JPS60863A - Fiber reinforcing method of surface part of article - Google Patents

Abstract

PURPOSE:To reinforce the surface of an article with good adhesion by sticking the micro-liquid droplets formed by melting a wire rod formed of a composite material composed of reinforcing fibers and a matrix material by thermal spraying onto the surface of the article. CONSTITUTION:A wire rod 4 consisting of a matrix material 3 such as an aluminum alloy or the like and reinforcing fibers 2 such as short fibers of alumina- silica, etc. is thermally sprayed with a thermal spraying device 5. Then the wire rod is made into many micro-liquid droplets 18 which are sprayed by blowing air 7 onto the surface 10 of a base material 9 and are laminated thereon to form a thermally sprayed layer 11. Then the surface reinforcement with good adhesion is obtd. and therefore the article is made durable for longer time.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for reinforcing the surface of an article, and more particularly to a method for reinforcing the surface of an article using reinforcing fibers.

For example, in the case of an article that has a sliding surface with other articles and is required to be lightweight as a whole, the article is made of a lightweight material such as a light metal, and the surface part is made of a reinforced m fiber composite. It is known that reinforcement is preferable, and a method of covering only the surface part of an article with composite reinforcement with reinforcing fibers is to place a fiber molded body made of reinforcing fibers at a predetermined position in a mold in which the article is cast. A pressure casting method, such as the so-called high-pressure casting method, in which a molten matrix material is poured into the mold and the molten metal is solidified while being pressurized in the mold, or an m-fiber reinforced method consisting of reinforcing fibers and a matrix material. There are known methods of fixing composite materials to the surface of articles by welding, brazing, adhesion with adhesives, mechanical fastening with bolts, etc.

However, in the former method, it is necessary to form a fiber molded body in a predetermined shape in advance, and high enough pressure is applied to infiltrate and fill the molten matrix or material between the individual reinforcing fibers of the fiber molded body. This has the disadvantage of increasing the manufacturing cost of the article, and the matrix material of the surface area that is compositely reinforced with reinforcing fibers and the part of the article that is not compositely reinforced with reinforcing fibers. The disadvantage is that there is little freedom in selecting the constituent materials of the article because the materials used are the same. In addition, in the latter method, it is necessary to form a fiber-reinforced composite material having a surface shape that corresponds to the surface shape of the article to be reinforced, and it is necessary to fix the fiber-reinforced composite material to the surface of the article. Because it requires a complicated process, the manufacturing cost of the article is high.There are also restrictions on the shape and size of the fiber-reinforced composite material that is fixed to the surface of the article. Furthermore, the adhesion between the fiber-reinforced composite material and the article to which it is fixed is not always good, so the fiber-reinforced composite material may fall off after long-term use. The disadvantage is that it can sometimes cause

SUMMARY OF THE INVENTION In view of the above-mentioned drawbacks of the conventional method of compositely reinforcing the surface of an article with reinforcing fibers, it is an object of the present invention to provide a method for reinforcing fibers of the surface of an article without causing such drawbacks. .

According to the present invention, this object is a method of compositely reinforcing the surface portion of an article with reinforcing fibers to form a wire made of a fiber-reinforced composite material made of reinforcing fibers and a matrix material,
This is achieved by a method characterized in that minute droplets emitted from the wire by thermal spraying are prevented from adhering to the surface of the article.

According to the present invention, minute droplets of a fiber-reinforced composite material made of reinforcing fibers and a matrix material are attached to the surface of an article, thereby forming a sprayed layer made of the fiber-reinforced composite material on the surface of the article. Therefore, the desired thickness and desired 1fi
The surface of the article can be compositely reinforced with reinforcing fibers at lff volume fraction, and since the surface of the article and the sprayed layer made of fMM reinforced composite material are well bonded, composite reinforcement with reinforcing fibers is possible. It is possible to efficiently manufacture an article at a low location without causing problems such as the surface layer peeling off from the main part of the article. Furthermore, according to the present invention, the material constituting the article and the matrix material of the fiber-reinforced composite material constituting the sprayed layer may be different materials.
Depending on the characteristics required for the main part of the article and the surface part of the article (each material can be arbitrarily selected).

The reinforcing fibers used in the method of the present invention may be either long fibers or fibers 1 (t (including voice strength)),
In addition, the material may be any material such as metal or ceramic, but when long fibers are used as reinforcing fibers, the long fibers are made by melting wire rods made of fiber-reinforced composite material by thermal spraying. The fiber must be able to be fused into minute lengths while retaining its fiber properties when transformed into droplets. Furthermore, if the melting point of the reinforcing fibers is close to the melting point of the matrix material, the reinforcing 1M1tL will melt during thermal spraying and will no longer be able to maintain its original shape in the thermal spraying layer, so the melting point of the reinforcing fibers will be It is necessary that the melting point of the matrix material be at least 2°C higher than the melting point of the matrix material.

Furthermore, the matrix material used in the method of the present invention may be any material that is compatible with the reinforcing fibers used and the material that constitutes the main part of the article, as long as it is thermally sprayable. For example, it may be made of aluminum alloy, copper alloy, tin alloy, lead alloy, resin, etc.

Furthermore, in order to transfer the reinforcing fibers to the surface of the article while retaining the properties of the original fibers as much as possible, the materials of the reinforcing fibers and matrix material, the feeding speed of the wire rod, the strength of the flame or arc of the melting device, etc. It is preferable that the thermal spraying layer is selected appropriately, and as in the case of normal thermal spraying, the thermal spraying layer is preferably selected on the surface of the article on which the thermal spraying layer is to be formed so that the thermal spraying layer of the fiber-reinforced composite material adheres well to the surface of the article. It is preferable that degreasing, cleaning, blasting, and preheating treatment be performed prior to thermal spraying.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings.

First, a quartz tube 1 with an inner diameter of 3.2 mm, a wall thickness of 0.8 mm, and a length of 1.2 rings is prepared, and inside the quartz tube, a tube with a substantially three-dimensional random orientation and a bulk density of 0.15 g/cc is prepared. Alumina-silica staple fiber (49% At t O8, 51% sr
02, fiber diameter 0.5 to 15μ, #A fiber length several mm to several tens of mnt, melting point 1760°C)2.

Next, one end of the quartz tube 1 filled with alumina-silica short fibers was placed in a molten metal 3 (temperature 700°C) of aluminum alloy (JIS standard AC8A, melting point 590°C) as shown in FIG. By immersing the quartz tube 1 in the quartz tube and deaerating the inside of the quartz tube 1 using a vacuum pump from the other end (not shown in the figure), the molten aluminum alloy 3 is infiltrated and filled between the alumina and silica short #l1N2. By cooling and then breaking the quartz tube 1 and taking out the solidified material inside, a wire rod 4 made of a fiber-reinforced composite material made of alumina-silica short fibers 2 as reinforcing fibers and aluminum alloy 3' as a matrix material is produced. 2 and 3 are enlarged cross-sectional views of the cross section and the axial section of the wire 4 thus formed, respectively.

Next, using the thus formed wire rod 4, a gas-fired thermal spraying device (METCO10E type thermal spraying device) was used to degrease, clean, and blast the wire rod 4, which was then preheated to 150° C.
0x30x5sun)0)e.

Thermal spraying was carried out on a surface (50 x 30 mm) under the spraying conditions shown in Table 1 below.

Table 1: Thermal spraying conditions Fuel gas Acetylene: 16.9+//min Oxygen: 18.94/1llin Air spraying: 23.6d/1llin Spraying distance:
120 mm Wire feed rate: 90/111 Thermal spray layer thickness: 0.5 mm Figure 4 is an illustration showing the above-mentioned thermal spraying step 1. This fourth
In the figure, 5 indicates the nozzle of the thermal spraying device, 6 and 7 indicate the flow of fuel gas and blowing air, respectively. The fuel gas 6 is supplied at a constant supply speed, and is melted by the heat generated by combustion of the fuel gas 6 at the tip of the nozzle 5, and is formed into a large number of minute droplets 8 by the action of blown air 7. In this case, the droplet 8 is composed of the molten aluminum alloy 3 and the alumina-silica short 11A miscellaneous material 2 which has substantially maintained its original fiber state.
As a result, it adhered to the surface 10 and was laminated to form the sprayed layer 11. In order to form the molten IJ4 layer 11 with as uniform a thickness as possible, the nozzle 5 of the thermal spraying device is attached to the base material 9.
The surface 10 of was scanned by weaving.

The properties of the molten rA layer formed as described above are shown in Table 2 below.

Table 2: Properties of solvent layer Hardness: 90-120 (HVlk (1) Fiber length: Approx. 5-150μ Porosity: Approx. 5-10% Fiber bulk density: Approx. 0.135-0.145Q/Q table 2, the porosity of the sprayed layer is small, the sprayed layer is formed with high density, the variation in fiber bulk density is small, the alumina-silica short fibers are relatively uniformly dispersed, and the sprayed layer has a low porosity. It can be seen that the hardness is also high.

For comparison purposes, instead of alumina-silica short fibers, glass mta <sH diameter 23μ, average lIi fiber length 11+nn+
.

A thermal spray layer was formed in the same manner as in the above-mentioned example, except that the melting point was 750°C. When the properties of this thermally sprayed layer were investigated, it was found that glass #A retained its fiber shape in the thermally sprayed layer and was distributed in a layered manner. This is thought to be because the glass fibers were melted and aggregated together with the aluminum alloy as a matrix material during thermal spraying and sprayed onto the surface of the base material.

Although the present invention has been described in detail with respect to specific embodiments above, the present invention is not limited to such embodiments, and various embodiments are possible within the scope of the present invention. This will be clear to those skilled in the art. For example, when the reinforcing fibers are short fibers, a wire rod made of a fiber-reinforced composite material may be formed by subjecting a rod-shaped fiber-reinforced composite material to extrusion processing and/or drawing processing.

[Brief explanation of drawings]

Figure 1 is an illustration showing the process of manufacturing a wire rod made of fiber-reinforced composite material, Figures 2 and 3 are sectional views showing a cross section and an axial cross-section of the wire rod made of fiber-reinforced composite material, and Figure 4 is an illustration showing the thermal spraying process. 1...Quartz tube, 2...Alumina-silica short fiber, 3
... Molten aluminum alloy, 3'... Aluminum alloy, 4... Wire, 5... Nozzle, 6... Fuel gas, 7... Air spraying, 8... Droplets, 9... Base material, 10... Surface. 11... Molten J 1 layer patent applicant Toyota Automatic Table Co., Ltd. Representative Patent attorney Masaki Akashi

Claims (1)

[Claims] By compositely reinforcing the surface of the article with reinforced W4 fibers, a wire made of fiber-reinforced composite material consisting of reinforcing mm and matrix material is formed, and minute droplets melted from the wire by thermal spraying are A method characterized by adhering to the surface of an article.