U.S. patent number 3,827,129 [Application Number 05/215,785] was granted by the patent office on 1974-08-06 for methods of producing a metal and carbon fibre composite.
This patent grant is currently assigned to British Railways Board. Invention is credited to Albert W. Denham, Brian A. W. Redfern.
United States Patent |
3,827,129 |
Denham , et al. |
August 6, 1974 |
METHODS OF PRODUCING A METAL AND CARBON FIBRE COMPOSITE
Abstract
A process of producing a metal and carbon fibre composite in
which carbon fibres are treated to produce a very thin coating on
the surface and the treated fibres are then wetted by metal melts
to which a particular alloying metal has been added. The fibres are
treated with a metal carbide and the alloying metal is preferably
of the same metal as that of the carbide. The carbon fibres are
infiltrated into the matrix metal while the latter is in a molten
state and the invention is particularly concerned with the
production of a wetting interface between the metal alloys and the
carbon fibres. The method enables shaped bodies such as shaft
bearings to be made in a convenient manner. The composite may have
other forms such as continuous tapes for subsequent assembly into
more complex shapes.
Inventors: |
Denham; Albert W. (Derby,
EN), Redfern; Brian A. W. (Derby, EN) |
Assignee: |
British Railways Board (London,
EN)
|
Family
ID: |
22804377 |
Appl.
No.: |
05/215,785 |
Filed: |
January 6, 1972 |
Current U.S.
Class: |
29/419.1; 75/229;
164/97; 29/527.3; 75/243; 428/539.5 |
Current CPC
Class: |
B23P
17/04 (20130101); F16C 33/14 (20130101); F16C
33/16 (20130101); C22C 49/14 (20130101); F16C
2223/60 (20130101); Y10T 29/49801 (20150115); Y10T
29/49984 (20150115) |
Current International
Class: |
B23P
17/00 (20060101); B23P 17/04 (20060101); C22C
49/14 (20060101); C22C 49/00 (20060101); F16C
33/04 (20060101); F16C 33/14 (20060101); F16C
33/16 (20060101); B23p 017/04 () |
Field of
Search: |
;164/97
;29/419,527.1,527.3,527.5,191.2 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Lanham; Charles W.
Assistant Examiner: Reiley, III; D. C.
Attorney, Agent or Firm: Pollock, Philpitt & Vande
Sande
Claims
We claim:
1. Method of forming a metal and carbon fibre composite which
comprises coating the carbon fibres with a carbide of a member
selected from the group consisting of titanium, vanadium, hafnium,
tantalum, zirconium, niobium, other monocarbide forming metals, and
chromium; then employing a molten technique to cause infiltration
of the coated carbon fibres into a matrix metal while the matrix
metal is in a molten state, and obtaining said metal and carbon
fibre composite.
2. A method as claimed in claim 1, wherein the coating is
continuous and does not exceed 500 A thickness.
3. A method as claimed in claim 1, wherein the coating is formed as
a preliminary step by reacting the metal with the carbon of the
fibres.
4. A method as claimed in claim 3 wherein the coating is produced
by a metal halide vapour deposition method.
5. A method as claimed in claim 1, wherein an amount of at least
one of the metals specified is added to the matrix metal.
6. A method as claimed in claim 5, wherein the metal added to the
matrix is the same as that forming the carbide coating on the
carbon fibres.
7. A method as claimed in claim 5 in which the added metal is
insolid solution in the matrix metal in an amount of at least 0.05
percent by weight of the whole.
8. A method as claimed in claim 5, wherein the matrix metal is
copper or a copper alloy and the added metal is titanium.
9. A method as claimed in claim 5, wherein the added metal forms an
intermetallic compound with the matrix metal and the melt into
which the carbon fibres are infiltrated is maintained at a
temperature high enough to release the added metal from the
intermetallic compound.
10. A method as claimed in claim 5, wherein the matrix metal is a
tin lead alloy and the added metal is titanium.
11. A method as claimed in claim 5, wherein the matrix metal is
aluminium and the added metal is titanium.
12. A method as claimed in claim 5, wherein the matrix metal is
magnesium and the added metal is titanium.
Description
This invention is concerned with the production of metal and carbon
fibre composites using molten metal techniques in which the carbon
fibres are infiltrated into a matrix metal while the latter is in a
molten state.
The purpose of producing metal and carbon fibre composites is
essentially to maintain the mechanical properties of the metal and
combine them with the anisotropic strengthening influence of carbon
fibres.
Metal and carbon fibre composites can only be fabricated without
the application of large pressures if the metal in the molten state
wets the fibres. However, most engineering metals do not wet carbon
fibres.
It is the object of this invention to provide a statisfactory
wetting system. Such a wetting system will display several
advantages. Infiltration of the carbon fibres into the matrix of
the metal will be complete producing a composite with sustantially
no porosity. Conventional molten metal casting techniques can be
employed to produce the composites. The manufacturing process will
be rapid. Continuous production of metal and carbon fibre
composites in the form of tapes for subsequent assembly into
complex shapes becomes possible.
According to the invention a method of producing a metal and carbon
fibre composite by a molten metal technique includes the use of
carbon fibres having a coating of a carbide of titanium vanadium,
hafnium, tantalum, zirconium, niobium or of other monocarbide
forming metals or of chromium.
Such a coating will by itself provide a reasonably satisfactory
wetting system for certain matrix metals such as aluminium. However
in further advantageous development of the invention a small
addition of one of the aforesaid metals is added to the matrix
metal.
The coating on the carbon fibres and the addition to the matrix
metal of one of the aforesaid metals will produce a chemical bond
across the carbon fibre-metal interface. Particularly in the case
of low melting point metals this will allow high temperature
strength to be retained and will prevent dewetting if a subsequent
local melting occurs in, for example, a hot pressing treatment.
Preferably the carbide coating on the fibres is formed by reacting
the carbide forming metal with the carbon of the fibres for example
using a metal halide vapour deposition method.
Depending upon the matrix metal and the added metal used, the added
metal will either be present in solid solution in the matrix metal
or as an intermetallic compound with the matrix metal. When in
solid solution, it is preferable that there is at least 0.05
percent by weight added metal in solid solution. When forming an
intermetallic compound, it is preferable that the melt into which
the coated carbon fibres are infiltrated is maintained above
700.degree.C.
It is advantageous if the coating is continuous and does not exceed
500 A thickness.
In experiments so far conducted, titanium has been found to be the
most suitable both for use as the carbide coating on the carbon
fibres and as the metal added to the matrix metal.
Matrix metals to which the invention may be applied include, for
example tin-lead alloy, which brings the application of the
invention into the field of plain bearings as will be described,
and also include copper, aluminium and magnesium which bring the
application of the invention into the field of structural
artifacts.
The invention will now be further explained by way of example in
which titanium is used as the carbide forming metal on the carbon
fibres and is also used as the metal added to the matrix metal.
A carbide coating is formed on the carbon fibres by a reaction of
titanium with the carbon of the fibres using a titanium iodide
vapour deposition method. The reaction can be expressed as:
TiI.sub.2 + C .revreaction. TiI.sub.4 + Ti C.
For this process to occur (where G denotes Gibbs Free Energy
change)
.DELTA.G .sub.reaction = .DELTA.G .sub.formation TiI +
G.sub.formation TiC - 2.DELTA.G.sub.formation TiI
.sub.<.sub.0
In the temperature range 700.degree.C - 1,000.degree.C, .DELTA.
G.sub.decomp TiI is positive but G.sub.reaction is negative so the
titanium is deposited specifically onto the carbon, forming
titanium carbide.
The coating is adherent to the carbon fibre and evenly distributed.
The particle size is 100A - 500A and the thickness can be
controlled to the same order.
The coating is brittle and weaker than the carbon fibre but
provided the thickness is kept below 500A degradation in strength
is acceptable.
The carbon fibres are coated by passing them through a reaction
furnace one or two tows at a time in an atmosphere of argon, the
tows each consisting of for example 10,000 fibres.
The reaction chamber is isolated by using liquid traps either side,
these keep the reactants, namely titanium and iodine, in and oxygen
out. The fibres pass through constructions on the inlet and outlet
passages of the furnace to prevent seepage of iodide from the
furnace.
At an operating temperature of 950.degree.C, with a titanium to
iodine ratio of 5 : 1, titanium iodide is formed and reacts with
the carbon as described above and the coating rate and hence the
speed at which the tows are pulled through the reaction chamber is
25 feet per hour.
Similar considerations of thermodynamic data show that the process
could be adopted for other carbide forming metals notably chromium,
niobium, zirconium, molybdenum using the iodides and other halides.
Titanium, however, produces the most adherent and continuous
carbide coating and the iodide process allows a greater measure of
control over coating thickness.
The titanium carbide coated fibres thus formed are infiltrated into
a matrix metal using conventional molten metal casting techniques,
a small addition of titanium having been added to the matrix metal.
The presence of the titanium carbide coating and the added titanium
metal ensure a satisfactory wetting interface between the carbon
fibres and the matrix metal.
Two main possibilities exists for ensuring that the titanium is
present in the melt of a particular matrix metal, which may itself
be an alloy. It may be in solid solution and will therefore be
released at the melting point of the alloy. Cu alloys offer such a
system when the titanium is present at least by 0.5 percent by
weight. Alternatively titanium may have restricted solid solution
in a metal alloy and the chemical thermodynamics may favour the
formation of an intermetallic compound. When such an alloy melts,
the solubility of the intermetallic compound in the liquid metal
(and therefore the availability of the titanium) may be very low
and consequently temperatures in excess of the alloy matrix melting
point may be reached before wetting occurs. For example the alloy
system which is the basis of white metal bearing alloys, tin-lead,
when combined with 0.5 percent titanium by weight forms a
tintitanium intermetallic compound, which does not have appreciable
solubility in the melt until about 800.degree.C. To produce a
composite in this alloy, the melt is superheated to this
temperature before casting into it the coated carbon fibres.
The tensile properties of composites produced in the manner
described above compare favourably with those produced by
alternative methods. The characteristics of the fracture surfaces
in copper, tin-lead and aluminium alloy composites show no pull out
of fibres which would infer that a good bond exists between the
carbon fibres and the metal matrices.
One application of a composite produced as described above in a
plain bearing will now be described by way of example with
reference to the accompanying drawing in which:
FIG. 1 is a perspective view of the bearing,
FIG. 2 is a cross-sectional view of the bearing, and
FIG. 3 is a longitudinal sectional view.
The bearing has a body 1 and incorporates a bearing insert 2. The
insert 2 comprises a tin-lead alloy and carbon fibre composite
bonded to a tin-lead alloy block.
To form the insert 2, coated carbon fibres represented at 3 coated
with titanium carbide by the method described above are placed in a
silica mould in the neck of which is contained the matrix metal
alloy having a nominal composition by weight of 8 percent tin 0.5
percent titanium and the remainder lead. The alloy is melted in the
neck by radio frequency (RF) heating until it has all flowed into
the cylindrical mould containing the coated carbon fibres and forms
a composite, i.e., a strip of matrix metal into which the fibres
have been infiltrated. To ensure optimum distribution, the mould is
vibrated. The cast composite thus formed containing 10 percent by
volume of carbon fibres is then placed in a mould and bonded by
melting to the tin-lead alloy block to form a test specimen, so
that the carbon fibres are concentrated near the bearing surface 4
and extend parallel to the bearing surface.
A bearing incorporating an insert 2 was tested against a
conventional white metal alloy bearing and gave the following
result on a standard Amsler test machine.
__________________________________________________________________________
Weight loss Scar width (mg) (.times. 0.001 ins)
__________________________________________________________________________
White Metal (Sn12%, Sb13% Cu : 7% Pb remainder) 23.0 71.0 Insert 2
12.0 47.0
__________________________________________________________________________
* * * * *