DE102009046003A1 - Method for producing a component with a ceramic first area and a metallic second area, comprises applying the ceramic material in a first tool area by first injection molding step and applying the metallic material in a second tool area - Google Patents

Abstract

The method for producing a component with a ceramic first area and a metallic second area, where a ceramic material is present in the first area and a metallic material is present in the second area, comprises applying the ceramic material in a first tool area (3) of a tool (19) by means of a first injection molding step, applying the metallic material in a second tool area of the tool by means of a second injection molding step and heating the tool in such a way that the ceramic material is connected with the metallic materials. The method for producing a component with a ceramic first area and a metallic second area, where a ceramic material is present in the first area and a metallic material is present in the second area, comprises applying the ceramic material in a first tool area (3) of a tool (19) by means of a first injection molding step, applying the metallic material in a second tool area of the tool by means of a second injection molding step and heating the tool in such a way that the ceramic material is connected with the metallic materials. The ceramic material is introduced by a first powder injection molding process into the first tool area and the second metallic material is introduced by a second powder injection molding process into the second tool area. The ceramic material and the metallic material are introduced by a 2-component-injection molding process into the first and second tool area. The tool is heated at 1200-1500[deg] C. A laser radiation and microwave radiation are used for heating the tool. An independent claim is included for a component.

Description

State of the art

The invention is based on a method according to the preamble of claim 1 or of a component according to the preamble of claim 8.

Injectors for dosing media, such. As special fuels or ureas, make comparatively high demands on the corrosion resistance of components with media contact. These high requirements meet z. As ceramics, ceramics also allow a comparatively long service life. However, because of their mechanical properties, ceramics can only be used to a limited extent in areas in which comparatively high dynamic loads occur. In these areas with high dynamic loads metals are often used. In order to take advantage of both the benefits of ceramics and metals, it is necessary to add ceramics and metals to one component.

The joining of a ceramic joining partner with a joining partner made of a metallic material is problematic. Positive connections are unsuitable due to the brittleness of a ceramic material.

From the publication DE 10 2007 044 503 A1 a method is known in which a solder is applied to a joining partner and the joining partners are brought together in a joint area. Then, the joining area is heated by means of microwave radiation and the joining partners are soldered together by the heating.

From the publication DE 10 2007 034 609 A1 a method is known for joining at least one first ceramic joining partner with at least one second joining partner, wherein the method comprises the steps of applying at least one preceramic polymer to the first or the second joining partner in a joining region, bringing together the joining partners in the joining region and heating the joining region in such a way in that the preceramic polymer transforms into an amorphous or crystalline ceramic which connects the joining partners with one another.

A disadvantage of these methods mentioned is that a joining adjuvant such as a solder, a polymer or an adhesive must be applied to at least one joining partner, since such application of the joining adjuvant is a complex manufacturing process. Furthermore, the joining partners must be brought together, this merge process is also expensive. Another disadvantage is that after the manufacturing process, the remainders of the joining adjuvants must be removed. As a result, elaborate post-processing steps are necessary.

Disclosure of the invention

The inventive method according to claim 1 and the independent claims and the inventive component according to claim 8 and the independent claims have the advantage over the prior art that no joining adjuvant is required. The costs for solders, polymers or adhesives are therefore eliminated. Furthermore, eliminating the application of the joining adjuvant to a joining partner, whereby it is possible to dispense with a complex manufacturing process. In addition, the merging of the joining partners in the joint area after application of the joining adjuvant is eliminated. This eliminates the complex merge process.

Due to the shaping by means of two injection molding, it is also advantageously possible to produce even complex geometries. Furthermore, a post-processing of the composite component requires relatively little effort, because no residues of a joining adjuvant such as solders, polymers or adhesives must be removed. Overall, comparatively few production steps are required in the method according to the invention, so that it is possible to shorten the process chain considerably. This shortening leads to a considerable time savings and thus to a cost saving.

Advantageous embodiments and modifications of the invention are the dependent claims, as well as the description with reference to the drawings.

According to a preferred development, it is provided that the ceramic material is introduced into the first tool region by means of a first powder injection molding process and that the metallic material is introduced into the second tool region by means of a second powder injection molding process. The introduction of the materials preferably takes place by means of a two-component powder injection molding process. The implementation of the method according to the invention by means of powder injection molding or by means of a two-component powder injection molding method offers the advantage that for comparatively large quantities or relatively technically demanding and complex Bai parts (especially in the microtechnology sector) a relatively efficient manufacturing process with relatively good adherence to the manufacturing tolerances can be realized , By comparatively well reproducible process comparatively accurate and filigree components can be produced.

According to two other preferred developments, it is provided that the tool is heated to a temperature from a temperature range between about 300 ° C and about 800 ° C, or is heated to a temperature in a temperature range between about 1200 ° C and 1500 ° C. By heating in different temperature ranges, it is advantageously possible to optimally adapt the sintering process to the desired properties.

According to other preferred developments, it is provided that laser radiation or microwave radiation is used to heat the tool. Advantageously, this makes it possible to limit the effect of heat on locally limited areas, with laser or microwave radiation can also be used in addition to the sintering furnace.

Another object of the present invention is a component comprising a ceramic first region and a metallic second region, wherein the first region is fixedly connected to the second region, wherein a ceramic material cast into a tool and a metallic material cast into the tool by heating of the tool are connected to each other. Preferably, the ceramic and the metallic material are poured into the tool by means of a two-component injection molding process. As a result, the component can be produced in a large number of different geometries in a comparatively large number of pieces while keeping the manufacturing tolerances as good as possible. Further preferably, the ceramic and the metallic material are connected by heating the tool by means of laser radiation. This makes it possible in an advantageous manner to achieve the advantages of the invention by only local heating of the component.

Embodiments of the present invention are illustrated in the drawings and explained in more detail in the following description.

Brief description of the drawings

Show it 1 to 4 each a schematic representation of a tool 19 for carrying out an exemplary first embodiment of the method according to the invention.

1 schematically shows a first step of the method according to the invention,

2 schematically shows a second step of the method according to the invention,

3 schematically shows a third step of the method according to the invention and

4 schematically shows a fourth step of the method according to the invention.

Embodiment (s) of the invention

In the various figures, the same parts are always provided with the same reference numerals and are therefore usually named or mentioned only once in each case.

In the 1 to 4 is schematically each a tool 19 which is used to carry out an exemplary first embodiment of the method according to the invention. The 1 to 4 each further show a manufacturing step of the first embodiment of the method according to the invention.

In 1 is a schematic representation of the tool 19 to illustrate an exemplary first embodiment of the method according to the invention. The 1 shows the first step of the first embodiment of the method according to the invention. The tool 19 has a first tool area 3 and a second tool area 3 ' on. The first tool area 3 is with a first filling opening 11 connected. In the second tool area 3 ' there is a slider 18 in the second tool area 3 ' is inserted and the second tool area 3 ' wears. The slider 18 also closes a second filling opening 12 through which a metallic material is introduced in the second step.

Through the first filling opening 11 The ceramic material is by means of a casting process in the first tool area 3 brought in. In particular, it is possible for the ceramic material to be introduced into the first tool area by means of an injection molding method or a powder injection molding method, in particular by means of a CIM (Ceramic Injection Molding) method or a ceramic powder injection molding method 3 is introduced. As a result, it is possible to realize a comparatively efficient production method with comparatively good tolerance compliance at the same time for comparatively large quantities or relatively complex components (in particular also in the field of microtechnology). Due to the comparatively good reproducible process, accurate and filigree components can be produced.

The ceramic material is used for example in media-carrying components (in particular an injection valve or a pump), because ceramics have a comparatively great insensitivity, for example to corrosion. Furthermore, ceramics have a high hardness, high pressure resistance, high temperature resistance and good electrical insulation. It is still possible to use silicate ceramics, oxide ceramics or non-oxide ceramics, exemplified by its only aluminum, magnesium, zirconium oxide, aluminum titanate and piezoceramics, as well as carbides or nitrides.

In 2 is a schematic representation of the tool 19 displayed. The 2 shows the second step of the first embodiment of the method according to the invention. After in the first step, the ceramic material in the first tool area 3 is injected in the second step, the slider 18 from the second tool area 3 ' pulled out and gives the second tool area 3 ' free, so that the metallic material through the second filling opening 12 by means of a casting process in the second tool area 3 ' can be introduced. In particular, it is possible for the metallic material to be introduced into the second tool area by means of an injection molding method or a powder injection molding method, in particular by means of an MIM (Metal Injection Molding) method or a metal powder injection molding method 3 ' is introduced.

The production by means of MIM process offers the advantage that even complex or complicated geometries can be produced. By means of MIM technology, for example, holes with a minimum bore diameter of about 0.4 mm can be produced. For example, wall thicknesses less than about 1 mm can still be produced by MIM technology. The manufacturing tolerances are comparatively low. In addition, components with layer thicknesses of about 1 μm can be produced using MIM technology. Binder systems are used in the manufacture of the powder injection molding compounds to homogenize the metal powders for the injection molding machines. The aim of the treatment is the sheathing of all metal powder particles with the binder system, the prevention or destruction of agglomerates of the metal powder grains and the production of a very homogeneous granules (also called feedstock). As starting materials for the injection molding of metal powder, for example, all sinterable powders of suitable grain size can be used, such as metals, hard metals, steel, low alloy steel, stainless steel, precious metals, carbonyl iron, carbonyl iron with about 50% by weight nickel, tungsten carbide with about 12% by weight cobalt and metal alloys, in particular superalloys. The grains of the metal powder used preferably have an average particle size of about 4 microns to about 20 microns.

For shaping, the feedstock is pressed by means of a heated screw into cooled, for example, liquid-cooled (in particular cooling by water or oil) tools. The screw conveyors and cylinders are preferably made of comparatively hard material, in particular of steel material. After the injection molding process, the components (also called green bodies) are removed from the mold.

Wax materials can be used as the binder system. By comparatively slow heating, the wax material is melted out of the green body. This process is referred to as debindering and then present porous molding as Braunling. Furthermore, as binder systems thermoplastic material, polyalcohols, polyoxymethylene (POM) or polyvinyl alcohols can be used.

By using the MIM process, the manufacturing costs are considerably reduced. The MIM process can be used to produce complex and complicated geometries and to make different materials into a one-piece component.

In 3 is another schematic representation of the tool 19 displayed. The 3 shows the third step of the first embodiment of the method according to the invention. The injection molding of the ceramic and the metallic material are completed and the preferably dried white or brownling is compacted by heating by a thermal process (sintering), so that the composite component receives its material end properties.

Due to the final sintering, the end product is produced from the Braunling. The brownling is heated in a sintering furnace. The sintering is preferably carried out in a protective gas atmosphere of nitrogen or hydrogen, more preferably in a vacuum. The sintering is possible in several temperature ranges, for example in the temperature range between about 300 ° C and about 800 ° C and in the temperature range between about 1200 ° C and about 1500 ° C. In the case of silicate ceramics, sintering takes place in a temperature range from about 800 ° C. to about 1400 ° C., in technical ceramics sintering takes place at temperatures up to about 2500 ° C. The heating takes place, for example, in a sintering furnace, preferably by means of laser radiation or by means of microwave radiation, wherein microwave radiation is understood to mean electromagnetic radiation from a frequency range between approximately 0.3 GHz and approximately 300 GHz.

In 4 is another schematic representation of the tool 19 displayed. The 4 shows the fourth step of the first embodiment of the method according to the invention. The composite component of the ceramic and the metallic material has a ceramic first region 1 and a metallic second area 2 on that solid connected to each other. The composite part can be used for example at temperatures of about -40 ° C to about 130 ° C, preferably up to about 250 ° C. The area with the ceramic material is suitable for example in a fuel injection valve to come into contact with the medium to be sprayed. The ceramic region is relatively well protected against corrosion and is therefore particularly well suited, for example, to realize a valve seat of a fuel valve. The area with the metallic material reinforces the component structure and allows the connection of the composite component with, for example, the injection valve. The metallic region is suitable for example in a fuel injection valve for components without media contact, in particular for a valve sleeve. Alternatively, the metallic region may be used, for example, as a metallic base for a welded joint. Furthermore, the metallic area is still workable. For example, by sandblasting, galvanizing, brazing, hardening, or machining.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102007044503 A1 [0004]
• DE 102007034609 A1 [0005]

Claims (10)

Method for producing a component with a ceramic first region ( 1 ) and a metallic second region ( 2 ), whereas in the first area ( 1 ) a ceramic material and in the second area ( 2 ) is a metallic material, characterized by the following steps: • introducing the ceramic material into a first tool area ( 3 ) of a tool ( 19 ) by means of a first injection molding step; Introducing the metallic material into a second tool area ( 3 ' ) of the tool ( 19 ) by means of a second injection molding step; • heating the tool ( 19 ) such that the ceramic material is firmly connected to the metallic material. A method according to claim 1, characterized in that the ceramic material by means of a first powder injection molding process in the first tool area ( 3 ) is introduced and that the metallic material by means of a second powder injection molding process in the second tool area ( 3 ' ) is introduced. Method according to one of the preceding claims, characterized in that the ceramic material and the metallic material by means of a two-component injection molding process in the first and second tool area ( 3 . 3 ' ) are introduced. Method according to one of the preceding claims, characterized in that the tool ( 19 ) is heated to a temperature from a temperature range between about 300 ° C and about 800 ° C. Method according to one of the preceding claims, characterized in that the tool ( 19 ) is heated to a temperature from a temperature range between about 1200 ° C and about 1500 ° C. Method according to one of the preceding claims, characterized in that for heating the tool ( 19 ) Laser radiation is used. Method according to one of the preceding claims, characterized in that for heating the tool ( 19 ) Microwave radiation is used. Component comprising a ceramic first region ( 1 ) and a metallic second region ( 2 ), the first area ( 1 ) fixed to the second area ( 2 ), characterized in that a tool ( 19 ) cast ceramic material and a metallic material cast into the tool by heating the tool ( 19 ) are interconnected. Component according to claim 8, characterized in that the ceramic material and the metallic material by means of a two-component injection molding process in the tool ( 19 ) are poured. Component according to claim 8 or 9, characterized in that the ceramic material and the metallic material by heating the tool ( 19 ) are connected by means of laser radiation.

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