A composite of brittle material and metal and a method of making the same

Abstract

The present application provides a kind of brittle material and metal composite material and its manufacturing method, including metal base layer, adhesive layer, first buffer layer, stress release layer, second buffer layer, three-dimensional network structure layer and brittle material layer, adhesive layer, first buffer layer, second buffer layer, for alloy material quality, stress release layer, three-dimensional network structure layer is single metal material quality, manufacturing steps include manufacturing composite material base, manufacturing three-dimensional network structure layer and hot pressing.The present application provides a kind of metal as base, brittle material as the surface of new composite material and manufacturing method, eliminate the stress generated between structure interface in hot pressing process due to the different thermal expansion coefficient of metal material and brittle material, the bonding strength between each material layer after manufacturing is large, the brittle material on the surface of metal material layer is tightly combined, not easy to fall off.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of composite material processing, and particularly relates to a brittle material and metal composite material and a manufacturing method thereof. BACKGROUND

[0002] A composite material is composed of two or more than two materials with different chemical and physical properties, which are combined in a designed form, proportion and distribution, and there is a clear interface between each component, forming a laminated structure. The composite material can take advantage of various materials and overcome the defects of single material, and has the characteristics of light weight, high strength, convenient processing and molding, excellent elasticity, chemical corrosion resistance and good weather resistance, etc. It has gradually replaced wood and metal alloys and is widely used in the fields of aerospace, automobile, electronics and electrical appliances, building, fitness equipment, etc. In recent years, it has developed rapidly. In the composite material, it is generally divided into metal and metal composite material, non-metal and metal composite material, and non-metal and non-metal composite material. The forming method is generally divided into solid phase forming method and liquid phase forming method according to the difference of material components. The former is realized by applying pressure below the melting point of the matrix, including diffusion welding, powder metallurgy, hot rolling, hot drawing, hot pressing and explosive welding, etc. The latter is to fill the matrix into the reinforcing material after melting, including traditional casting, vacuum suction casting, vacuum counter-pressure casting, extrusion casting and spray casting, etc. The forming method of ceramic matrix composite material mainly includes solid phase sintering, chemical vapor infiltration forming and chemical vapor deposition forming. Among them, hot pressing technology is a common technical means in the field of composite material manufacturing. However, when using hot pressing technology to produce composite materials, due to the high temperature and high pressure in the processing process, the expansion coefficients of metal materials and non-metal materials are different, and the expansion degree of metal is greater than that of non-metal material during processing. When the processing process is finished, the shrinkage of metal is greater than that of non-metal material, and a large stress is generated at the connecting surface of the two materials, which causes the composite material to be layered and cannot be directly made into a composite material of metal material and brittle non-metal material. SUMMARY

[0003] In order to solve the stress problem of the material interface layer in the production process of the composite material made of metal and brittle material, the present application provides a brittle material and metal composite material, which increases the material layer with bonding and stress buffering function between the metal material and the brittle material, and improves the bonding strength between the metal material and the brittle material.

[0004] In the hot pressing process, the expansion coefficient of the metal material is greater than that of the brittle material. If all the metal material layers are solid structures, a large stress will be generated at the interface between the layers after forming. Therefore, the metal base layer is used as the bottom layer, and the layers are sequentially arranged from the metal base layer to the adhesive layer, the first buffer layer, the stress release layer, the second buffer layer, the three-dimensional network structure layer and the brittle material layer. The adhesive layer, the first buffer layer and the second buffer layer are made of alloy materials, and the stress release layer and the three-dimensional network structure layer are made of single metal materials. The melting point of the metal constituting the stress release layer is in the range of 150-300℃. During hot pressing, the stress release layer melts into a liquid state under the action of high temperature, and becomes solid again after cooling after pressing. During the phase transformation process, the stress generated by the expansion or contraction of the first buffer layer and the second buffer layer is absorbed by the stress release layer, and the stress between the layers of the finished composite material is completely released in this process. At the same time, there is a three-dimensional network structure layer between the second buffer layer and the brittle material layer. During the hot pressing process, part of the brittle material powder will penetrate into the pores of the three-dimensional network structure layer under the action of pressure, and after pressing, the embedded effect will tightly combine the brittle material layer and the three-dimensional network structure layer, greatly enhancing the structural strength of the composite material.

[0005] In the forming process of the composite material, in addition to solving the stress problem caused by the difference in thermal expansion coefficient between the brittle material and the metal material, the bonding strength between the metal material layers also needs to be solved. The present application solves the above problems by limiting the metal materials constituting the first buffer layer, the stress release layer, the second buffer layer, the three-dimensional network structure layer. The first buffer layer and the second buffer layer are XY metal alloys, the stress release layer is X metal, the three-dimensional network structure layer is Y metal, and the adhesive layer is XZ alloy. X, Y and Z represent metal materials. Since the materials constituting the adjacent alloy material layer and single metal material layer have one same metal element, the adjacent alloy material layer and single metal material layer can be tightly combined together due to the easier combination and greater structural strength of the same metal material.

[0006] As a specific composite material structure provided by the present application, the metal X in the metal material layer is tin or indium, Y is nickel or zirconium, Z is chromium, the metal layer is titanium, nickel, stainless steel, molybdenum, niobium, tungsten, tantalum or zirconium, and the brittle material is ceramic or silicon. Nickel-chromium alloy is used as the adhesive layer, which has good adhesive effect and can be tightly combined with the metal base layer. The stress release layer is made of tin or indium. Tin and indium have a low melting point and can quickly melt after high-temperature heating. They are in solid form at room temperature, which can meet the processing and use requirements. At the same time, the texture of tin and indium is soft, which can also release the stress generated by the first buffer layer and the second buffer layer.

[0007] The application further provides a manufacturing method of the brittle material and metal composite material.

[0008] (1) The metal base layer, the adhesive layer, the first buffer layer, the stress release layer and the second buffer layer are made into a composite material base, and a common metal composite material processing technology, such as a spraying process or an adhesive pressing process, can be used, and only the close combination between the metal base layer, the adhesive layer, the first buffer layer, the stress release layer and the second buffer layer needs to be ensured.

[0009] (2) The three-dimensional network structure layer with internal pores is made of a metal material.

[0010] (3) The three-dimensional network structure layer is attached to the composite material base, then a layer of brittle material powder is covered on the three-dimensional network structure layer, and finally the composite material base, the three-dimensional network structure layer and the brittle material powder are pressed together to form a composite structure material, and the pressing process adopts a hot pressing process.

[0011] The brittle material and metal composite material and the manufacturing method thereof provided by the application provide a new type of composite material and manufacturing method in which metal is used as a base and brittle material is used as a surface, solve the problem of material delamination caused by stress generated between structural interfaces due to different thermal expansion coefficients of metal materials and brittle materials, and the combination between material layers can be completed by using a hot pressing method, the combination strength between material layers after manufacturing is large, the brittle material on the surface is tightly combined on the metal material layer, and is not easy to fall off. BRIEF DESCRIPTION OF DRAWINGS

[0012] The application will be further described in detail below with reference to the drawings.

[0013] Figure 1 FIG. 1 is a structural schematic view of a plate-shaped brittle material and metal composite material;

[0014] Figure 2 FIG. 2 is a structural schematic view of a tubular brittle material and metal composite material;

[0015] In the drawings: 1-metal base layer; 2-adhesive layer; 3-first buffer layer; 4-stress release layer; 5-second buffer layer; 6-three-dimensional network structure layer; 7-brittle material layer. DETAILED DESCRIPTION

[0016] In order to further illustrate the concept of the application, the application will be further described in detail below through specific embodiments, and the following embodiments are only used to illustrate and explain the application, and should not be interpreted as limiting the protection scope of the application. Any technology achieved based on the content described in the application is covered in the range intended to be protected by the application. Example 1

[0017] A composite material of brittle material and metal, such as Figure 1 As shown in the figure, from the metal base layer 1 upwards are in turn the adhesive layer 2, the first buffer layer 3, the stress release layer 4, the second buffer layer 5, the three-dimensional network structure layer 6 and the brittle material layer 7, the metal base layer 1 is made of titanium material, the adhesive layer 2 is nickel-chromium alloy, the first buffer layer 3 and the second buffer layer 5 are nickel-tin alloy, the mass ratio of nickel to tin in the nickel-tin alloy is 1:1, the stress release layer 4 is made of tin material, the three-dimensional network structure layer 6 is made of nickel material, and the brittle material layer 7 is ceramic.

[0018] The manufacturing process includes the following steps:

[0019] (1) Take the metal base layer 1 as the base, and successively coat the adhesive layer 2, the first buffer layer 3, the stress release layer 4 and the second buffer layer 5 by the spraying process to make the composite material base, the coating thickness of the first buffer layer 3 and the second buffer layer 5 is 0.05mm, and the coating thickness of the stress release layer 4 is 0.1mm.

[0020] (2) Make the three-dimensional network structure layer 6.

[0021] (3) Attach the three-dimensional network structure layer 6 on the composite material base, then cover a layer of brittle material powder on the three-dimensional network structure layer 6, and press the composite material base, the three-dimensional network structure layer 6 and the brittle material powder together by the hot pressing process. Example Two

[0022] A composite material of brittle material and metal, from the metal base layer 1 upwards are in turn the adhesive layer 2, the first buffer layer 3, the stress release layer 4, the second buffer layer 5, the three-dimensional network structure layer 6 and the brittle material layer 7, the metal base layer 1 is made of nickel material, the adhesive layer 2 is nickel-chromium alloy, the first buffer layer 3 and the second buffer layer 5 are nickel-indium alloy, the mass ratio of nickel to indium in the nickel-indium alloy is 1:1, the stress release layer 4 is made of indium material, the three-dimensional network structure layer 6 is made of nickel material, and the brittle material layer 7 is ceramic.

[0023] The manufacturing process includes the following steps:

[0024] (1) Take the metal base layer 1 as the base, and successively coat the adhesive layer 2, the first buffer layer 3, the stress release layer 4 and the second buffer layer 5 by the spraying process to make the composite material base, the coating thickness of the first buffer layer 3 and the second buffer layer 5 is 0.1mm, and the coating thickness of the stress release layer 4 is 0.2mm.

[0025] (2) Make the three-dimensional network structure layer 6.

[0026] (3) The three-dimensional network structure layer 6 is attached to the composite material substrate, and then a layer of brittle material powder is covered on the three-dimensional network structure layer 6, and the composite material substrate, the three-dimensional network structure layer 6 and the brittle material powder are pressed together by using a hot pressing process. Example Three

[0027] A composite material of brittle material and metal, from the metal base layer 1 upwards, in turn, is the bonding layer 2, the first buffer layer 3, the stress release layer 4, the second buffer layer 5, the three-dimensional network structure layer 6 and the brittle material layer 7, the metal base layer 1 uses titanium material, the bonding layer 2 is nickel-chromium alloy, the first buffer layer 3 and the second buffer layer 5 are titanium-tin alloy, the mass ratio of titanium and tin in the titanium-tin alloy is 1:1, the stress release layer 4 is tin material, the three-dimensional network structure layer 6 is titanium material, and the brittle material layer 7 is silicon.

[0028] The manufacturing process includes the following steps:

[0029] (1) Take the metal base layer 1 as the substrate, and successively coat the bonding layer 2, the first buffer layer 3, the stress release layer 4 and the second buffer layer 5 by using a spraying process to make a composite material substrate, the coating thickness of the first buffer layer 3 and the second buffer layer 5 is 0.5mm, and the coating thickness of the stress release layer 4 is 0.5mm.

[0030] (2) Manufacture a three-dimensional network structure layer 6.

[0031] (3) Attach the three-dimensional network structure layer 6 to the composite material substrate, and then cover a layer of brittle material powder on the three-dimensional network structure layer 6, and press the composite material substrate, the three-dimensional network structure layer 6 and the brittle material powder together by using a hot pressing process. Example Four

[0032] A composite material of brittle material and metal, from the metal base layer 1 upwards, in turn, is the bonding layer 2, the first buffer layer 3, the stress release layer 4, the second buffer layer 5, the three-dimensional network structure layer 6 and the brittle material layer 7, the metal base layer 1 uses zirconium material, the bonding layer 2 is nickel-chromium alloy, the first buffer layer 3 and the second buffer layer 5 are zirconium-tin alloy, the mass ratio of zirconium and tin in the zirconium-tin alloy is 1:1, the stress release layer 4 is tin material, the three-dimensional network structure layer 6 is zirconium material, and the brittle material layer 7 is ceramic.

[0033] The manufacturing process includes the following steps:

[0034] (1) Take the metal base layer 1 as the substrate, and successively coat the bonding layer 2, the first buffer layer 3, the stress release layer 4 and the second buffer layer 5 by using a spraying process to make a composite material substrate, the coating thickness of the first buffer layer 3 and the second buffer layer 5 is 0.05mm, and the coating thickness of the stress release layer 4 is 0.05mm.

[0035] (2) manufacturing the three-dimensional net structure layer 6.

[0036] (3) attaching the three-dimensional net structure layer 6 on the composite material substrate, then covering a layer of brittle material powder on the three-dimensional net structure layer 6, and pressing the composite material substrate, the three-dimensional net structure layer 6 and the brittle material powder together by using the hot pressing process.

[0037] In the above embodiment, the metal materials of the three-dimensional net structure layer 6 and the stress release layer 4 are different, the metal material of the three-dimensional net structure layer 6 is harder and has higher strength, and the metal material of the stress release layer 4 is softer and has lower melting point, the alloy of the two metal materials of the three-dimensional net structure layer 6 and the stress release layer 4 is used to make the first buffer layer 3 and the second buffer layer 5, which can tightly combine the adjacent two structure layers together, since zirconium and nickel have high hardness, the three-dimensional net structure layer 6 made of them can tightly fix the brittle material layer 7 by the brittle material infiltrating into the internal pores, and tin and tin alloy have the characteristics of low melting point and low thermal expansion coefficient, which can make the stress release layer 4, the first buffer layer 3 and the second buffer layer 5 produce smaller thermal expansion phenomenon in the hot pressing process, and the generated stress can be released more quickly by melting, so the three-dimensional net structure layer 6 made of nickel or zirconium metal and the stress release layer 4 made of tin metal are the best embodiment of the present application.

[0038] The structural strength of the composite material prepared in Example 1 is tested to detect the bonding firmness of the composite material, a force perpendicular to the surface is applied to the composite material until the material is broken, and then the bonding part of the broken surface is observed, and through experiments, the ceramic layer and the titanium metal material layer are still tightly connected together after the composite material is broken under stress, and no delamination phenomenon occurs, which proves that the perfect combination between the brittle material layer 7 and the metal material layer of the composite material provided by the present application has been realized.

[0039] The composite material of brittle material and metal provided by the present application can release the stress generated in the hot pressing process of the metal base layer 1 and the brittle material layer 7, and tightly combine the two together by setting the adhesive layer 2, the first buffer layer 3, the stress release layer 4, the second buffer layer 5 and the three-dimensional net structure layer 6 between the metal base layer 1 and the brittle material layer 7, which can be applied to the composite material structure composed of most metal materials and non-metal materials, since the material layer between the metal base layer 1 and the brittle material layer 7 can be adjusted in thickness according to the needs, very good bonding effect can be provided even in the case of very small material layer thickness, and even ultra-thin composite materials can be manufactured by using the structure and method provided by the present application, and different shapes can be manufactured according to product design, such as Figure 1 the plate shape shown in the figure, or Figure 2 the pipe shape shown in the figure.

[0040] There are many methods and approaches that can achieve the technical solutions of the present application, and the above only provides the preferred embodiments in an exemplary manner. Those skilled in the art can think of many changes, alterations and substitutions without departing from the present application. It should be understood that various alternatives to the embodiments of the application described herein can be employed in practicing the application. The appended claims are intended to define the scope of the application and thus cover the methods within the scope of these claims and their equivalents. Based on the examples in the present application, all other examples obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

Claims

1. A composite of a brittle material and a metal, characterized by: The structure is metal base layer, adhesive layer, first buffer layer, stress release layer, second buffer layer, three-dimensional network structure layer and brittle material layer in turn, the adhesive layer, the first buffer layer, the second buffer layer are alloy material, the stress release layer, the three-dimensional network structure layer are single metal material; The first buffer layer and the second buffer layer are XY metal alloy, the stress release layer is X metal, the three-dimensional network structure layer is Y metal, and the adhesive layer is YZ alloy; Y is nickel or zirconium, X is tin or indium, and Z is chromium; the mass ratio of X and Y is 1:1; The brittle material is ceramic or silicon, and the metal base layer is titanium, nickel, stainless steel, molybdenum, niobium, tungsten, tantalum or zirconium; The manufacturing method of the brittle material and the metal composite material comprises the following steps: (1) the metal base layer, the adhesive layer, the first buffer layer, the stress release layer and the second buffer layer are made into a composite material base; (2) a three-dimensional network structure layer with internal pores is made of metal material; (3) the three-dimensional network structure layer is attached to the composite material base, then a layer of brittle material powder is covered on the three-dimensional network structure layer, and the composite material base, the three-dimensional network structure layer and the brittle material powder are hot-pressed together to form a composite structure material; in the hot-pressing process, part of the brittle material powder penetrates into the pores between the three-dimensional network structure layer under the action of pressure, and after pressing, the embedded effect is formed to tightly combine the brittle material layer and the three-dimensional network structure layer together.

2. The brittle material and metal composite of claim 1, wherein: The melting point of the stress release layer is 150-300℃.

3. The brittle material and metal composite of claim 1, wherein: In step (1), the adhesive layer, the first buffer layer, the stress release layer and the second buffer layer are combined with the metal base layer by spraying or adhesive pressing process.

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