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Advanced production of thermally sprayed prepregs for UD fibre reinforced light metal MMCs

机译：先进生产用于UD纤维增强轻金属MMC的热喷涂预浸料

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摘要

Thermal spraying and thixoforging technologies can be combined in a new manufacturing method for the production of light metal matrix composites. Laminated prepregs are produced by coating unidirectional fiber bundles with light metal matrix material. The prepregs are heated up and densified by thixoforging to near net-shape composites. Compared to conventional technologies for the integration of fibers in light metal matrices, like squeeze casting, hot pressing and diffusion bonding, this method offers the possibility to realize complex component geometries with short cycle times. Due to its high deposition rate and reduced thermal load on the substrate, the arc wire spraying technique is used for the coating of fiber bundles with the matrix material (AlSi{sub}6). The final fiber volume content of the MMC can be tailored by the thickness of the coating. Prior to the coating process, a continuous fiber strand is coiled on a cylindrical workpiece with adapted dimensions by using a winding unit provided with fiber guiding system. The speed and horizontal range of the fiber guide unit can be continuously varied in order to control overlapping and ensure homogeneous thickness of the fiber layer. An efficient air cooling system is installed in order to control the thermal load, which affects the formation of microcracks and influence the final residual stress distribution in the coating. An innovative method to wind and coat continuous fibers for manufacturing fiber reinforced light metal matrix composites will be presented.
机译：可以将热喷涂和触变性技术结合到一种用于生产轻金属基体复合材料的新制造方法中。层压预浸料是通过用轻金属基质材料涂覆单向纤维束而制成的。将预浸料加热并通过触变性使之致密化为接近最终形状的复合材料。与将纤维集成到轻金属基体中的常规技术（如挤压铸造，热压和扩散粘合）相比，此方法提供了以较短的循环时间实现复杂部件几何形状的可能性。由于其高的沉积速率和减少的在基板上的热负荷，电弧丝喷涂技术被用于用基质材料（AlSi {sub} 6）涂覆纤维束。 MMC的最终纤维体积含量可以根据涂层的厚度进行调整。在涂覆过程之前，通过使用配备有纤维引导系统的卷绕单元，将连续的纤维束以合适的尺寸卷绕在圆柱形工件上。纤维引导单元的速度和水平范围可以连续变化，以控制重叠并确保纤维层的厚度均匀。为了控制热负荷，安装了有效的空气冷却系统，该热负荷影响微裂纹的形成并影响涂层中的最终残余应力分布。将介绍一种创新的缠绕和涂覆连续纤维的方法，以制造纤维增强的轻金属基质复合材料。

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