Method for manufacturing a composite component and composite component

Abstract

Provided is a composite member manufacturing method and a composite member that can efficiently manufacture a composite member having high welding strength at a low cost. A resin-containing member 13 is pressed against a metal porous film 12 formed on the surface of a metal member 11, and the metal member 11 is heated to weld the metal member 11 and the resin-containing member 13. The metal porous film 12 is preferably formed by cold spraying metal powder onto the surface of the metal member 11.

Description

TECHNICAL FIELD

[0001] The present application relates to a manufacturing method of a composite member and a composite member. BACKGROUND

[0002] As a method of welding metal and resin, in recent years, a direct welding method in which resin is melted and fused to a metal surface has been vigorously researched (for example, refer to Non-Patent Literature 1). As such a direct welding method, for example, a method in which, after forming a fine hole corrosion or a concave-convex pattern on a metal surface by a chemical etching treatment or by laser irradiation, a molten resin is filled to the fine structure using a hot press or injection molding, and the resin is cooled and solidified, thereby manufacturing a composite member firmly welded using an anchoring effect has been proposed (for example, refer to Patent Literature 1, Non-Patent Literatures 2 to 4).

[0003] Prior Art Documents

[0004] Non-Patent Literature

[0005] Non-Patent Literature 1: Susumu Horinouchi, "International Standard for Evaluation Test Method of Bonding Properties of Resin-Metal Dissimilar Material Composite", Control and Measurement, 2015, 54, p. 743-747

[0006] Non-Patent Literature 2: Masahiro Seto, Yoshitaka Asami, Masahiko Bantora, Hiromasa Tanaka, Shoji Yamabe, "Influence of Molding Conditions on Bonding Strength of Resin-Metal Bonded Injection Molded Products", Forming Processing, 2015, 27, p. 68-74

[0007] Non-Patent Literature 3: Susumu Horinouchi, Tsuyoshi Hanada, Takayuki Miyamae, Tadashi Yamazaki, Kohei Mitsumoto, Naoki Ando, Masataka Narumi, "Analysis of Metal / Resin Bonding Interface by Energy Filter Transmission Electron Microscopy", Journal of the Adhesion Society of Japan, 2012, 48, p. 322-330

[0008] Non-Patent Literature 4: B. Henriques, "Laser surface structuring of Ti6Al4V substrates for adhesion enhancement in Ti6Al4V-PEEK joints", Materials Science and Engineering: C, 2017, 79, p. 177-184

[0009] Patent Literature

[0010] Patent Literature 1: Japanese Patent Application Publication No. 2019-177704 SUMMARY

[0011] Technical problem to be solved by the invention

[0012] However, for the manufacturing method of the composite member based on direct welding described in Patent Literature 1 and Non-Patent Literatures 2 to 4, in the case where laser irradiation is utilized, there are technical problems that the pulling in the direction perpendicular to the hole formed by laser irradiation is weak, and the resin easily peels off. Also, there are technical problems that the number of parameters involved in controlling the laser irradiation is large, the manufacturing process is complicated, and the device is expensive. Furthermore, in the case where chemical etching treatment is utilized, there are technical problems that when immersed in the etching solution, the pre-cleaning such as cleaning and degreasing of the metal surface needs to be repeated multiple times, and cleaning treatment using chemical solution and waste liquid treatment are also required, so the manufacturing efficiency is poor.

[0013] The present invention is directed to the above technical problems, and an object of the present invention is to provide a manufacturing method of a composite member and a composite member, which can efficiently manufacture a composite member having high welding strength at a low price.

[0014] Technical means for solving the technical problem

[0015] In order to achieve the above object, the manufacturing method of the composite member of the present invention is characterized in that the metal member and the resin-containing member are welded by heating the metal member in a state where the resin-containing member is pressed on the metal-made porous film formed on the surface of the metal member.

[0016] The composite member of the present invention is characterized by having a metal member, a porous film formed on the surface of the metal member, and a resin-containing member provided on the side of the porous film opposite to the metal member, and the metal member and the resin-containing member are welded by allowing a part of the resin-containing member to enter the pores of the porous film.

[0017] The manufacturing method of the composite member of the present invention can be suitable for manufacturing the composite member of the present invention. The manufacturing method of the composite member of the present invention can melt or soften the resin-containing member by heating the metal member, and further allow it to enter the pores of the porous film. At this time, since the pores of the porous film do not point in one direction like the holes formed by laser irradiation, the resin-containing member is less likely to peel off, and a composite member having high welding strength can be manufactured.

[0018] The manufacturing method of the composite member of the present application can form the porous film by any method, but it is particularly preferable to form the porous film by a cold spraying method in which metal powder is made to collide with the surface of the metal member. By using the cold spraying method, a porous film containing a large number of pores can be formed in a state in which oxidation and decomposition of the raw material metal powder hardly occur and the metal powder is well welded to each other. By forming the porous film using the cold spraying method, the composite member can be manufactured at a low cost without the need for an expensive device as in the case of laser irradiation. Furthermore, by the cold spraying method, the porous film can be formed on a wide range of surfaces in a short time, and there is no need for cleaning treatment or waste liquid treatment as in the case of chemical etching treatment, so the composite member can be efficiently manufactured in a short time.

[0019] In the manufacturing method of the composite member of the present application and the composite member, the metal member and the porous film can be composed of the same metal or different metals. The metal member can be composed of any metal, for example, it can be composed of aluminum or an aluminum alloy. The porous film can be composed of any metal such as aluminum, an aluminum alloy, stainless steel, titanium, a titanium alloy, or the like, but if it is formed by the cold spraying method, it is preferably composed of titanium or a titanium alloy. At this time, titanium powder or a titanium alloy can be used as the metal powder, and a firm porous film can be formed.

[0020] The manufacturing method of the composite member of the present application can press the metal member toward the resin-containing member while rubbing the metal member to heat the metal member in a state in which the resin-containing member is in contact with the porous film. At this time, for example, a cylindrical welding tool is pressed against the surface of the metal member while being rotated from the side opposite to the porous film by friction stir welding (FSW), whereby the metal member and the resin-containing member can be welded.

[0021] In the manufacturing method of the composite member of the present application and the composite member, the resin-containing member can be composed of any material according to the required properties or use, for example, it can have a thermoplastic resin material or a thermosetting resin material before heat curing. Furthermore, the resin-containing member can be composed of only resin or a part thereof. When the resin-containing member has a thermoplastic resin material, it is preferable to heat the metal member at a temperature lower than the melting point of the thermoplastic resin material. At this time, the resin-containing member can be welded without being melted, and the composite member can be easily manufactured. Furthermore, as the thermoplastic resin material, for example, PEEK (polyether ether ketone) or PA6 (polyamide 6) having high strength or the like can be used. When the resin-containing member has a thermosetting resin material before heat curing, it is preferable to heat the metal member at a temperature higher than the melting point of the thermosetting resin material. At this time, the resin-containing member can be composed of a thermosetting member having a fibrous reinforcing material and a resin such as a prepreg or the like.

[0022] In the composite member manufacturing method and the composite member of the present application, the porosity of the porous film is preferably 4% or more and preferably 30% or less. Further, the film thickness of the porous film is preferably 25 μm or more and preferably 280 μm or less. In the above case, the strength of the welded portion of the metal member and the resin-containing member is high, and the welded metal member and the resin-containing member are not easily separated. Further, the porosity of the porous film is preferably 6% or more and further preferably 27% or less. Further, the film thickness of the porous film is preferably 35 μm or more and preferably 150 μm or less. In the above case, the strength of the porous film is further increased, and the welded metal member and the resin-containing member are particularly not easily separated.

[0023] Effects of the Invention

[0024] According to the present application, it is possible to provide a composite member manufacturing method and a composite member capable of efficiently manufacturing a composite member having high welding strength at a low cost. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 (a) of FIG. 1 is a side view showing a method of pressing a resin-containing member, heating a metal member using a heater or the like, and thereby welding the metal member and the resin-containing member in the composite member manufacturing method of the embodiment of the present application; Figure 1 (b) of FIG. 1 is a perspective view showing a method of heating a metal member by frictional heat using friction stir welding (FSW), and thereby welding the metal member and a resin-containing member in the composite member manufacturing method of the embodiment of the present application; Figure 1 (c) of FIG. 1 is a side view of the welding method of (b).

[0026] Figure 2 FIG. 2 is a photograph of an optical microscope showing a cross section near a welding interface under each metal powder used when forming a porous film and each porous film forming condition (left photograph) and porosity of the porous film (Porosity), porosity filled with a resin-containing member (Filled by PEEK), and filling rate of the resin-containing member (Filling rate) (right photograph) of a composite member manufactured by the composite member manufacturing method of the embodiment of the present application.

[0027] Figure 3 FIG. 2 is a photograph of an optical microscope showing a cross section near a welding interface under each metal powder used when forming a porous film and each porous film forming condition (left photograph) and porosity of the porous film (Porosity), porosity filled with a resin-containing member (Filled by PEEK), and filling rate of the resin-containing member (Filling rate) (right photograph) of a composite member manufactured by the composite member manufacturing method of the embodiment of the present application.

[0028] Figure 4 Optical microscope photographs of cross sections near the welding interface under each metal powder used when forming the porous membrane and each porous membrane forming condition, porosity of the porous membrane, porosity filled by the resin-containing member (Filled by PEEK), and filling rate of the resin-containing member (Filling rate) of the composite member manufactured by the manufacturing method of the composite member according to the embodiment of the present application (right).

[0029] Figure 5 Optical microscope photographs of cross sections near the welding interface of the composite member manufactured by the comparative example of the manufacturing method of the composite member according to the embodiment of the present application without forming the porous membrane but only by the sandblasting treatment, in which (a) is an optical microscope photograph when the alumina particles used in the sandblasting treatment is #24; (b) is an optical microscope photograph when the alumina particles used in the sandblasting treatment is #60; and (c) is an optical microscope photograph when the alumina particles used in the sandblasting treatment is #120.

[0030] Figure 6 Graph showing the relationship between the porosity of the porous membrane and the tensile shear strength of the composite member manufactured by the manufacturing method of the composite member according to the embodiment of the present application.

[0031] Figure 7 Optical microscope photographs of cross sections near the welding interface and the film thickness of the porous membrane of the composite member manufactured by the manufacturing method of the composite member according to the embodiment of the present application when each traverse speed (ts) and with or without the sandblasting treatment when forming the porous membrane.

[0032] Figure 8 Graph showing the relationship between the film thickness of the porous membrane and the tensile shear strength of the composite member shown in Table 1. Figure 7

[0033] Figure 9 Graph showing the relationship between the porosity of the porous membrane and the tensile shear strength of the composite member manufactured by the manufacturing method of the composite member according to the embodiment of the present application. Figure 7

[0034] Figure 10 ​​An optical microscope photograph of a cross section near a welding interface of a composite member manufactured without forming a porous film and by filling a molten resin to a surface of a metal member by hot pressing, for a comparative example of a manufacturing method of a composite member of an embodiment of the present application, wherein (a) is an optical microscope photograph when the metal member is a metal member subjected to sand blasting; (b) is an optical microscope photograph when the metal member is a metal member in which fine pores are formed at an area ratio of 40% by laser irradiation; and (c) is an optical microscope photograph when the metal member is a metal member in which fine pores are formed at an area ratio of 70% by laser irradiation.

[0035] Figure 11 (a) in FIG. 1 is a perspective view showing a test method of a tensile test for studying strength of a porous film, relating to a manufacturing method of a composite member of an embodiment of the present application; Figure 11 (b) in FIG. 1 is an optical microscope photograph of a cross section of the formed porous film for the tensile test, relating to a manufacturing method of a composite member of an embodiment of the present application.

[0036] Figure 12 (a) in FIG. 2 is a perspective view showing a tensile test shown by (a) in FIG. 1. Figure 11 FIG. 2 is a graph showing a relationship between thickness and tensile strength of a porous film obtained by the tensile test shown by (a) in FIG. 1.

[0037] Figure 13 (a) in FIG. 3 is a distribution of porosity of a porous film when a gas pressure of a compressed gas at the time of jetting of metal powder in a cold spray method is 312 kPa, relating to a manufacturing method of a composite member of an embodiment of the present application; Figure 13 (b) in FIG. 3 is a scanning electron microscope photograph of a cross section of the porous film of (a); Figure 13 (c) in FIG. 3 is a distribution of porosity of a porous film when a gas pressure of a compressed gas at the time of jetting of metal powder in a cold spray method is 483 kPa, relating to a manufacturing method of a composite member of an embodiment of the present application; Figure 13 (d) in FIG. 3 is a scanning electron microscope photograph of a cross section of the porous film of (c); Figure 13 (e) in FIG. 3 is a distribution of porosity of a porous film when a gas pressure of a compressed gas at the time of jetting of metal powder in a cold spray method is 620 kPa, relating to a manufacturing method of a composite member of an embodiment of the present application; Figure 13 (f) in FIG. 3 is a scanning electron microscope photograph of a cross section of the porous film of (e).

[0038] Figure 14 (a) in FIG. 4 is a perspective view showing a tensile test shown by (a) in FIG. 1. Figure 11 FIG. 4 is a graph showing a relationship between a gas pressure of a compressed gas at the time of jetting of metal powder in a cold spray method and a tensile strength of a porous film obtained by the tensile test shown by (a) in FIG. 1. DETAILED DESCRIPTION

[0039] Hereinafter, an embodiment of the present application will be described based on the drawings and examples.

[0040] Figures 1 to 14 A manufacturing method of a composite member and a composite member showing an embodiment of the present application.

[0041] As Figure 1 shown, in the manufacturing method of the composite member of the embodiment of the present application, first, a porous film 12 made of metal is formed on the surface of a metal member 11. At this time, the porous film 12 can be formed by any method, but in Figure 1 one specific example shown, a metal powder is made to impact the surface of the metal member 11 by a cold spraying method, thereby forming the porous film 12. The metal member 11 is preferably plate-shaped, and the porous film 12 is formed on one side surface.

[0042] The metal member 11 and the porous film 12 can be composed of the same metal, or can be composed of different metals. The metal member 11 can be composed of any metal, for example, aluminum or an aluminum alloy. The porous film 12 can be composed of any metal. For example, a titanium powder or a titanium alloy powder can be used as the metal powder, and a firm porous film 12 composed of titanium or a titanium alloy can be formed by a cold spraying method.

[0043] After the porous film 12 is formed, the metal member 11 is heated in a state of pressing a resin-containing member 13, thereby welding the metal member 11 and the resin-containing member 13. At this time, the resin-containing member 13 can be composed of any material according to the required characteristics or use. In addition, the resin-containing member 13 can be composed of only a resin, or can be partially a resin. The resin-containing member 13 can be composed of a thermoplastic resin material such as PEEK (polyether ether ketone) or PA6 (polyamide 6) having high strength, or can be composed of a thermosetting member having a fiber-like reinforcing material and a resin such as a prepreg.

[0044] The method of heating the metal member 11 can be any method, for example, can be a method of heating the metal member 11 by a heater or the like in a state of pressing the resin-containing member 13 as shown in (a) of Figure 1 , a method of heating the metal member 11 by frictional heat by friction stir welding (FSW) in a state of bringing the resin-containing member 13 into contact with the porous film 12, while rotating and pressing a cylindrical welding tool 21 against the surface of the metal member 11 on the side opposite to the porous film 12 as shown in (b) and (c) of Figure 1 . In addition, the welding tool 21 of the friction stir welding is usually formed in a shape having a probe 21b protruding from the center portion of a cylindrical shoulder portion 21a, but it is preferable to include a probe 21b having a very small amount of protrusion in order to suppress the deformation of the metal member 11 and make the welding interface as flat as possible.

[0045] By heating the metal component 11 in the manner described above, the resin-containing component 13 can be melted or softened, thereby allowing it to enter the pores of the porous membrane 12. This enables the manufacture of a composite component according to an embodiment of the present invention, formed by welding the metal component 11 and the resin-containing component 13. Furthermore, when heating the metal component 11, if the resin-containing component 13 contains a thermoplastic resin material, by heating at a temperature below the melting point of the resin-containing component 13, welding can be performed without melting the resin-containing component 13, making it easier to manufacture the composite component.

[0046] According to the method for manufacturing composite components according to embodiments of the present invention, a porous membrane 12 containing numerous pores can be formed by using a cold spraying method, where the metal powders are well welded together with almost no oxidation or decomposition of the raw material metal powders. Since the pores of the porous membrane 12 are not oriented in one direction like those formed by laser irradiation, the resin-containing component 13 is less prone to peeling, and composite components with high weld strength can be manufactured.

[0047] Furthermore, by using a cold spray method to form the porous membrane 12, the expensive equipment required for laser irradiation can be eliminated, enabling the manufacture of composite components at a low cost. Moreover, the cold spray method allows for the formation of the porous membrane 12 over a wide area in a short time, without the need for cleaning or wastewater treatment as required by chemical etching processes, thus enabling the efficient manufacture of composite components in a short time.

[0048] Example

[0049] Example 1

[0050] pass Figure 1 The method for manufacturing the composite component according to embodiments of the present invention shown in (b) and (c) involves forming a porous membrane 12 using a cold spraying method, followed by welding a metal component 11 to a resin-containing component 13 using friction stir welding (FSW). A5052 aluminum alloy rolled material is used as the metal component 11. The metal component 11 is a rectangular plate with its long side in the rolling direction, a length of 200 mm, a width of 50 mm, and a thickness of 5 mm. Furthermore, alumina powder (particle size of...) is sprayed onto one surface (welding surface) of the metal component 11 at a pressure of 0.3 MPa. The surface is roughened by the process of applying PEEK, a thermoplastic resin material, to the resin-containing component 13. The resin-containing component 13 is a rectangular plate with a length of 200 mm, a width of 50 mm, and a thickness of 5 mm.

[0051] When the porous film 12 is formed by the cold spraying method, a low-pressure type cold spraying device ("KM-CDS 3.0" manufactured by INOVATI Co., Ltd.) is used. In the cold spraying method, the metal powders shown in Table 1 are used. In Table 1, the film formation conditions [presence or absence of pretreatment (Blast), powder feed rate, gas pressure, gas temperature, traverse speed of spray nozzle] are also shown for each metal powder.

[0052] [Table 1]

[0053]

[0054] In addition, as the pretreatment, the welding surface of the metal member 11 after the surface roughening treatment is subjected to a blast treatment using alumina particles (#24). Further, as the process gas, helium is used. Further, in order to control the porosity and the thickness of the porous film 12, the traverse speed is changed as shown in Table 1. Further, in order to improve the adhesion of the metal member 11 and the porous film 12, heat treatment after film formation is sometimes performed. The heat treatment is performed using a muffle furnace and in an atmospheric atmosphere. In the case of using Al powder, the heat treatment temperature is 500°C, and the holding time is 30 minutes, and in the case of using Ti-20, Ti-45, Ti-20+Ti-45, Ti-20+Al203 powder, the heat treatment temperature is 600°C, and the holding time is 4 hours (in the case of using Ti-20 only, part is 600°C, 2 hours or 14 hours), but all are air cooling.

[0055] When the welding of the metal member 11 and the resin-containing member 13 is performed, a high-rigidity friction stir welding device ("TU-01" manufactured by NITTO SEIKI CO., LTD.) is used. The overlapping width of the metal member 11 and the resin-containing member 13 is set to 20 mm, and as the welding tool 21, a welding tool made of SKD61 is used. The welding tool 21 is formed in a shape in which a probe 21b having a diameter of 5 mm protrudes by 1.4 mm from the center portion of a shoulder portion 21a in a cylindrical shape having a tool diameter of 15 mm. The welding speed of the welding tool 21 at the time of welding is set to 10.0 mm / s, the rotation speed of the welding tool 21 is set to 1200 rpm, the insertion depth of the welding tool 21 into the metal member 11 is set to 1.1 mm, and the advancing angle of the welding tool 21 is set to 3°.

[0056] The optical microscope photographs of the cross section of the vicinity of the welding interface of the composite member manufactured by welding the metal member 11 (Al alloy) and the resin-containing member (PEEK) 13 for each metal powder and each film forming condition of the porous film 12 are shown in the left drawing of FIG. 10. In addition, "HT" indicates that heat treatment was performed after the formation of the porous film 12. Further, "BL (Blast less)" indicates that sand blasting treatment was not performed before the formation of the porous film 12. Figures 2 to 4

[0057] The porosity of each porous film 12, the porosity filled with the resin-containing member 13 (Filled by PEEK), and the filling rate of the resin-containing member 13 were measured from each optical microscope photograph by the point counting method. The results are shown in the right drawing of FIG. 10. The horizontal axis of each drawing is the ratio of the depth of the porous film 12 from the surface of the resin-containing member 13, 0% is the interface of the porous film 12 and the resin-containing member 13, and 100% is the interface of the porous film 12 and the metal member 11. Further, the average values of the thickness and the porosity of each porous film 12 were calculated from each optical microscope photograph and are shown in Table 2. Figures 2 to 4

[0058] [Table 2]

[0059]

[0060] As shown in FIG. 10 and Table 2, the resin-containing member 13 was found to be filled in the pores present inside the porous film 12 to some extent, and the filling of the resin-containing member 13 was confirmed even for the porous film 12 having a small porosity such as SUS316L. Further, it was confirmed that the filling rate gradually decreased as the distance of the porous film 12 from the surface of the resin-containing member 13 increased. It was thus considered that there was a certain limit to the depth of the filling of the resin-containing member 13. Figures 2 to 4

[0061] In addition, for comparison, a rolled material of A5052 aluminum alloy (without surface roughening treatment, without pretreatment) was used as the metal member 11, and the porous film 12 was not formed, and the metal member 11 and the resin-containing member (PEEK) 13 were welded by friction stir welding. As a result, the resin-containing member 13 was found to be peeled off from the metal member 11 immediately after the welding, and the welding was hardly performed.

[0062] ​​​Further, for comparison, a member made by sandblasting the surface of a rolled material of A5052 aluminum alloy using alumina particles (#24, #60, #120) was used as the metal member 11, and the porous film 12 was not formed, and the metal member 11 was welded to the resin-containing member (PEEK) 13 by friction stir welding, thereby manufacturing a composite member. An optical microscope photograph of a cross section near the welded interface of this composite member is shown in Figure 5 . As shown in Figure 5 , the resin-containing member 13 was confirmed to be closely adhered to the metal member 11 without a gap by being immersed in the fine concavo-convex structure of the surface of the metal member 11 formed by the sandblasting treatment.

[0063] Next, a tensile shear test was performed on each of the manufactured composite members. This test was performed using a universal testing machine (manufactured by INSTRON) at room temperature at a crosshead speed of 1.0 mm / minute. In this test, a short strip-shaped test piece having a width of 20 to 25 mm was cut from each of the composite members, and this test piece was obtained by cutting the composite member in a direction perpendicular to the welding direction. Further, three test pieces were cut from each of the composite materials, and a tensile shear test was performed on each of the test pieces, the tensile shear strength of each of the composite materials was calculated by dividing the obtained fracture load by the welding area, and the average value of the thus calculated values was taken as the tensile shear strength of each of the composite materials. The calculated tensile shear strengths of each of the composite materials are shown in Table 3.

[0064] [Table 3]

[0065]

[0066] Further, for comparison, a tensile shear test was also performed on a composite member without the porous film 12 shown in Figure 5 . As a result, the tensile shear strength was 7.9 to 8.7 MPa, and it was confirmed that the strength decreased as the surface of the metal member 11 became smooth. As shown in Table 3, the tensile shear strength of the composite member with the porous film 12 was 9.62 to 15.8 MPa, and it was confirmed that the strength was higher than that of the composite member without the porous film 12.

[0067] Further, the fracture surfaces after the tensile shear test were observed, and it was confirmed that the composite members in which the porous film 12 was formed using the Al, Ti-20, Ti-45, Ti-20 + Ti-45, Ti-20 + Al203powders were fractured at the interface between the metal member 11 and the porous film 12. Further, it was also confirmed that the composite member in which the Ti-45 powder was used and heat treatment was performed was fractured in the porous film 12. Further, it was also confirmed that the composite member in which the powder other than the Ti-45 powder was used and heat treatment was performed and the composite member in which the SUS316L powder was used were fractured at the interface between the porous film 12 and the resin-containing member 13.

[0068] When the tensile shear test was performed, for the composite members in which the fracture occurred at the interface between the porous film 12 and the resin-containing member 13, the relationship between the porosity of the porous film 12 and the tensile shear strength was found, and is shown in Figure 6 . As shown in Figure 6 , it was confirmed that the tensile shear strength gradually increased as the porosity increased. Further, it was also confirmed that even when the porosity was about 6.8%, the tensile shear strength was about 12 MPa, and had sufficiently high strength.

[0069] Next, in order to measure the relationship between the film thickness of the porous film 12 and the strength, the tensile shear strength was measured for the composite members in which the porous film 12 was formed using the Ti-20 powder at various traverse speeds (ts) and heat treatment was performed after the film formation. In addition, this measurement was performed for the composite members in which the metal member 11 subjected to sand blasting treatment as a pretreatment was used and the composite members in which the metal member 11 not subjected to sand blasting treatment was used. Further, the film thickness of the porous film 12 was changed by changing the traverse speed. The optical microscope photograph of the cross section in the vicinity of the welding interface of the composite member for which the measurement was performed and the film thickness of the porous film 12 are shown in Figure 7 . Further, the relationship between the film thickness of the porous film 12 and the tensile shear strength is shown in Figure 8 .

[0070] As shown in Figure 7 and Figure 8 , although the tensile shear strength increased as the film thickness of the porous film 12 increased, it was confirmed that it was saturated at a certain film thickness with a certain strength. Further, it was also confirmed that even when the film thickness of the porous film 12 was 38 μm, the tensile shear strength was 12 MPa or more, and had very high strength.

[0071] In order to investigate the influence of the difference in the porosity of the porous film 12 on the relationship between the film thickness of the porous film 12 and the strength, the relationship between the film thickness of the porous film 12 and the tensile shear strength was found for the composite members in which the porous film 12 was formed using the Ti-20 powder and heat treatment was performed after the film formation, and is shown in Figure 7 and Figure 8In the same manner, the tensile shear strength was measured for the composite member in which the porous film 12 was formed using the Ti-20 + Ti-45 powder at various traverse speeds and was subjected to heat treatment after film formation. The relationship between the film thickness of the porous film 12 and the tensile shear strength is shown in Figure 9 . In addition, the porosity of the porous film 12 formed using the Ti-20 + Ti-45 powder was greater than that of the porous film 12 formed using the Ti-20 powder.

[0072] As shown in Figure 9 , as with Figure 8 , it was confirmed that the tensile shear strength became greater as the film thickness of the porous film 12 increased, but it saturated at a certain strength at a certain film thickness. However, it was confirmed that the saturated strength was higher than that of Figure 8 , and the film thickness at which the saturated strength was exhibited was also greater. It is considered that this is because the shear strength of the resin-containing member 13 was ensured as the porosity increased.

[0073] [Comparative Example Using Laser Irradiation]

[0074] As described in Non-Patent Literature 4, a composite member was manufactured by forming many fine pores on the surface of the metal member 11 by laser irradiation, and filling the surface of the metal member 11 with molten resin by hot pressing, and allowing the resin to cool and solidify. A Ti alloy was used as the metal member 11, and PEEK was used as the resin. In addition, the pore diameter of the fine pores formed by laser irradiation was about 270 μm, and the temperature of the hot pressing was 300°C. The optical microscope photographs of the cross section in the vicinity of the welded interface of the composite member when the area ratio of the fine pores on the surface of the metal member 11 was 40% and 70% are shown in Figure 10 (b) and (c), respectively.

[0075] In addition, in order to make a comparison, the optical microscope photograph of the cross section in the vicinity of the welded interface of the composite member manufactured using a metal member in which laser irradiation was not performed and the surface of which was subjected to a sandblasting treatment using alumina particles (particle diameter: 250 μm) as the metal member 11 is shown in Figure 10 (a). As shown in Figure 10 (a) to (c), it was confirmed that the resin of all of the composite members was immersed in the inside of the fine pores or the concavities and convexities on the surface of the metal member 11, and the metal member 11 and the resin were closely adhered without gaps. In addition, as shown in Figure 10 (b) and (c), it was confirmed that the fine pores formed by laser irradiation extended only in the direction perpendicular to the surface of the metal member 11.

[0076] Tensile shear tests were performed on the composite members shown in Figure 10 (a) to (c) in the same manner as in Example 1. As a result, Figure 10The tensile shear strength of the composite member shown in (a) in which the metal member 11 was subjected to sandblasting was 11 MPa, Figure 10 The tensile shear strength of the composite member shown in (b) in which the fine holes formed by laser irradiation had an area ratio of 40% was 25 MPa, Figure 10 The tensile shear strength of the composite member shown in (c) in which the fine holes formed by laser irradiation had an area ratio of 70% was 51 MPa. Comparing this result with the result shown in Table 3, the composite member using laser irradiation had a higher tensile shear strength than the composite member in which the porous film 12 was formed by the cold spraying method. However, as Figure 10 The composite member using laser irradiation was weaker in the peeling of the resin in the direction perpendicular to the surface of the metal member 11 because the holes formed by laser irradiation extended only in the direction perpendicular to the surface of the metal member 11, as shown in (b) and (c). Therefore, it was considered that the composite member using laser irradiation was weaker than the composite member in which the porous film 12 was formed by the cold spraying method.

[0077] Example 2

[0078] A rolled material of A5052 aluminum alloy was used as the metal member 11, and a thermoplastic resin material of PA6 was used as the resin-containing member 13. The composite member was manufactured by the method shown in (b) in Example 1. The cold spraying method was performed using Ti powder. The other manufacturing conditions were the same as in Example 1. Figure 1 The manufacturing method of the composite member of the embodiment of the present application shown in (b) and (c) was performed after the porous film 12 was formed by the cold spraying method, and the metal member 11 and the resin-containing member 13 were welded by friction stir welding (FSW). In the cold spraying method, Ti powder was used. In the friction stir welding, the welding speed of the welding tool 21 was set to 13 mm / s, the rotational speed of the welding tool 21 was set to 1000 rpm, and the penetration depth of the welding tool 21 into the metal member 11 was set to 1.0 mm. The other manufacturing conditions were the same as in Example 1.

[0079] The manufactured composite member was subjected to a tensile shear test in the same manner as in Example 1. As a result, the tensile shear strength was 10 MPa, which was higher than that of the composite member shown in (a) in which the metal member 11 was not subjected to sandblasting. Figure 5 In addition, the film thickness of the porous film 12 of the manufactured composite member was about 130 μm.

[0080] Example 3

[0081] A rolled material of A5052 aluminum alloy was used as the metal member 11, and PA6 was used as the resin-containing member 13. The composite member was manufactured by the method shown in (b) in Example 1. The cold spraying method was performed using Ti powder. The other manufacturing conditions were the same as in Example 1. Figure 1The method for manufacturing a composite component according to an embodiment of the present invention shown in (a) involves forming a porous membrane 12 using a cold spraying method, and then heating a metal component 11 with a heater while the resin-containing component 13 is pressed, thereby welding the metal component 11 to the resin-containing component 13. The resin-containing component 13 is pressed onto the metal component 11 using a manual press, and the heating temperature of the metal component 11 is 300°C.

[0082] The composite component was subjected to a tensile shear test in the same manner as in Example 1. The tensile shear strength was 7 MPa or higher. Furthermore, the thickness of the porous membrane 12 in the manufactured composite component was approximately 270 μm.

[0083] Example 4

[0084] To investigate the relationship between the thickness and strength of the porous membrane 12, a tensile test was conducted on the porous membrane 12 after it was formed by cold spraying using the composite component manufacturing method of the present invention. Figure 11 As shown in (a), A5052 aluminum alloy was used as the metal component 11 in the tensile test. The metal component 11 is cylindrical with a diameter of 25 mm and a length of 40 mm. In the cold spraying method, Ti-45 powder with a particle size of 1–45 μm was used, the pressure of the compressed gas was set to 620 kPa, the temperature of the process gas was set to 427 °C, and the lateral velocity of the spray nozzle was set to 500 mm / s. Furthermore, by changing the number of layers in the cold spraying method, porous films 12 of various thicknesses were formed. The porosity of the porous films 12 was all above 6%. An example of an optical microscope photograph of a cross-section of the porous film 12 formed on one side surface of the metal component 11 is shown. Figure 11 (b) in the middle.

[0085] like Figure 11 As shown in (a), in the tensile test, after applying adhesive 31 to the surface of each formed porous membrane 12, an A5052 aluminum alloy substrate 32 of the same size as the metal component 11 was bonded. The adhesive 31 used was “3M Scotch-Weld DP-460 Off-White (3M Japan Ltd.)”. After bonding with the adhesive, the metal component 11 and the substrate 32 were stretched to determine the tensile strength of each porous membrane 12. The results of the tensile test are shown below. Figure 12 .

[0086] like Figure 12As shown, the tensile test results confirmed that when the thickness of the porous membrane 12 is 150 μm or less, fracture occurs within the adhesive, and the tensile strength is 35 MPa or more. Furthermore, it was confirmed that when the thickness of the porous membrane 12 is 150 μm or more, fracture occurs within the porous membrane 12 near the metal member 11, and the tensile strength is 35 MPa or less. These results indicate that by setting the porous membrane 12 to 150 μm or less, the strength of the porous membrane is at least 35 MPa or more, making it less likely for the welded metal member 11 and the resin-containing member 13 to separate during the manufacture of the composite component.

[0087] Example 5

[0088] To investigate the relationship between the porosity and strength of the porous membrane 12, a porous membrane 12 was formed and tensile tests were conducted in the same manner as in Example 4. In the cold spraying method, porous membranes 12 with different porosities were formed by varying the gas pressure of the compressed gas used to spray the metal powder to 312 kPa, 483 kPa, and 620 kPa. Scanning electron microscope images of the distance between the porous membrane 12 and the surface of the metal component 11 and the porosity under each gas pressure, as well as cross-sectional images of the porous membrane 12, are shown below. Figure 13 .

[0089] like Figure 13 As shown, when the gas pressure is 312 kPa, the porosity of the porous membrane 12 is approximately 4%–9%, ​​with an average of 5.58%. When the gas pressure is 483 kPa, the porosity of the porous membrane 12 is approximately 8%–16%, with an average of 12.4%. When the gas pressure is 620 kPa, the porosity of the porous membrane 12 is approximately 6%–20%, with an average of 13.5%. It is confirmed that the higher the gas pressure, the higher the porosity of the porous membrane 12. This is believed to be because when the gas pressure is low, the impact force of the metal powder is small, so large particles are not welded, and only small metal powder particles accumulate and fill the gaps between the particles. However, when the gas pressure is high, the impact force of the metal powder becomes large, so large particles are welded, and gaps are easily formed between the particles.

[0090] The results of tensile tests on various porous membranes 12 under different gas pressures are shown below. Figure 14 .like Figure 14As shown, with respect to the results of the tensile test, it was confirmed that when the gas pressure was 483 kPa, 620 kPa, a fracture occurred inside the adhesive, and the tensile strength was 40 MPa or more. Further, it was also confirmed that when the gas pressure was 312 kPa, a fracture occurred inside the porous film 12, and the tensile strength was about 32 MPa. From this result, by setting the gas pressure to 483 kPa or more, that is, by setting the porosity of the porous film 12 to 6% or more, and the average porosity to 12% or more, the strength of the porous film is at least 40 MPa or more, and the welded metal member 11 and the resin-containing member 13 are not easily separated during the manufacture of the composite member.

[0091] BRIEF DESCRIPTION OF DRAWINGS

[0092] 11: metal member; 12: porous film; 13: resin-containing member; 21: welding tool; 21a: shoulder; 21b: probe; 31: adhesive; 32: base material.

Claims

1. A method of manufacturing a composite member, characterized by, The metal member and the resin-containing member are welded by heating the metal member in a state where the resin-containing member is pressed against a metal-made porous film formed on a surface of the metal member, the metal-made porous film having a porosity of 4% or more and a film thickness of 25 μm or more and 150 μm or less.

2. The method of manufacturing a composite member according to claim 1, characterized by The porous film is formed by cold spraying a metal powder against a surface of the metal member.

3. The method of manufacturing a composite member according to claim 1 or 2, characterized in that, The metal member and the porous film are made of different metals.

4. The method of manufacturing a composite member according to claim 1 or 2, characterized in that, The metal member is pressed against the resin-containing member while rubbing the metal member to thereby heat the metal member in a state where the resin-containing member is in contact with the porous film.

5. The method of manufacturing a composite member according to claim 1 or 2, characterized in that, The resin-containing member is a thermoplastic resin material.

6. The method of manufacturing a composite member according to claim 1 or 2, characterized by, The resin-containing member is made of a thermosetting member having a fiber-like reinforcing material and a resin.

7. A composite member characterized by comprising: It has a metal member, a porous film formed on a surface of the metal member, and a resin-containing member disposed on a side of the porous film opposite the metal member, The metal member and the resin-containing member are welded by causing a part of the resin-containing member to enter pores of the porous film, The porous film has a porosity of 4% or more and a film thickness of 25 μm or more and 150 μm or less.

8. The composite member of claim 7, wherein, The metal member and the porous film are made of different metals.

9. The composite member of claim 7 or 8, wherein, The resin-containing member is a thermoplastic resin material.

10. The composite member of claim 7 or 8, wherein The resin-containing member is made of a thermosetting member having a fiber-like reinforcing material and a resin.

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