the outer layer. The porosity of the outer layer (8) and the pre-infiltration layer (9) is differentiated by compacting and firing the outer layer (8) and the pre-infiltration layer (9).

Next, as shown in Fig. 4, the cylindrical ceramic composite material (7) is fixed in a centrifugal casting mold (l) with refractory material 00 and a band (101 (10)), and in this state, the mold (+
+1 is rotated on a roller (12+021, inner layer θ
4) The desired casting material molten metal is poured into the pouring machine 03 to form
) and centrifugally cast the inner layer 041. At this time, a space θ space O is provided on both end surfaces of the pre-penetration layer (9) of the cylindrical ceramic composite material (7) so as to contact the molten metal.
It is desirable to have a beat. This is because the end face solidifies quickly when cooled, making it difficult to achieve the required penetration into the ceramics.

Further, as a means to aid infiltration, it is desirable to preheat the cylindrical ceramic composite material (7) to 400 to 1000°C. At this time, preheating in an inert gas is also an effective means to prevent deterioration such as oxidation due to preheating. In addition, the preheating has the effect of preventing the cylindrical ceramic composite material (7) from cracking due to thermal shock caused by casting and from cracking due to the difference in shrinkage between the two after casting.

Regarding the mold rotation speed during centrifugal force casting, GNO,
The higher the casting temperature, the greater the penetration. Generally, GNO is about G20 to G150, but of course 0150
Even more than this is good because it increases penetration.

In particular, the ceramic particles in the pre-penetration layer (9) are small,
If the porosity is small and the permeation layer needs to be thick, use G.
It is sufficient to increase MOo. As described above, centrifugal force casting is suitable because the thickness of the permeation layer can be easily controlled.

As mentioned above, the material of the molten metal for the inner layer (I4) is appropriately selected from among high-grade cast iron, ductile cast iron, etc. depending on the required properties and strength. It's the best.

After casting the inner layer (I4), it is preferable to balance the mold under a high temperature condition and to sufficiently slowly cool it in a heat retention furnace, heat treatment furnace, etc.

The above explanation is for a cylindrical composite material, but vertical centrifugal casting allows the inner layer to be solid, and as shown in Figure 5, the amount of cast material to be poured can be reduced. It is also possible to create a composite material consisting only of the ceramic outer layer (4) and the metal permeable layer (5).

In this case, it can be obtained by removing the metal inner layer (6) of the cylindrical ceramic-metal composite material (3) shown in FIG. 2 by processing.

In addition, as shown in Figure 6, the pre-penetration layer (9) with high porosity
Use a metal that easily penetrates, such as high-grade cast iron, and make the wall thickness exactly the same, or cast a little extra to create a penetration layer (5).
1, and then inside the metal, which requires strength,
For example, the inner layer (
6) Formation of l is advantageous because it can easily combine easy penetration and strong root plate strength.

Next, specific manufacturing examples will be listed and explained.

Manufacturing example of a conveying roller material with an outer diameter of φ305 x total length of 400' x wall thickness of 501 mm.

1. Prepare a cylindrical ceramic composite material of outer diameter φ305 x total length 400' x outer layer x pre-infiltration layer (porosity 5 to 50%) 5 t jff, and after preheating to 800°C, as shown in Fig. 4 described above. , installed in a centrifugal force casting mold via a refractory material.

2. The mold was rotated, and the mold rotation was set to 150 in ClNo.

3. Next, high-grade cast iron was cast at 1380°C as a penetration metal and an inner layer metal.

4. After solidifying the inner layer, take out the ceramic-metal composite from the mold under high temperature conditions, break the mold and place it in a heat retention furnace.
It was slowly cooled.

5. In the above manner, a ceramic-metal composite conveying roller material in which 5 MM of high-grade cast iron penetrated into the cylindrical ceramic composite material was obtained.

As described above, the composite material of the present invention includes an outer layer formed of a ceramic material, a ceramic material continuously sintered with the ceramic material of the outer layer, and a metal casting material in the sintered particle voids. or a two-layer structure consisting of a permeable layer, or an inner layer formed of the same or different type of metal casting material that is metallurgically continuous with the metal casting material of the permeation layer, in addition to the outer layer and the permeation layer. Because of the layered structure, the bond between the ceramic and the metal is good, and we can provide a long-life, high-quality ceramic-metal composite material with no fear of peeling between the two.Also, the manufacturing method allows us to precisely form the ceramic material using ceramic materials. A cylindrical ceramic composite material is used, which is made of a cylindrical ceramic composite material consisting of an outer layer made of ceramic material, and a pre-infiltration layer made of a ceramic material with a high porosity that is continuously sintered with the ceramic material of the outer layer. A metal casting material is cast, and a permeation layer is formed by infiltrating the metal casting material into the sintered particle voids of the pre-penetration layer, or in addition to forming the permeation layer, the metal casting material and metallurgy of the permeation layer are formed. The composite material of the present invention can be easily and
It can be manufactured economically, and the permeation layer can be easily controlled by changing the mold rotation speed in centrifugal casting. In addition, using the cylindrical ceramic composite material, a metal casting material having good permeability is cast inside the cylindrical ceramic composite material by centrifugal force casting, and the metal casting material is infiltrated into at least the sintered particle voids of the pre-penetration layer. If you form a permeable layer and then cast a different type of metal casting material with the properties required for the inner layer,
To provide a high-quality, economical ceramic-metal composite material that can be easily applied as an inner layer even with a high-toughness cast material that usually has poor permeability, has a strong inner layer, and is free from the fear of peeling of the outer layer of the ceramic material. I can do it.

[Brief explanation of the drawing]

Fig. 1 is a sectional view showing the structure of a conventional ceramic-metal composite, Fig. 2 is a sectional view showing the structure of a cylindrical ceramic-metal composite to which the present invention is applied, and Fig. 3 is a manufacturing method of the present invention. FIG. 4 is a cross-sectional view showing an example of the outline of the manufacturing apparatus according to the present invention, and FIG. 5 is a cross-sectional view showing the structure of a cylindrical ceramic composite material according to the present invention, and FIG. FIG. 6 is a partial sectional view showing the structure of the composite material of the present invention when the metal of the inner layer and the metal of the permeation layer are different materials. (3)...Cylindrical ceramic-metal composite material, (4)
... Outer layer, (5), (5)1... Penetration layer, (61,
(61'...inner layer, (7)...cylindrical ceramic composite material, (8)...outer layer, (9)...pre-penetration layer, (
11)...Mold.

Claims (1)

[Claims] 1. An outer layer made of a ceramic material, and a permeation layer that is made of a ceramic material that is continuously sintered with the ceramic material of the outer layer and has a metal casting material in the sintered particle voids. A ceramic-metal composite material. 2. Using a cylindrical ceramic composite material consisting of an outer layer made of a dense ceramic material and a pre-infiltration layer made of a high porosity ceramic material that is continuously sintered with the outer layer ceramic material. , a metal casting material is cast therein by centrifugal force casting to form a permeation layer in which the metal casting material is infiltrated into the sintered particle voids of the pre-penetration layer. Method 0 3: an outer layer formed of a ceramic material, and a permeation layer that is made of a ceramic material that is continuously sintered with the ceramic material of the outer layer and has a metal casting material in the sintered particle voids;
A ceramic-metal covering material comprising the metal casting material of the permeation layer and an inner layer formed of metallurgically continuous metal casting materials of the same or different kind. 4. Using a cylindrical ceramic composite material consisting of an outer layer made of a dense ceramic material and a pre-infiltration layer made of a ceramic material with high empty PJI that is continuously sintered with the ceramic material of the outer layer. , a permeation layer in which a metal casting material is cast by centrifugal casting, and the metal casting material is infiltrated into the sintered particle voids of the pre-infiltration layer, and metallurgically continuous with the metal casting material of the permeation layer. , and an inner layer made of the metal casting material. 5. Using a cylindrical ceramic composite material consisting of an outer layer made of a dense ceramic material and a pre-infiltration layer made of a high porosity ceramic material that is continuously sintered with the outer layer ceramic material. , a metal casting material with good permeability is cast inside it by centrifugal force casting, and a permeation layer is formed in which the metal casting material is infiltrated into at least the sintered particle voids of the pre-penetration layer, and then as an inner layer. A method for manufacturing a ceramic-metal composite material, characterized by casting dissimilar metal casting materials having required properties. 6. The permeation layer has a thickness of 1 to 5R. 71. Ceramic-metal composite material according to item 3. 7. Ceramic materials with high porosity have a porosity of 15
80%. The method for producing a ceramic-metal composite material according to claim 2, 4, or 5.