U.S. patent number 3,864,807 [Application Number 05/398,778] was granted by the patent office on 1975-02-11 for method of manufacturing a shaped element of fiber-reinforced material.
This patent grant is currently assigned to G. Rau. Invention is credited to Friedrich Schneider, Dieter Stockel.
United States Patent |
3,864,807 |
Schneider , et al. |
February 11, 1975 |
METHOD OF MANUFACTURING A SHAPED ELEMENT OF FIBER-REINFORCED
MATERIAL
Abstract
A shaped element of fibre reinforced material comprises a bundle
of wires, each enclosed in a jacket of matrix substance, which has
been subjected to a mechanical working, such as drawing, to reduce
to cross-sectional area of the wires and jackets and to bond the
jackets together. The bundle of jacketed wires may be enclosed in
an outer casing of the matrix substance prior to mechanical working
and each jacket may consist of a tube into which a wire is
threaded.
Inventors: |
Schneider; Friedrich
(Pforzheim, DT), Stockel; Dieter (Pforzheim,
DT) |
Assignee: |
G. Rau (Pforzheim,
DT)
|
Family
ID: |
27183022 |
Appl.
No.: |
05/398,778 |
Filed: |
September 19, 1973 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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203381 |
Nov 30, 1971 |
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Foreign Application Priority Data
Current U.S.
Class: |
148/530; 428/611;
29/419.1; 428/614 |
Current CPC
Class: |
C22C
47/068 (20130101); B22F 3/002 (20130101); C22C
47/20 (20130101); Y10T 29/49801 (20150115); Y10T
428/12486 (20150115); Y10T 428/12465 (20150115) |
Current International
Class: |
C22C
47/00 (20060101); B22F 3/00 (20060101); C22C
47/20 (20060101); B23p 017/00 () |
Field of
Search: |
;29/419R,423,191.6,419G
;148/4 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lanham; C. W.
Assistant Examiner: Reiley, III; D. C.
Attorney, Agent or Firm: Wenderoth, Lind & Ponack
Parent Case Text
This is a continuation of application Ser. No. 203,381, filed Nov.
30, 1971, now abandoned.
Claims
What we claim is:
1. A method for producing a shaped element formed of a homogeneous
matrix substance and having intimately embedded therein a plurality
of substantially circular reinforcing fibers of a diameter in the
magnitude of microns, the ductility properties of said matrix
substance and said fibers being substantially different, said
method consisting essentially of the steps of:
rigidly and metallurgically connecting to each of a plurality of
substantially circular wires of reinforcing material a jacket of
said matrix substance, each of said wires having a diameter in the
magnitude of millimeters;
arranging said plurality of thus jacketed wires in a loose bundle
in contact with each other; and
subjecting said bundle to a non-cutting mechanical working
operation;
thereby reducing the cross-sectional area of said wires and said
jackets, the cross-sectional area of said wires being reduced from
a magnitude of mm.sup.2 to a magnitude of 10.sup.-.sup.6 mm.sup.2,
mechanically bonding said jackets together into a uniform
homogeneous matrix, subjecting said jacketed wires to a diffusion
treatment to facilitate the mechanical bonding of said matrix, and
generating said substantially circular micron sized fibers embedded
in said uniform homogeneous matrix, thereby reinforcing said
matrix.
2. A method as claimed in claim 1, further consisting essentially
of enclosing said bundle of jacketed wires in an outer casing of
matrix substance prior to said step of mechanical working.
3. A method as claimed in claim 2, wherein said outer casing has a
shape designed to suit the geometrical form which the element has
after the mechanical working.
4. A method as claimed in claim 1, wherein said plurality of
jacketed wires are arranged about a core of matrix substance prior
to said step of mechanical working.
5. A method as claimed in claim 1, wherein each said jacket of
matrix substancee is a tube into which one of said wires is
threaded.
6. A method as claimed in claim 1, wherein said matrix substance is
silver and said wire is a copper-coated austenitic chromium-nickel
steel.
7. A method as claimed in claim 1, wherein said mechanical working
is effected by drawing.
Description
BACKGROUND OF THE INVENTION
The invention relates to a shaped element of fibre-reinforced
material in which a large number of aligned fibres are embedded in
a matrix substance, and to methods of manufacturing such shaped
elements.
Combinations of glass, ceramic, polymer or metallic fibres embedded
in metallic or non-metallic matrix are known in industry as fibre
reinforced materials. Such fibre-reinforced materials based on
metallic and non-metallic substances are used on a large scale and
possess many advantageous physical and chemical properties as
compared with other known materials. These properties depend upon a
number of factors and in particular upon the characteristics of the
matrix and/or fibre material, that proportion of the total
cross-sectional area constituted by the fibres, and the
arrangement, distribution and bonding of the fibres. Optimum
properties can generally be obtained in such fibre-reinforced
substances only if the fibres are oriented and distributed in the
matrix substance in a particular manner.
The known methods of producing fibre-reinforced materials are based
on surrounding the prepared fibres with matrix metal by fusion
processes, by powder-metallurgy methods or by sintering under
compression between compact materials. In other known methods,
prepared fibres are surrounded by the matrix substance by treatment
in a melting bath, a slurry or an electrolytic bath, or by
spraying, vacuum deposition or other deposition processes. Finally,
the composite material is produced with uniformly distributed
fibres by stacking and compressing the fibres pretreated in this
manner. Also known are methods of manufacture in which randomly
arranged pretreated fibres are first put into the matrix substance
and then aligned by plastic-shaping processes.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a shaped element
of fibre-reinforced material which can be produced in a simple
manner without the use of pretreated fibres, advantageous physical
properties being obtained by means of the subsequently produced and
oriented fibres.
According to the present invention the improved shaped element
comprises a bundle of wires, each enclosed in a jacket of matrix
substance, which bundle has been subjected to mechanical working
whereby to reduce the cross sectional area of the wire and jackets
and to bond the jackets together. Mechanical working processes that
may be advantageously used are drawing, rolling and swaging. A
shaped element of this kind is expediently additionally provided
with an outer casing of matrix substance which is also shaped
during the mechanical working process.
An advantageous method of producing the shaped elements of this
invention comprises the steps of providing a wire with a jacket of
matrix substance, arranging a plurality of jacketed wires in a
bundle, and subjecting the bundle to mechanical working whereby to
reduce the cross sectional areas of the wires and jackets and to
bond the jackets together.
Expediently, the bundle of jacketed wires may be enclosed in an
outer casing constituted by a thin layer of matrix substance in the
solid phase, e.g. in the form of a tube. This enclosed bundle is
then compressed by a mechanical-shaping operation and particularly
by drawing. During this shaping operation metallic bonding of the
jacket materials with each other and with the additional outer
casing takes place on the one hand, and at the same time there
occurs a cross-sectional reduction of the entire shaped element and
thus also of the embedded wires. This shaping operation is
expediently carried out several times and continued until the
required fibre cross-section is obtained. In some cases, it may be
advantageous to carry out intermediate annealing for softening the
core material and/or for bonding the matrix substance by diffusion.
The required proportion by volume of the fibres can be established
beforehand by the correct choice of jacketed wires and can be
varied within wide limits.
In a preferred form both the wire and the jacket are made of
metallic materials.
An example of a particularly advantageous fibre-reinforced material
will now be given for the purpose of describing how the invention
may be carried out. In this example, the matrix substance consists
of pure silver in which a fibre material consisting of an
austenitic chromium-nickel steel wire is to be embedded. The
starting material for each of the jacketed wires is constituted by
a silver tube of an outer diameter of 10 mm and a thickness of the
wall of 3.4 mm the interior surface of which has been cleaned by
any suitable known method and into which a core of a round shape of
3 mm diameter of copper-coated alloy steel has been introduced. In
the method of production used, the volume of alloy steel is about
10 percent of the silver matrix substance. The starting material
will be worked to an outer diameter of about 1 mm; i.e., by 10
drawings. The jacketed wires of round cross-section having a
diameter of about 1 mm., are bundled and inserted into a
thin-walled silver tube, 5 mm., outside diameter and 0.2 mm.,
thick, which is to form an additional outer casing. This
semi-finished product was then shaped by undergoing 25 drawing
passes and in such manner that finally, whilst the fibres were thus
formed, a shaped element in the form of a wire was obtained in
which steel fibres having a diameter in the order of magnitude of a
few .mu. were embedded in the matrix substance. On account of the
bundling, an almost ideal distribution of the fibres in the matrix
substance was achieved. Furthermore, these shaped elements may be
advantageously arranged in the above-described manner and shaped
again, and possibly several times, in order to obtain a still
smaller diameter of fibre.
The method of manufacture described may be modified in various
ways; for example, apart from being disposed parallel with each
other, the jacketed wires can also be arrayed in a special manner,
e.g. in groups extending in a preferred direction, or helically, so
that it is always possible to obtain given directionalities of the
fibres even when a pure matrix core and the like are used.
The method is not limited to the production of cylindrical
elements; elements of rectangular or other cross-sectional shapes
can also be obtained by the method described.
BRIEF DESCRIPTION OF THE DRAWINGS
Some cross-sections of shaped elements of fibre-reinforced material
are illustrated in the drawings in which:
FIGS. 1, 3, 5, 7 and 9 show cross-sections through semi-finished
products composed of jacketed wires, prior to mechanical working,
and
FIGS. 2, 4, 6, 8 and 10 show cross-sections through the finally
shaped elements in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows on an enlarged scale a tube 1 of matrix substance
which forms an additional outer casing and in the interior of which
is placed a plurality of jacketed wires 2. The core 3 of each of
these jacketed wires 2 consists of the desired fibre material,
whereas the jacket 4 contains the matrix substance.
After all the components of the element have been jointly shaped by
drawing, a homogeneous shaped element consisting of matrix
substance in which the fibres are embedded parallel with each other
is obtained (FIG. 2).
The remaining FIGS., 3 to 10, show other geometrical arrangements,
a core 5 of matrix substance or any other appropriately
advantageous material (e.g. one of high electrical conductivity)
being present in the arrangements shown in FIGS. 5 and 6 and FIGS.
9 and 10.
As shown in FIGS. 9 and 10 the element can have such a distribution
of the fibres to provide for a metallic homogeneous core. Such a
metallic homogeneous core may be of advantage if the element should
combine high electrical conductance and good spring qualities. In
the example of FIG. 9 jacketed wires 4 of high-grade steel of 1
mm-square, as well as a solid fine-silver sheet 5 of 2 mm.,
thickness are arranged in a rectangular tube 1 having an inside
dimension of 6 .times. 30 mm and about 1 mm thickness of the wall,
and also being made of solid fine-silver. All parts are arranged in
the way shown in FIG. 9.
By the forming of this element, for instance by a five-times
drawing through correspondingly stepwise reduced dies, a body of
0.8 .times. 5 mm is obtained, the section of which is as shown in
FIG. 10 (not to scale).
An element built in this way will offer spring-bending limits or up
to 100 kp/mm.sup.2 and an electrical conductivity of up to 45
SE.
* * * * *