Method for combining dissimilar materials based on mortise and tenon grooves and pressing and scraping process

Abstract

The invention discloses a dissimilar material combination method based on a mortise and tenon groove and a pressing and scraping process, and belongs to the technical field of material processing. The method comprises the steps that a groove is formed in the surface of a base material, the groove is provided with a narrow part, and a cured filling material forms mechanical interlocking at the narrow part; after the base material is preheated, molten metal is poured to the surface of the base material; a high-temperature-resistant scraping plate is adopted for pressing and scraping, vibration and / or heating are / is applied at the same time, metal is extruded and filled into the groove, and redundant metal is scraped away; and finally, carrying out surface leveling treatment. The mechanical locking effect of the mortise and tenon joint structure is combined with pressure, shearing force and vibration assistance generated by the pressing and scraping technology, the technical problems that when dissimilar materials (such as metal, wood, stone, pottery and dissimilar metal) are combined, metal is prone to falling off, and fine patterns are difficult to manufacture are thoroughly solved, superfine line filling larger than or equal to 0.15 mm can be achieved, the bonding strength is high, the surface is smooth, and the service life is long. The method is suitable for high-efficiency batch production.

Description

Technical Field

[0001] This invention relates to the field of material processing and composite manufacturing technology, specifically to a method for joining dissimilar materials based on mortise and tenon joints and pressing and scraping processes, which is particularly suitable for the firm bonding and fine inlay of metals with wood, stone, ceramics, dissimilar metals, and other materials. Background Technology

[0002] Currently, the main methods for bonding metals with dissimilar materials include:

[0003] (1) Casting process: Molten metal is poured directly into the gaps of the substrate, and then polished smooth after cooling. This method makes it easy for metal to fall off and makes it difficult to produce fine lines <0.7mm.

[0004] (2) Inlay process (such as gold and silver inlay): It requires manual inlay of metal wires or sheets, hammering the metal to produce deformation to form the inlay effect, or relying on the wetting and adhesion of low melting point metals. The precision depends on the technician's experience, the surface quality is unstable, the process is complicated, and it is difficult to produce large-area plates.

[0005] (3) Metal lamination process (such as wood grain gold, damascus steel): It is only applicable to the combination of metal and dissimilar metals. It is a sintering process and cannot be used for non-metallic materials such as wood and stone.

[0006] (4) Electric wood process: suitable for the combination of wood and resin. The wood is electrically heated to create patterns, and resin is poured into the grooves of the patterns to form a whole. Using metal casting is easy to fall off and unstable.

[0007] (5) Black Copper with Silver Welding Process: This process is only suitable for bonding black copper and silver, where the melting points are similar. High temperature is used to achieve effective welding of copper and silver. It is not applicable to non-metallic materials such as wood, stone, and ceramics. It is also difficult to firmly bond dissimilar metals with significantly different melting points, such as iron and bismuth.

[0008] (6) Repairing porcelain: a type of repair technique.

[0009] The main problem with existing technology is that:

[0010] (1) Metal is prone to detachment when combined with non-metallic materials such as wood, stone, and ceramics;

[0011] (2) It is difficult to create fine patterns or lines;

[0012] (3) The process is complex and the production efficiency is low.

[0013] (4) It is difficult to manufacture large-area composite panels.

[0014] (5) It is difficult for metals to bond firmly with dissimilar metals with large differences in melting points.

[0015] To address the aforementioned technical issues, a method for combining dissimilar materials based on mortise and tenon grooves and a pressing and scraping process is urgently needed. Summary of the Invention

[0016] To solve the above-mentioned technical problems, the technical solution provided by the present invention is: a method for combining dissimilar materials based on mortise and tenon grooves and pressing and scraping process, which achieves a firm composite of dissimilar materials through the synergistic effect of mechanical locking and physical bonding.

[0017] The technical solution adopted in this invention mainly includes the following steps:

[0018] (1) Select a substrate, which includes wood, stone, cement, ceramic or metal; when the substrate is metal, its melting point must be higher than the melting point of the metal to be filled;

[0019] (2) A groove is engraved on the surface of the substrate, the groove having a narrow portion, such that the cured filler material forms a mechanical interlock at the narrow portion; for example, hourglass shape, dovetail shape or T shape;

[0020] (3) The surface of the substrate is preheated to reduce the thermal stress between the molten metal and the substrate;

[0021] (4) Heat the filler metal to a molten state;

[0022] (5) Pour molten metal onto the preheated substrate surface, and use a scraper to squeeze the metal into the groove through a scraping process, while scraping off excess metal from the substrate surface.

[0023] (6) During the scraping process, vibration and / or continuous heating are used to promote metal flow and expel gas, ensuring that the metal completely fills the groove;

[0024] (7) After the metal has cured, the surface of the substrate is polished to make the filler metal and the surface of the substrate flat.

[0025] Furthermore, the scraping process employs a high-temperature resistant scraper with elasticity and toughness, applying pressure and friction before the metal solidifies to ensure that the metal tightly fills the groove.

[0026] Furthermore, the minimum width of the mortise and tenon structure groove can be 0.15 mm, and the depth can be customized according to the pattern requirements.

[0027] Furthermore, the filler metal is a pure metal, an alloy, or a mixture of metal and an organic binder.

[0028] Furthermore, when the substrate is wood, hardwood is preferred and it is pre-treated with fire retardant; when it is stone, the metal temperature needs to be controlled and pre-treated by etching or sandblasting to increase adhesion.

[0029] The advantages of the invention compared to existing technologies are:

[0030] 1. High bonding strength: The mortise and tenon structure forms a mechanical lock, and the pressing and scraping process ensures that the metal and the groove wall are tightly attached. The dual effect greatly improves the bonding force and the metal is not easy to fall off.

[0031] 2. High precision: The combination of shearing force generated by the pressure scraping and vibration assistance can achieve complete filling of ultra-fine lines (≥0.15mm), meeting the requirements of high-precision patterns.

[0032] 3. High efficiency and good surface quality: The pressure scraper can simultaneously smooth the surface, reducing the amount of subsequent sanding work, and is suitable for the efficient production of large-area boards.

[0033] 4. Wide applicability: By selecting metals and substrates with different melting points, it is possible to achieve a strong bond between metals and non-metals (wood, stone, ceramics), as well as dissimilar metals with large differences in melting points. Detailed Implementation

[0034] The present invention will now be described in further detail.

[0035] In a specific implementation, this invention provides a method for joining dissimilar materials based on mortise and tenon joints and a pressing and scraping process. The method includes the following steps:

[0036] (1) Select a substrate, which may be wood, stone, cement, ceramic or metal, etc. The melting point of the metal substrate must be higher than the melting point of the metal to be filled.

[0037] (2) A groove is engraved on the surface of the substrate. The groove is flat, hourglass, dovetail or T-shaped, etc. The groove has a narrow part, so that the cured filling material forms a mechanical interlock at the narrow part.

[0038] (3) Preheat the surface of the substrate to reduce thermal stress; the preheating temperature range is: 100-580℃ for stone, 80-280℃ for wood, 200-1000℃ for ceramics, and 30%-90% of the melting point of the substrate for metals.

[0039] (4) Heat low-melting-point metals (such as tin, lead, bismuth, zinc and their alloys, with melting points controlled below 380℃) or high-melting-point metals (such as gold, silver, copper, aluminum, iron, magnesium and their alloys, with melting points controlled below 1300℃) to a molten state. Wood and stone are suitable for low-melting-point metals; refractory bricks, volcanic rock, graphite plates, alumina ceramics, steel and other high-temperature resistant materials are suitable for both high-melting-point and low-melting-point metals.

[0040] (5) Molten metal is poured into the preheated substrate surface in multiple stages. A scraping process is used to press the metal into the groove, introducing the molten filler material onto the substrate surface. A scraper is used to scrape the molten filler material on the substrate surface, generating pressure perpendicular to the substrate surface and shear force parallel to the substrate surface, forcing the filler material to completely fill the groove and scraping away excess filler material from the substrate surface. The filler material solidifies within the groove, and the mechanical interlocking structure formed by the narrow section ensures a firm bond between the filler material and the substrate.

[0041] (6) Vibration and continuous heating are used during the scraping process to prevent the metal from cooling too quickly, so that the metal can completely fill the groove and solidify.

[0042] (7) Grind the filled substrate to make the filler metal and the substrate surface flat.

[0043] Example: Hardwood combined with tin-bismuth alloy (fine pattern making)

[0044] Application scenario: Metal inlay on the surface of mahogany furniture.

[0045] Step-by-step instructions: 1. Substrate pretreatment: Material selection: Burmese rosewood. Carving: Use a CNC carving machine to process dovetail-shaped grooves with a traditional meander pattern, the finest line width being 0.4mm. Fireproofing treatment: Apply a sodium silicate water glass coating to prevent high-temperature carbonization.

[0046] II. Metal-filled alloy ratio: 42% tin + 58% bismuth (melting point 138℃), with rosin flux added to improve fluidity.

[0047] III. Pressing and Scraping Process: Preheat the wooden board to 85℃ (using a hot air gun for uniform heating). Pour the molten alloy in 3-10 stages, each time using a carbon steel scraper (temperature resistant above 1350℃) at an angle of 0-85°. The pushing force applied by the scraper to the metal slurry is sufficient to overcome its yield stress and shear it, while the scraper undergoes moderate deformation to ensure close adhesion to the substrate surface. While smoothing the metal, scrape off any excess metal outside the groove from the substrate surface until the groove is completely filled.

[0048] Vibration assistance: The scraping process is accompanied by an ultrasonic vibrator (frequency 28kHz) to expel air bubbles.

[0049] 4. After post-treatment and curing, first use 400-grit sandpaper for rough sanding, and gradually increase the grit to 3000-grit for polishing until the surface is smooth and glossy.

[0050] Apply wood wax oil to the wood surface for protection.

[0051] Performance Verification: Peel Test: The metal strip requires a tensile force of ≥52N / mm to detach. Precision: It can achieve continuous and complete filling of strips with a width of ≥0.15mm.

[0052] The pressing and scraping process includes multiple additions of molten metal, vibration, and heating until the metal completely fills the groove and forms a solid. As a further explanation of the invention, the post-processing includes progressive grinding and polishing, culminating in a mirror polishing of the metal area. As a further explanation of the invention, the method also includes applying a transparent protective layer to the substrate surface to enhance the durability of the bond.

[0053] The present invention and its embodiments have been described above. This description is not restrictive, and the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and, without departing from the spirit of the invention, design similar structures and embodiments without creative effort, all such designs should fall within the protection scope of the present invention.

Claims

1. A method for bonding dissimilar materials, characterized in that, The process includes the following steps: preparing a groove on the surface of a substrate, the groove having a narrow portion, such that the cured filler material forms a mechanical interlock at the narrow portion; Molten filler material is introduced onto the surface of the substrate; a scraper is used to scrape the molten filler material on the substrate surface, the scraping operation simultaneously generating pressure perpendicular to the substrate surface and shear force parallel to the substrate surface, forcing the filler material to completely fill the groove and scraping off excess filler material from the substrate surface; the filler material is then cured within the groove, and a mechanical interlocking structure formed by the narrow portion ensures a firm bond between the filler material and the substrate, the minimum opening width of the groove being 0.15 mm; during the scraping operation, vibration is simultaneously applied or the substrate is continuously heated.

2. The method according to claim 1, characterized in that: The narrow portion is formed by the cross-sectional shape of the groove, which is one of a dovetail shape, an hourglass shape, an inverted T shape, or an L shape.

3. The method according to claim 1, characterized in that: The scraper is made of a high-temperature resistant, elastic, and tough material; during the scraping operation, the scraper undergoes elastic deformation under pressure to ensure adhesion to the substrate surface.

4. The method according to claim 1, characterized in that: The filler material is a metal or alloy.

5. The method according to claim 5, characterized in that: The filler material is a low-melting-point metal alloy with a melting point below 400°C; or a high-melting-point metal with a melting point above 400°C.

6. The method according to claim 6, characterized in that: The low-melting-point metals include tin, bismuth, lead, zinc, or their alloys; the high-melting-point metals include silver, copper, aluminum, iron, magnesium, or their alloys.

7. The method according to claim 1, characterized in that: The substrate is wood, stone, cement, ceramic or metal.

8. The method according to claim 1, characterized in that: The substrate is preheated before the molten filler material is introduced.

9. A dissimilar material bonding system for implementing the method of any one of claims 1-8, characterized in that, include: A worktable is used to fix the substrate. A heating device for preheating and / or continuously heating the substrate; A pouring device for introducing the molten filler material onto the surface of the substrate; a leveling device including the scraper; and a control unit for controlling the sequential and coordinated operation of each device.

10. The system according to claim 9, characterized in that: It also includes a vibration device for applying vibration to the worktable or the scraper during the scraping operation.