A method for manufacturing a ceramic metal composite structure and a ceramic metal composite structure

Abstract

The application discloses a manufacturing method of a ceramic metal composite structure and the ceramic metal composite structure, and comprises the following steps: producing a ceramic blank by an additive manufacturing method, so that a fixed cavity is formed in the ceramic blank, and an inner wall of the fixed cavity is formed with a buffer layer blank; sintering the ceramic blank to obtain a ceramic structure and a buffer layer inside the ceramic structure; performing heat preservation on the ceramic structure, injecting a molten metal liquid into the fixed cavity; and obtaining the ceramic metal composite structure by gradually reducing the temperature. The ceramic blank is manufactured by the additive manufacturing method, a fixed cavity with complex shape and structure can be formed in the ceramic blank, the shape of the molten metal liquid after solidification in the fixed cavity matches the shape of the fixed cavity; moreover, the buffer layer can adapt to the shape of the fixed cavity, the force of the molten metal liquid cooling and shrinking acts on the buffer layer, the shrinking force directly acts on the outer ceramic is avoided, the molten metal pulling the outer ceramic is reduced, and the impact resistance and service life of the ceramic are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of ceramic metal composite, in particular to a manufacturing method of ceramic metal composite structure and the ceramic metal composite structure. BACKGROUND

[0002] Ceramics are brittle, poor thermal stability, but good wear resistance, high hardness, strong corrosion resistance, metal has good thermal stability, good ductility, high impact strength, by combining ceramics and metal can combine the advantages of both to form a kind of excellent performance material.

[0003] Publication No. CN209687784U discloses a ceramic structure, which comprises a ceramic structure, the ceramic structure comprises a driving cover plate and a driven cover plate, a vane is arranged between the driving cover plate and the driven cover plate, one side of the driving cover plate is a multilayer composite structure, the multilayer composite structure is composed of the driving cover plate, a first adhesive energy absorption layer, a metal layer, a second adhesive energy absorption layer and a second driving cover plate from inside to outside, wherein the second driving cover plate is an independent structure, and is made of ceramic or hard alloy, the metal layer is a disc-shaped structure, a shaft handle for connecting a main shaft is connected to the radial inner side of the metal layer, and the first adhesive energy absorption layer and the second adhesive energy absorption layer are filled with resin or a mixture of resin and wear-resistant particles.

[0004] This kind of ceramic and metal composite by bonding can not put the metal with complex structure into the ceramic, can not effectively play the performance of the metal such as impact resistance, and can not realize the composite of the metal with complex structure and the ceramic. SUMMARY

[0005] Therefore, it is necessary to provide a manufacturing method of ceramic metal composite structure and the ceramic metal composite structure, which solves the technical problem that the composite of the metal with complex structure and the ceramic cannot be realized in the prior art.

[0006] To achieve the above technical purpose, the technical scheme of the present application provides a manufacturing method of ceramic metal composite structure and the ceramic metal composite structure, which comprises the following steps:

[0007] The ceramic blank is produced by additive manufacturing, so that a fixed cavity is formed in the ceramic blank, and a buffer layer blank is formed on the inner wall of the fixed cavity;

[0008] The ceramic blank is sintered to obtain a ceramic structure;

[0009] The ceramic structure is heat preserved, and a molten metal liquid is injected into the fixed cavity;

[0010] The ceramic metal composite structure is obtained by gradually reducing the temperature.

[0011] In one embodiment, after the step of injecting the molten metal into the fixed cavity, the method further comprises the step of:

[0012] The composite filler is injected into the fixed cavity.

[0013] In one embodiment, the ceramic body is produced by an additive manufacturing method, and the fixed cavity is formed in the ceramic body, and the outer wall of the ceramic body forms a filling opening in communication with the fixed cavity.

[0014] After the step of injecting the composite filler into the fixed cavity, the filling opening is filled with inorganic micropowder, and finally cured at 200°C for 6-12h.

[0015] In one embodiment, the buffer layer is made of ceramic, and abuts and adheres to the inner wall of the fixed cavity.

[0016] In one embodiment, the thickness of the buffer layer is 3-15mm.

[0017] In one embodiment, after the step of injecting the molten metal into the fixed cavity, the molten metal is injected into the fixed cavity by pressurization.

[0018] In one embodiment, the ceramic body is vibrated during or after the step of injecting the molten metal into the fixed cavity of the sintered ceramic body.

[0019] In one embodiment, the components of the raw material used in the additive manufacturing include silicon carbide micropowder and additives, wherein the additives at least include a binder and a sintering aid, and the proportion of the binder in the raw material of the buffer layer body is less than the proportion of the binder in the raw material of the ceramic body.

[0020] In one embodiment, the components of the composite filler include inorganic micropowder, silica sol, resin, defoaming agent, coupling agent, curing agent and solvent.

[0021] In one embodiment, the ceramic material can be one or more of silicon oxide ceramic, silicon carbide ceramic, silicon nitride ceramic, silicon oxide combined with silicon carbide ceramic, aluminum oxide ceramic, and composite phase ceramic.

[0022] The application also relates to a ceramic metal composite structure manufactured by the above method.

[0023] The ceramic metal composite structure comprises:

[0024] A ceramic structure is formed with a fixed cavity;

[0025] A buffer layer is built in the fixed cavity and integrally formed with the ceramic structure; and

[0026] A metal structure is built in the fixed cavity and attached to the buffer layer.

[0027] Compared with the prior art, the present application has the following advantages: in the present application, the ceramic body is manufactured by additive manufacturing, a fixed cavity with complex shape and structure is formed in the ceramic body, then the ceramic body is sintered and solidified, and the molten metal liquid is injected into the fixed cavity of the sintered ceramic body, the shape of the solidified molten metal liquid matches the shape of the fixed cavity, a metal structure with complex shape is formed in the ceramic body, and the metal structure is fully combined with the ceramic; in the present application, the buffer layer body is formed in the fixed cavity of the ceramic body by additive manufacturing, the buffer layer body can adapt to the shape of the complex fixed cavity, and when the molten metal liquid is injected into the fixed cavity, the buffer layer can isolate the molten metal and the ceramic structure, avoid the molten metal directly contacting the outer ceramic, and because the buffer layer is formed by high-temperature sintering, it can withstand the high temperature when the molten metal liquid is injected; when the molten metal liquid cools down, the cooling and shrinking force of the molten metal liquid acts on the buffer layer, avoiding the shrinking force directly acting on the outer ceramic, reducing the stress generated by the molten metal pulling the outer ceramic, and improving the impact resistance and service life of the ceramic. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 is a process flow chart of the manufacturing method of the ceramic metal composite structure described in the present application;

[0029] Figure 2 is a structure schematic diagram of the ceramic metal composite structure described in the present application. DETAILED DESCRIPTION

[0030] The preferred embodiments of the present application will be specifically described below in combination with the drawings, wherein the drawings constitute a part of the present application, and are used to illustrate the principles of the embodiments of the present application, but are not used to limit the scope of the present application.

[0031] As shown in Figure 1 and Figure 2 , the present application provides a manufacturing method of a ceramic metal composite structure, comprising the following steps:

[0032] The ceramic body is produced by the method of additive manufacturing, so that a fixed cavity is formed in the ceramic body, and the inner wall of the fixed cavity is formed with a buffer layer body;

[0033] sintering the ceramic body to obtain the ceramic structure 1 and the buffer layer 2 inside the ceramic structure 1;

[0034] injecting the molten metal liquid into the fixed cavity after the ceramic structure 1 is kept at high temperature;

[0035] obtaining the ceramic-metal composite structure by gradually reducing the temperature.

[0036] In the application, the ceramic body is manufactured by additive manufacturing, the fixed cavity with complex shape and structure is formed in the ceramic body, then the ceramic body is sintered and solidified, and the molten metal liquid is injected into the fixed cavity of the sintered ceramic body, the molten metal liquid enters the fixed cavity, and the metal structure 3 is formed after the molten metal liquid is solidified, the shape of the metal structure 3 matches the shape of the fixed cavity, the metal structure 3 with complex shape is formed in the ceramic body, and the metal structure 3 is fully combined with the ceramic; moreover, in the application, the buffer layer body is formed in the fixed cavity of the ceramic body by additive manufacturing, the buffer layer body can adapt to the shape of the complex fixed cavity, and when the molten metal liquid is injected into the fixed cavity, the buffer layer 2 can isolate the molten metal and the ceramic structure 1, so that the molten metal does not directly contact the outer ceramic; moreover, since the buffer layer 2 is formed by high-temperature sintering, the buffer layer 2 can withstand the high temperature generated when the molten metal liquid is injected; when the molten metal liquid cools, the cooling and shrinking force of the molten metal liquid acts on the buffer layer 2, so that the shrinking force does not directly act on the outer ceramic, the stress generated by the molten metal pulling the outer ceramic is reduced, and the impact resistance and service life of the ceramic are improved; moreover, during the process of injecting the molten metal liquid into the ceramic structure 1, the ceramic structure 1 is kept at high temperature, the temperature difference between the ceramic body and the molten metal liquid is reduced, the possibility of generating bubbles due to the temperature difference is reduced, and the molten metal liquid is uniformly solidified because part of the molten metal liquid is solidified on the inner wall of the fixed cavity due to the temperature difference.

[0037] In one embodiment, after the step of injecting the molten metal liquid into the fixed cavity after the ceramic structure 1 is kept at high temperature, the method further comprises the step of:

[0038] injecting the composite filler into the fixed cavity.

[0039] By injecting the composite filler into the fixed cavity, the composite filler can fill the gap between the metal and the ceramic, strengthen the connection between the ceramic and the metal, avoid the gap between the ceramic and the metal, and increase the impact resistance of the ceramic-metal composite structure.

[0040] In one embodiment, the ceramic body is produced by the additive manufacturing method, and the fixed cavity is formed in the ceramic body, and the outer wall of the ceramic body forms a filling port communicating with the fixed cavity.

[0041] After the step of injecting the composite filler into the fixed cavity, the injection port is filled with inorganic powder, and finally cured at 200°C for 6-12h.

[0042] It should be understood that the number of injection ports can be one, two, and multiple, etc.

[0043] It should be understood that the inorganic powder can be a resin-bound silicon carbide filler.

[0044] In this embodiment, by setting the injection port, the molten metal liquid can enter the fixed cavity through the injection port, by setting multiple injection ports, injecting molten metal liquid into the fixed cavity through multiple injection ports, and injecting molten metal liquid through multiple injection ports at the same time, the molten metal liquid can be more evenly distributed in the entire cavity, thereby avoiding the problem of excessive local thermal stress or excessive metal content, improving the overall performance of the composite material; Multiple injection ports can ensure that the flow state and filling effect of the molten metal liquid in the entire cavity are consistent, so that the performance of the composite material at each position is more consistent; By controlling the opening time and flow rate of each injection port, the filling amount of the molten metal liquid can be accurately controlled, thereby better controlling the performance and quality of the composite material; By filling the injection port with inorganic powder, the injection port can be blocked to prevent metal from being exposed.

[0045] In one embodiment, the buffer layer 2 is made of ceramic, and the buffer layer 2 abuts and fits the inner wall of the fixed cavity.

[0046] By setting the ceramic buffer layer 2, the ceramic buffer layer 2 can be obtained together with the ceramic body by additive manufacturing, and when high-temperature sintering is performed, the ceramic buffer layer 2 is formed by high-temperature sintering, so the buffer layer 2 can withstand high temperatures and can prevent the molten metal liquid from directly contacting the ceramic structure 1, effectively protecting the ceramic structure 1.

[0047] In one embodiment, the composition of the raw material used for additive manufacturing is silicon carbide powder and additives, wherein the additives at least include a binder and a sintering aid, and the proportion of the binder in the raw material of the buffer layer body is less than the proportion of the binder in the raw material of the ceramic body.

[0048] The raw material components of the buffer layer body and the ceramic body are different, which can reduce the binding force of the buffer layer body and the ceramic body during the forming process. In addition, the proportion of the adhesive in the raw material of the buffer layer body is less than that in the ceramic body, which reduces the adhesion of the buffer layer body to the ceramic body. When the molten metal cools down after being injected into the fixed cavity, the shrinkage of the metal exerts a force on the buffer layer 2. The buffer layer 2 can be separated from the ceramic structure 1 under tension, which reduces the tension of the molten metal on the ceramic structure 1 and prevents the tension of the molten metal from damaging the ceramic structure 1.

[0049] It should be understood that the additive manufacturing method can be selective laser sintering.

[0050] In one embodiment, the ceramic body and the buffer layer body are manufactured by layer printing during additive manufacturing. When printing each layer of the body, the buffer layer body is printed first, and then the ceramic body is printed.

[0051] In the above arrangement, the buffer layer body is printed first during each layer printing, and the content of the adhesive in the buffer layer body is relatively small. The buffer layer body can be solidified first, and the ceramic body can be solidified later. The difference in solidification time between the two can reduce the binding force between the buffer layer body and the ceramic body. When the tension of the molten metal liquid acts on the buffer layer 2 during cooling, the above arrangement can reduce the tension of the buffer layer 2 transmitted to the ceramic body and reduce the tension inside the ceramic structure 1.

[0052] In one embodiment, the thickness of the buffer layer 2 is 3-15 mm.

[0053] In one embodiment, the ceramic structure 1 is subjected to high-temperature heat preservation in step, and the molten metal liquid is injected into the fixed cavity by pressurization.

[0054] By pressurization, the metal and the buffer layer 2 can be better combined at the micro level, thereby improving the integrity and strength of the composite material. By pressurization, air bubbles in the fixed cavity can be discharged, and air bubbles in the metal structure 3 can be avoided.

[0055] In one embodiment, the ceramic body is vibrated during or after the molten metal liquid is injected into the fixed cavity in step.

[0056] During the process of injecting the molten metal liquid into the fixed cavity or after the injection, the ceramic body is vibrated so that the molten metal liquid can move in the fixed cavity, and air and bubbles remaining in the fixed cavity can flow out of the fixed cavity, thereby avoiding the existence of bubbles in the solidified metal.

[0057] In one embodiment, the components of the composite filler include inorganic micropowder, silica sol, resin, defoaming agent, coupling agent, curing agent, and solvent.

[0058] In one embodiment, the components of the composite filler include 6 parts of nano zirconium oxide, 3 parts of nano aluminum nitride, 2 parts of nano titanium dioxide, 1 part of aluminum phosphate, 5 parts of sodium tripolyphosphate, 4 parts of silica sol, 8 parts of coupling agent KH-540, 2 parts of polydimethylsiloxane, 8 parts of n-butanol, 15 parts of n-propanol, 40 parts of xylene resin, 1 part of dibenzoyl peroxide, and 1 part of tert-butyl peroxybenzoate.

[0059] In one embodiment, the adhesion and protrusions on the inner wall of the fixed cavity are cleaned before the ceramic body is sintered in step.

[0060] The ceramic body is produced by additive manufacturing, which causes the inner wall of the fixed cavity of the ceramic body to have adhesion or protrusions. If the adhesion or protrusions are not cleaned, the molten metal liquid and the inner wall of the fixed cavity will have bubbles, which will cause the ceramic to not effectively adhere to the metal. In the present embodiment, the adhesion or protrusions are cleaned, which can avoid the adhesion or protrusions affecting the adhesion of the metal to the ceramic.

[0061] In one embodiment, the metal after solidification is annealed after the molten metal liquid is injected into the fixed cavity.

[0062] Since the molten metal cools at different rates at different positions, the metal structure 3 has internal stress due to the solidification of the molten metal at different positions at different times. Therefore, in the present embodiment, the annealing of the solidified metal can eliminate the thermal stress in the solidified metal, thereby avoiding the influence of the thermal stress on the impact strength of the metal.

[0063] In one embodiment, before the step of injecting the molten metal liquid into the fixed cavity after the ceramic structure 1 is kept at high temperature, a binding agent is introduced into the fixed cavity, and the binding agent is attached to the inner wall of the buffer layer 2 by vibration or shaking.

[0064] The bonding agent is attached to the inner wall of the buffer layer 2 by being poured into the fixed cavity and being vibrated or shaken, and the bonding agent has the following advantages: first, the bonding agent can promote the combination of ceramic and metal and can strengthen the bonding strength between ceramic and metal; second, after the bonding agent is attached to the inner wall of the fixed cavity, the uneven parts in the fixed cavity can be filled, the inner wall area of the fixed cavity is smooth, the metal and ceramic can be fully contacted and combined, and the gap between the ceramic and the metal can be reduced or avoided.

[0065] In one embodiment, the components of the bonding agent are as follows:

[0066]

[0067] By setting the adhesive, the ceramic and metal can be stably connected, and various components in the bonding layer can be bonded together;

[0068] By setting the accelerator, the accelerator is used to accelerate the curing of the adhesive and shorten the curing time;

[0069] By setting the coupling agent, the coupling agent is used to strengthen the connection between the metal and the ceramic;

[0070] By setting the high-temperature expansion agent, when the bonding agent is subjected to high-temperature molten metal, part of the solvent in the bonding agent will volatilize under the action of high temperature, which may cause a gap between the ceramic body and the metal, affecting the bonding strength of the ceramic and the metal. In the present application, the high-temperature expansion agent expands in volume when subjected to high-temperature treatment, which compensates for the possible gap between the ceramic and the metal. Moreover, the volume of the high-temperature expansion agent does not shrink after high-temperature treatment, which can fill the gap.

[0071] It should be understood that the adhesive is one or a mixture of two or more of phosphate adhesive, silicate adhesive, and epoxy resin; the accelerator concentration is 6% cobalt naphthenate; the curing agent can be m-phenylenediamine, the coupling agent is silane coupling agent, and the specific model can be KH-570; the high-temperature expansion agent refers to one or a mixture of two or more of powdery andalusite, kyanite, and sillimanite.

[0072] Through the above settings, andalusite, kyanite, and sillimanite are converted into mullite when subjected to high-temperature treatment, and the volume expands during the conversion process, which can compensate for the shrinkage of the bonding layer and further improve the high-temperature stability of the bonding layer.

[0073] In one embodiment, the ceramic material can be one or more of silicon oxide ceramic, silicon carbide ceramic, silicon nitride ceramic, silicon oxide combined silicon carbide ceramic, aluminum oxide high-temperature ceramic, and composite high-temperature ceramic.

[0074] The present application also relates to a ceramic metal composite structure manufactured by the method described above, which comprises a ceramic structure 1, a buffer layer 2 and a metal structure 3: the ceramic structure 1 is formed with a fixed cavity; the buffer layer 2 is embedded in the fixed cavity and is integrally formed with the ceramic structure 1; and the metal structure 3 is embedded in the fixed cavity and is attached to the buffer layer 2.

[0075] It should be understood that the integrally formed ceramic structure 1 and buffer layer 2 means that the ceramic structure 1 and buffer layer 2 are printed at the same time by additive manufacturing, and then sintered together.

[0076] The integrally formed ceramic structure 1 and buffer layer 2 can adapt to the shape of the complex fixed cavity, and when the molten metal liquid is injected into the fixed cavity, the buffer layer 2 can isolate the molten metal and the ceramic structure 1, avoiding direct contact between the molten metal and the outer ceramic. Moreover, since the buffer layer 2 is formed by high-temperature sintering, the buffer layer 2 can withstand the high temperature generated when the molten metal liquid is injected. When the molten metal liquid cools down, the cooling and shrinking force of the molten metal liquid acts on the buffer layer 2, avoiding the shrinking force acting directly on the outer ceramic and reducing the stress generated by the molten metal pulling the outer ceramic.

[0077] The above description is only the preferred embodiment of the present application, but the protection scope of the present application is not limited to this. Any changes or replacements within the technical scope disclosed by the present application can be easily thought by those skilled in the art, which should be covered within the protection scope of the present application.

Claims

1. A method for manufacturing a ceramic-metal composite structure, characterized in that, Includes the following steps: A ceramic preform is produced by additive manufacturing, in which a fixed cavity is formed within the ceramic preform, and a buffer layer is formed on the inner wall of the fixed cavity. The ceramic blank is sintered to obtain a ceramic structure and a buffer layer inside the ceramic structure; The ceramic structure is insulated, and molten metal is injected into the fixed cavity; A ceramic-metal composite structure was obtained by gradually cooling the temperature. The raw material components used in the additive manufacturing are silicon carbide micro powder and additives, wherein the additives include at least binders and sintering aids, and the proportion of binders in the raw material of the buffer layer blank is less than the proportion of binders in the raw material of the ceramic blank. Before sintering the ceramic blank, the attachments and protrusions on the inner wall of the fixing cavity are cleaned.

2. The method for manufacturing the ceramic-metal composite structure according to claim 1, characterized in that, After the steps of heat preservation of the ceramic structure and injection of molten metal into the fixed cavity, the method further includes the following step: A composite filler will be injected into the fixed cavity.

3. The method for manufacturing the ceramic-metal composite structure according to claim 2, characterized in that, In the step, a ceramic blank is produced by additive manufacturing, and a fixed cavity is formed inside the ceramic blank. A filling port communicating with the fixed cavity is also formed on the outer wall of the ceramic blank. After injecting the composite filler into the fixed cavity in the step, the injection port is filled with inorganic micro powder, and finally cured at below 200℃ for 6-12 hours.

4. The method for manufacturing the ceramic-metal composite structure according to claim 1, characterized in that, The buffer layer is made of ceramic and abuts against and fits against the inner wall of the fixed cavity.

5. The method for manufacturing the ceramic-metal composite structure according to claim 1, characterized in that, The thickness of the buffer layer is 3 to 15 mm.

6. The method for manufacturing the ceramic-metal composite structure according to claim 1, characterized in that, In the step of heat preservation of ceramic structure, molten metal liquid is injected into the fixed cavity by pressurization.

7. The method for manufacturing the ceramic-metal composite structure according to claim 1, characterized in that, During or after the process of heat preservation of the ceramic structure and injection of molten metal into the fixed cavity, the ceramic blank is vibrated.

8. The method for manufacturing the ceramic-metal composite structure according to claim 2, characterized in that, The composite filler comprises inorganic micro powder, silica sol, resin, defoamer, coupling agent, curing agent, and solvent.

9. The method for manufacturing the ceramic-metal composite structure according to claim 1, characterized in that, The ceramic material is one or more composites of silicon oxide ceramic, silicon carbide ceramic, silicon nitride ceramic, silicon oxide-bonded silicon carbide ceramic, and alumina ceramic.

10. A ceramic-metal composite structure, characterized in that, The ceramic-metal composite structure is manufactured using the manufacturing method of any one of claims 1 to 9; The ceramic-metal composite structure includes: A ceramic structure having a fixed cavity; A buffer layer, wherein the buffer layer is built into the fixing cavity and integrally formed with the ceramic structure; and A metal structure is built into the fixed cavity and fits the buffer layer.

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