Patent Application
20210016388
The present invention relates to a method for manufacturing a composite slab.
There is known a method for manufacturing a composite slab composed of different kinds of metals. By forming the composite slab by means of rolling or forging to make thin, a clad material, which is composed of different kinds of metals and has plural layers, can be manufactured. In a patent literature 1, a vacuum hot rolling method in which a composite slab is formed in non-oxidative atmosphere of the vacuum state is described. According to the method, since the composite slab is formed in the non-oxidative atmosphere, the composite slab can be processed without oxide film.
Furthermore, there is known an explosion pressure bonding method in which a composite slab is formed by a method of letting a metal plate collide against a base member at high speed to join them. And further, a composite slab can be formed also by a method of brazing metal plates of different kinds of metals to join them.
Patent Literature 1: Japanese Unexamined Patent Publication No. S57-134287
However, in the foresaid vacuum hot rolling process, rolling rollers need to be arranged in a vacuum chamber, so that it might cause upsizing of the device. And the explosion pressure bonding method has a limit for upsizing in the method. Furthermore, in the brazing, a reaction layer (Cu—Al compound) is made, so that there is a problem that thermal conductivity of the clad material having plural layers is low. And further, a portion joined by the brazing is brittle, so that there is a problem that plastic working cannot be done.
From such a view point, an object of this invention is to provide a method for manufacturing a composite slab, the method being capable of easily manufacturing the composite slab.
In order to solve the problem, the present invention is characterized by a method for manufacturing a composite slab to manufacture a plural layer clad material composed of different kinds of metals, the method comprising: a preparation process to prepare a metallic box body having a bottom portion and a peripheral wall portion standing on a peripheral edge of the bottom portion, and a metallic sealing body to seal an opening of the box body; abutting process to butt a side face of the sealing body against an inner wall face of the peripheral wall portion to form a butted portion with one or plural intermediate members being inserted in a recessed portion of the box body; and a closing process to join and close the butted portion, wherein at least one of the one or plural intermediate members is made of a material different from at least one of the box body and the sealing body.
And, the present invention is characterized by a method for manufacturing a composite slab to manufacture a plural layer clad material composed of different kinds of metals, the method comprising: a preparation process to prepare a metallic box body having a bottom portion and a peripheral wall portion standing on a peripheral edge of the bottom portion, and a metallic sealing body to seal an opening of the box body, and to form a peripheral wall step portion having a step bottom face and a step side face standing on the step bottom face at an inner peripheral edge of the peripheral wall portion; a butting process to place the sealing body on the peripheral wall step portion to butt a side face of the sealing body against the step side face to form a butted portion with one or plural intermediate members being inserted in a recessed portion of the box body; and a closing process to join and close the butted portion, wherein at least one of the one or plural intermediate members is made of a material different from at least one of the box body and the sealing body.
Furthermore, the present invention is characterized by a method for manufacturing a composite slab to manufacture a plural layer clad material composed of different kinds of metals, the method comprising: a preparation process to prepare a metallic box body having a bottom portion and a peripheral wall portion standing on a peripheral edge of the bottom portion, and a metallic sealing body to seal an opening of the box body; a butting process to butt a back face of the sealing body against a peripheral wall end face of the peripheral wall portion to form a butted portion with one or plural intermediate members being inserted in a recessed portion of the box body; and a closing process to join and close the butted portion, wherein at least one of the one or plural intermediate members is made of a material different from at least one of the box body and the sealing body.
According to the method for manufacturing a composite slab, the closing work can be easily performed since the intermediate members are sealed inside the box body and the sealing body.
Furthermore, it is preferable that the method for manufacturing a composite slab further comprises: an evacuation process to evacuate through an exhaust channel provided at the box body or the sealing body to communicate the recessed portion with the outside; and a blocking process to block the communication through the exhaust channel after performing the closing process and the evacuation process.
According to the method, the plural layer clad material is prevented from generating an oxide film inside thereof when the plural layer clad material is manufactured through a rolling or forging process since the inside of the composite slab is evacuated.
Further, it is preferable that in the preparation process of the method for manufacturing a composite slab, the exhaust channel is provided at the peripheral wall portion of the box body, in the closing process of the same, the butted portion is closed by friction stirring with use of a rotary tool, and in the blocking process of the same, the exhaust channel is crossed to be blocked by friction stir welding with use of the rotary tool.
According to the method, the butted portion can be easily joined by friction stirring, and the exhaust channel can be also easily blocked.
And furthermore, the present invention is characterized by a method for manufacturing a composite slab to manufacture a plural layer clad material composed of different kinds of metals, the method comprising: a preparation process to prepare a metallic frame member, a metallic bottom member to cover one opening of the frame member, and a metallic sealing body to cover the other opening of the frame member; a butting process to butt the frame member, the bottom member, and the sealing body against each other to form each butted portion with one or plural intermediate members being inserted in an inside of the frame member; and a closing process to join to close the each butted portion, wherein at least one of the one or plural intermediate members is made of a material different from at least one of the bottom member and the sealing body.
According to the method for manufacturing a composite slab, the closing work can be easily performed since one or plural intermediate members are sealed inside the frame member.
It is preferable that the method for manufacturing a composite slab further comprises: an evacuation process to evacuate through an exhaust channel provided at the frame member, the bottom member or the sealing body to communicate the inside with the outside; and a blocking process to block the communication through the exhaust channel after performing the closing process and the evacuation process.
According to the method, the plural layer clad material is prevented from generating an oxide film inside thereof when the plural layer clad material is manufactured through a rolling or forging process since the inside of the composite slab is evacuated.
It is preferable that in the preparation process of the method for manufacturing a composite slab, the exhaust channel is provided at the frame member, in the closing process of the same, the each butted portion is closed by friction stir welding with use of a rotary tool, and in the blocking process of the same, the exhaust channel is crossed to be blocked by friction stirring with use of the rotary tool.
According to the method, the butted portion can be easily joined by friction stirring, and the exhaust channel can be also easily blocked.
Furthermore, the present invention is characterized by a method for manufacturing a composite slab to manufacture a plural layer clad material composed of different kinds of metals, the method comprising: a butting process to enclose around one intermediate member with plural closing members and butt each member against each other to form a butted portion; an evacuation process to evacuate through an exhaust channel to communicate an inside of the closing members with the outside; a closing process to join and close the butted portion; and a blocking process to block the communication through the exhaust channel after performing the closing process and the evacuation process, wherein the intermediate member is made of copper or a copper alloy, and the closing members are made of aluminum or an aluminum alloy.
Further, the present invention is characterized by a method for manufacturing a composite slab to manufacture a plural layer clad material composed of different kinds of metals, the method comprising: a butting process to enclose around two intermediate members with plural closing members and butt the closing members against each other to form butted portions; an evacuation process to evacuate through an exhaust channel to communicate an inside of the closing members with the outside; a closing process to join and close the butted portion; and a blocking process to block the communication through the exhaust channel after performing the closing process and the evacuation process, wherein the two intermediate members are made of copper or a copper alloy, and the closing members are made of aluminum or an aluminum alloy.
According to the method for manufacturing a composite slab, a composite slab having a high thermal conductivity can be manufactured since oxidizing compound is prevented from being generated by the evacuation process. Further, the joining work can be easily performed by enclosing around the intermediate member(s) with the closing members.
Furthermore, the present invention is characterized by a method for manufacturing a composite slab to manufacture a plural layer clad material composed of different kinds of metals, the method comprising: a butting process to enclose around three or more intermediate members with plural closing members and butt the closing members against each other to form butted portions; an evacuation process to evacuate through an exhaust channel to communicate an inside of the closing members with the outside; a closing process to join and close the butted portion; and a blocking process to block the communication through the exhaust channel after performing the closing process and the evacuation process, wherein two or more of the intermediate members are made of copper or a copper alloy, and one or more of the intermediate members are made of aluminum or an aluminum alloy, and wherein the closing members are made of aluminum or an aluminum alloy.
According to the method for manufacturing a composite slab, a composite slab having a high thermal conductivity can be easily manufactured, since oxidizing compound is prevented from being generated by the evacuation process. Further, the joining work can be easily performed by enclosing around the intermediate members with the closing members.
It is preferable that in the butting process, remover or a removing member is interposed between the two intermediate members to peel off the two intermediate members from each other.
It is preferable that the removing member is made of an aluminum alloy containing 2 mass % or more of Mg.
Furthermore, the removing member is made of aluminum or an aluminum alloy, and at least one of a front face and a back face of the removing member is anodized.
According to the method, plural layer clad material can be easily manufactured since adjacent members can be easily peeled off from each other by remover or a removing member.
According to the method for manufacturing a composite slab according to the present invention, the composite slab can be easily manufactured.
A method for manufacturing a composite slab according to an embodiment of the present invention will be explained in detail with reference to Figures. As shown in
The box body 2 is a member to be a base of the composite slab 1 and has a box type shape. The box body 2 is composed of a bottom portion 11 and a peripheral wall portion 12. The bottom portion 11 has a rectangular plate shape. The peripheral wall portion 12 is a portion standing on the peripheral edge of the bottom portion 11 and has a rectangular frame shape. A recessed portion 13 is defined by the bottom portion 11 and the peripheral wall portion 12. An exhaust channel 14, which passes through in a thickness direction, is formed in the peripheral wall portion 12. The exhaust channel 14 is a channel in which air flows when an evacuation process to be described later is performed. The exhaust channel 14 is connected with an evacuation jig 15 at an outer end of the exhaust channel 14. The evacuation jig 15 is connected to an evacuation device when an evacuation process to be described later is performed. Material of the box body 2 is not specifically limited, and in this embodiment, it is aluminum or an aluminum alloy.
The intermediate members 3, 4 are metal members each of which has a rectangular plate shape. The intermediate members 3, 4 are accommodated in the recessed portion 13 as shown in
A remover (or a removing member) 6 is interposed between the intermediate members 3, 4. For example, the remover LBN (made by Showa Denko K. K.) can be used as the remover 6. The aluminum alloy A5083-O of a thin plate can be used as the removing member. The removing member contains 2 mass % or more of Mg. Furthermore, a thin plate member made of aluminum or an aluminum alloy, at least one of a front face and a back face of which anodic oxidation has been applied on, can be used as the removing member.
The remover 6 or the removing member is used to divide (peel off) the members between which the remover 6 or the removing member is located, the members having been formed by applying a rolling process or a forging process to the composite slab 1. Material and characteristics of the remover 6 or the removing member may be appropriately selected according to materials of the intermediate members 3, 4 and conditions of the rolling process or the forging process.
The sealing body 5 is a metal member having a rectangular plate shape. As shown in
Next, a method for manufacturing a composite slab will be explained. In the method for manufacturing a composite slab according to the embodiment, a preparation process, a butting process, an evacuation process, a closing process, and a blocking process are performed.
The preparation process is a process to prepare the box body 2, the intermediate members 3, 4, the sealing body 5, and the like. The evacuation jig 15 is beforehand connected to the peripheral wall portion 12 of the box body 2 to communicate with the exhaust channel 14.
As shown in
The evacuation process is a process in which the inside defined by the sealing body 5 and the box body 2 is evacuated to become vacuum. The evacuation process is performed in a state of connecting an evacuation device not shown with the evacuation jig 15. The evacuation process may be performed before or after performing the closing process, or continuously performed since before beginning of the closing process until the blocking process is finished. Furthermore, the evacuation process may be omitted.
As shown in
As shown in
As shown in
The stirring pin F2 hangs down from and is coaxial with the connecting portion F1. The stirring pin F2 has a smaller diameter with increasing distance from the connecting portion F1. The stirring pin F2 has a spiral groove formed on the outer circumferential face thereof. In the embodiment, since the second rotary tool F is rotated clockwise, the spiral groove is formed to rotate counterclockwise with increasing distance from the base end toward the tip. In other words, the spiral groove is formed to rotate counterclockwise with increasing distance from the base end toward the tip when it is viewed from the upper side.
Note that, in a case where the second rotary tool F is rotated counterclockwise, it is preferable that the spiral groove is formed to rotate clockwise with increasing distance from the base end toward the tip. In other words, the spiral groove of this case is formed to rotate clockwise with increasing distance from the base end toward the tip when it is viewed from the upper side. By forming the spiral groove in such a manner, plastically fluidized metal formed by friction stirring is led toward the tip of the stirring pin F2 through the spiral groove. By this, the amount of metal to leak out of the box body 2 can be reduced.
As shown in
Note that, the blocking process may be performed with use of the same rotary tool as that in the closing process. In that case, the closing process and the blocking process can be continuously performed. Furthermore, the blocking process may be performed, for example, by plastically deforming the peripheral wall portion 12 to crush the exhaust channel 14. And furthermore, the blocking process may be performed by pushing a filler or a filling member into the exhaust channel 14 to block it.
Through all the processes described in the above, the composite slab 1 is completed. And after the blocking process, a deburring process to remove burrs existing on the surfaces of the box body 2 and the sealing body 5 may be performed.
After the composite slab 1 is completed, the rolling process is performed to make a plural layer clad material. In the rolling process, the composite slab 1 is rolled with use of a rolling device (not shown) provided with rolling rollers. In the rolling process according to the embodiment, the hot rolling is performed in a state where the temperature of the atmosphere is set to, for example, about 500° C. In this way, the bottom portion 11 of the box body 2 and the intermediate member 3 are joined together and the sealing body 5 and the intermediate member 4 are joined together. On the other hand, since the remover 6 or a removing member is interposed between the intermediate members 3, 4, the intermediate members 3, 4 are not joined together even by the hot rolling. The temperature during the hot rolling process may be appropriately set according to metal material. For example, the hot rolling is performed at 460° C. to 600° C., and it is preferable that the hot rolling is performed at 470° C. to 550° C. The temperature during the hot rolling process may be appropriately set in the range where the bottom portion 11 of the box body 2 and the intermediate member 3 are joined together, the sealing body 5 and the intermediate member 4 are joined together and the intermediate members 3, 4 are not joined together in a case where the remover 6 or a removing member is used like the embodiment.
After the composite slab 1 comes to have a desired thin thickness, as shown in
Since the intermediate members 3, 4 are closed in the inside defined by the box body 2 and the sealing body 5 according to a method for manufacturing a composite slab according to the embodiment described in the above, the closing process can be easily done. That is, since positioning the intermediate members 3, 4 and the sealing body 5 relative to the box body 2 can be easily done, friction stir welding can also be easily performed. Furthermore, a method for the closing process is not specifically limited, but the joining can be easily done by using friction stir welding as the method.
The composite slab 1 having the vacuum inside can be formed by performing the evacuation process. Thus, an oxide film can be prevented from being generated in each of the plural layer clad materials N1, N2 when the plural layer clad materials N1, N2 are made through the rolling process or forging process. Further, the vacuum state in the composite slab 1 can be kept by performing the blocking process. And furthermore, the exhaust channel 14 can be easily blocked since the blocking process is performed by friction stirring.
Since the remover 6 is interposed between the intermediate members 3, 4 of the composite slab 1, the intermediate members 3, 4 are peeled off at the border between the intermediate members 3, 4 after the rolling or forging process is performed, so that the plural layer clad materials N1, N2, which are made of copper or a copper alloy; and aluminum or an aluminum alloy, can be manufactured. That is, the bottom portion 11 of the box body 2 and the intermediate member 3 are joined together and the intermediate member 4 and the sealing body 5 are joined together by performing the rolling process, but the intermediate members 3, 4 are prevented from being joined together because of the intervention of the remover 6. Thus, the plural layer clad materials N1, N2 can be made by removing the both members at the border of the remover 6. Therefore, the productivity can be enhanced.
The embodiment of the present invention has been explained in the above, but design changes can be appropriately done within the range of the purpose of the present invention. Furthermore, the “closing member” composed of the box body 2 and the sealing body 5 in the foresaid embodiment is an example and not specifically limited. Any embodiments are allowed as far as it can make the inside thereof vacuum and accommodates the intermediate members 3, 4. And furthermore, the butting form is not specifically limited either in the case. For example, a pair of box bodies or plural plate like members may cover the intermediate members. Further, the exhaust channel 14 may be formed at a portion of the “closing member”, and for example, at the bottom portion 11, the sealing body 5 or the like.
The remover 6 or a removing member is not necessary to be used. For example, if the remover 6 or a removing member is not used in the first embodiment, the intermediate members 3 and 4 are also joined together through the hot rolling process to manufacture a plural layer clad material composed of three layers of Al/Cu/Al.
Next, a method for manufacturing a composite slab according to a second embodiment of the present invention will be explained. As shown in
In the method for manufacturing a composite slab according to the second embodiment, a preparation process, a butting process, an evacuation process, a closing process, and a blocking process are performed. As shown in
A step portion 16 is formed along an inner edge of the peripheral wall portion 12 of the box body 2A made of aluminum or an aluminum alloy. The step portion 16 is defined by a step bottom face 16a and a step side face 16b standing on the step bottom face 16a. The intermediate members 21, 22, 23 are members to be accommodated in the recessed portion 13 of the box body 2A. Materials and thicknesses of the intermediate members 21, 22, 23 may be appropriately selected. The intermediate members 21, 22, 23 may be of the same material (for example, copper or a copper alloy) as one another, or respectively of different materials. Furthermore, it may be that the intermediate members 21, 22 are of the same material as each other and the intermediate member 23 is of a material different from the intermediate members 21, 22. In this embodiment, as an example, the intermediate members 21, 23 are of copper or a copper alloy, and the intermediate member 22 is of aluminum or an aluminum alloy. The remover or the removing member may be appropriately interposed between each adjacent two of the intermediate members, between the bottom portion 11 and the intermediate member 21, or between the sealing body 5 and the intermediate member 23 according to a desired plural layer clad material. The plate thickness of the sealing body 5 made of aluminum or an aluminum alloy is the same as the height dimension of the step side face 16b.
As shown in
The method for manufacturing a composite slab according to the second embodiment mentioned in the above has almost the same effect as the first embodiment. Furthermore, the three intermediate members 21, 22, 23 may be used like the second embodiment. Furthermore, the sealing body 5 may be butted against the step portion 16 to be formed on the box body 2A.
Next, a method for manufacturing a composite slab according to a third embodiment of the present invention will be explained. As shown in
In the method for manufacturing a composite slab according to the third embodiment, a preparation process, a butting process, an evacuation process, a closing process, and a blocking process are performed. As shown in
The intermediate members 31 to 34 are members to be accommodated in the recessed portion 13 of the box body 2. Materials and plate thicknesses of the intermediate members 31 to 34 may be appropriately selected. The intermediate members 31 to 34 may be of the same material (for example, copper or a copper alloy) as one another, or respectively of different materials. Furthermore, it may be that two or more of the intermediate members 31 to 34 are of the same material as each other and the other (s) is (are) of a material different from the two or more. In this embodiment, as an example, the intermediate members 31, 33 are of copper or a copper alloy, and the intermediate members 32, 34 are of aluminum or an aluminum alloy. The remover or the removing member may be appropriately interposed between each adjacent two of the intermediate members, between the bottom portion 11 and the intermediate member 31, or between the sealing body 5B and the intermediate member 34 according to a desired plural layer clad material. The size of the sealing body 5B is the same as that of the box body 2.
The butting process is a process in which the intermediate members 31 to 34 are accommodated in the recessed portion 13 of the box body 2, and the recessed portion is sealed with use of the sealing body 5B. A front face 34a of the intermediate member 34 being the top member is flush with the peripheral wall end face 12a. A butted portion J3 is formed by butting a back face 5b of the sealing body 5 against the peripheral wall end face 12a. A side face 5c of the sealing body 5 is flush with an outer side face 12c of the peripheral wall portion 12. The evacuation process is the same as that in the first embodiment.
In the closing process, the butted portion J3 is joined by friction stir welding with use of the first rotary tool G to close the portion. In the closing process, the first rotary tool G rotating clockwise is inserted into the sealing body 5 from the front face 5a thereof, and moved one lap along the butted portion J3. An insertion depth of the first rotary tool G is set so that the stirring pin G2 reaches the peripheral wall portion 12. After a starting edge and an ending edge of a plasticized region W1 are overlapped, the first rotary tool G is pulled out from the sealing body 5. The blocking process is the same as that in the first embodiment. Thus, a composite slab 1B is manufactured.
The method for manufacturing a composite slab according to the third embodiment mentioned in the above has almost the same effect as the first embodiment. Furthermore, the four intermediate members 31, 32, 33, 34 may be used like the third embodiment. Furthermore, the butted portion J3 may be formed so that the sealing body 5B is overlapped on the peripheral wall end face 12a like the third embodiment.
Next, a method for manufacturing a composite slab according to a fourth embodiment of the present invention will be explained. As shown in
In the method for manufacturing a composite slab according to the fourth embodiment, a preparation process, a butting process, an evacuation process, a closing process, and a blocking process are performed. As shown in
The frame member 40 has a rectangular frame shape. A material of the frame member 40 is not specifically limited, and in this embodiment, it is made of aluminum or an aluminum alloy. The bottom member 41 and the sealing body 42 are rectangular plate members. The exhaust channel 14 passing through in an inside and outside direction is formed in the frame member 40. The evacuation jig 15 is installed to communicate with the exhaust channel 14. The bottom member 41 and the sealing body 42 are formed to have sizes to be arranged inside the frame member 40 almost without gaps. Materials of the bottom member 41 and the sealing body 42 are not specifically limited, and in this embodiment, they are made of aluminum or an aluminum alloy.
The intermediate members 43, 44 are members to be accommodated inside the “closing member” and are rectangular plate members. The intermediate members 43, 44 are formed to have sizes to be arranged inside the frame member 40 almost without gaps. Materials of the intermediate members 43, 44 are not specifically limited, and in this embodiment, they are made of copper or a copper alloy. Materials of the intermediate members 43, 44 are appropriately selected from materials different from at least one of the bottom member 41 and the sealing body 42. In other words, one intermediate member or plural intermediate members of the present invention is/are inserted inside the frame member 40, and at least one of the intermediate members is to be made of a material different from at least one of the bottom member 41 and the sealing body 42. Remover or a removing member may be interposed between the intermediate members 43, 44. The thickness of the intermediate members 43, 44 may be appropriately set.
As shown in
The closing process is a process in which each of the bottom member 41 and the sealing body 42 is joined to the frame member 40 to close them. As shown in
Furthermore, in the closing process, friction stir welding is performed by inserting the first rotary tool G being rotated into the butted portion J41. After the first rotary tool G is moved one lap along the butted portion J41, a starting edge and an ending edge of a plasticized region W1 are overlapped, and the first rotary tool G is pulled out from the frame end face 40b. The blocking process is the same as that in the first embodiment. Thus, a composite slab 1C is manufactured.
The method for manufacturing a composite slab according to the fourth embodiment mentioned in the above has almost the same effect as the first embodiment. In the first embodiment, the box body 2 is used, but even though in a case where the frame member 40 is used like in this embodiment, the bottom member 41, the sealing body 42 and the intermediate members 43, 44 can be accommodated inside the frame member 40, so that positioning works and the closing process can be easily performed.
Next, a method for manufacturing a composite slab according to a fifth embodiment of the present invention will be explained. As shown in
In the method for manufacturing a composite slab according to the fifth embodiment, a preparation process, a butting process, an evacuation process, a closing process, and a blocking process are performed. As shown in
Step parts 56, 57 are formed along an upper portion and a lower portion of an inner side face 50c of the frame member 50 made of aluminum or an aluminum alloy. The step portion 56, which is formed at the upper portion of the frame member 50, is defined by a step bottom face 56a and a step side face 56b standing on the step bottom face 56a. The step portion 57, which is formed at the lower portion of the frame member 50, is defined by a step bottom face 57a and a step side face 57b standing on the step bottom face 57a.
The intermediate members 53, 54, 55 are members to be accommodated inside the frame member 50. Materials and thickness of the intermediate members 53, 54, 55 may be appropriately selected. The intermediate members 53, 54, 55 all may be of one material (for example, copper or a copper alloy), or each may be of a material different from one another. Furthermore, it is allowed that the intermediate members 53, 55 are of the same material as each other and the intermediate member 54 is different from the other two. In this embodiment, for example, the intermediate members 53, 55 are made of copper or a copper alloy, and the intermediate member 54 is made of aluminum or an aluminum alloy. Remover or a removing member may be appropriately interposed between each adjacent two of the intermediate members, between the bottom member 51 and the intermediate member 53, or between the sealing body 52 and the intermediate member 55 according to a desired plural layer clad material.
As shown in
The method for manufacturing a composite slab according to the fifth embodiment mentioned in the above has almost the same effect as the fourth embodiment. Three intermediate members 53, 54, 55 may be used like the fifth embodiment. The bottom member 51 and sealing body 52 may be butted against the step parts 57, 56 to be formed on the frame member 50, respectively like the fifth embodiment.
Next, a method for manufacturing a composite slab according to a sixth embodiment of the present invention will be explained. As shown in
In the method for manufacturing a composite slab according to the sixth embodiment, a preparation process, a butting process, an evacuation process, a closing process, and a blocking process are performed. As shown in
The frame member 60 is made of aluminum or an aluminum alloy and has a rectangular frame shape. The bottom member 61 and the sealing body 62 are made of aluminum or an aluminum alloy and each has substantially the same size as the frame member 60.
The intermediate members 63 to 66 are members to be accommodated inside the frame member 60. Materials and thicknesses of the intermediate members 63 to 66 may be appropriately selected. The intermediate members 63 to 66 all may be of one material (for example, copper or a copper alloy), or each may be of a material different from one another. Furthermore, it is allowed that two or more of the intermediate members 63 to 66 are of the same material as each other and the other or the others is/are of a different material or different materials. In this embodiment, for example, the intermediate members 63, 65 are made of copper or a copper alloy, and the intermediate members 64, 66 are made of aluminum or an aluminum alloy. Remover or a removing member may be appropriately interposed between each adjacent two of the intermediate members, between the bottom member 61 and the intermediate member 63, or between the sealing body 62 and the intermediate member 66 according to a desired plural layer clad material.
In the butting process, the frame member 60 is arranged on the bottom member 61, the intermediate members 63 to 66 are arranged inside the frame member 60, and the sealing body 62 is arranged on the intermediate member 66 and the frame member 60. A front face 66a of the intermediate member 66 and a frame end face 60a are flush with each other, and a back face 63b of the intermediate member 63 and a frame end face 60b are flush with each other. A butted portion J62 is formed by butting a back face 62b of the sealing body 62 and the frame end face 60a against each other. Furthermore, a butted portion J61 is formed by butting a front face 61a of the bottom member 61 and the frame end face 60b against each other. A side face 61c of the bottom member 61, a side face 62c of the sealing body 62, and a side face 60c of the frame member 60 are flush with one another.
As shown in
The method for manufacturing a composite slab according to the sixth embodiment mentioned in the above has almost the same effect as the fourth embodiment. Furthermore, the four intermediate members 63, 64, 65, 66 may be used like the sixth embodiment. And further, the butted portions J61, J62 may be formed by overlapping the bottom member 61 and the sealing body 62 on the frame member 60 like the sixth embodiment.
Next, an example of the present invention will be explained.
In the example, four sorts of test bodies T1, T2, T3, T4 of composite slabs of the present invention are made. As shown in
The intermediate member 103 is made of the copper alloy C1020. As shown in
Each composite slab was manufactured from the test bodies T1 to T4 by the same method as that of the first embodiment. As shown in
The thickness of the test body T1 became 9.3 mm (the reduction rate is 69.0%) by the hot rolling process. By the hot rolling process, plates of the intermediate member 103, 103 of the test body T1 were not joined together but separated. There existed poor joint between Al and Cu (that is, between the box body 101 and the intermediate member 103, and between the sealing body 102 and the intermediate member 103).
The thickness of the test body T2 became 8.3 mm (the reduction rate is 72.3%) by the hot rolling process. By the hot rolling process, plates of the intermediate member 103, 103 of the test body T2 were not joined together but separated. There partly existed poor joint between Al and Cu (that is, between the box body 101 and the intermediate member 103, and between the sealing body 102 and the intermediate member 103).
The thickness of the test body T3 became 6.4 mm (the reduction rate is 78.7%) by the hot rolling process. By the hot rolling process, both copper plates of the intermediate member 103, 103 of the test body T3 were well joined together. Furthermore, Al and Cu (that is, the box body 101 and the intermediate member 103, and the sealing body 102 and the intermediate member 103) were also well joined together.
The thickness of the test body T4 became 6.6 mm (the reduction rate is 78.0%) by the hot rolling process. By the hot rolling process, Al and Cu (that is, the box body 101 and the intermediate member 103, and the sealing body 102 and the intermediate member 103) of the test body T4 were well joined together.
As shown by the results of the test bodies T1, T2, it was proved that in a case where the heating temperature during a hot rolling process is equal to or less than 450° C., a good plural layer clad material cannot be manufactured because Al and Cu cannot originally be joined. On the other hand, as shown by the results of the test bodies T3, T4, in a case where the heating temperature during a hot rolling process is 500° C., Al and Cu were well joined. However, as shown by the result of the test body T3, Cu and Cu (both plates of the intermediate member 103, 103) also result in being joined together, so that a plural layer clad material of Al/Cu/Al is manufactured. That is, a plural layer clad material of three layers is manufactured rather than the desired two layers. Similarly, since the intermediate member 103 of the test body T4 is composed of one plate, a plural layer clad material of three layers of Al/Cu/Al results in being manufactured.
The removing member 106 contains 2 mass % or more of Mg. Since the thickness of the removing member 106 of the test body T6 is 2.0 mm, the depth of a recessed portion 110 is 16 mm.
Each composite slab is manufactured from the test bodies T5 and T6 by the same method as that of the first embodiment. After that, a hot rolling process was performed to each to make it thin to a desired thickness. As shown in
As shown in
As shown in
As shown in
As shown in
As shown in
The temperature during a hot rolling process may be adequately set according to the metal material. For example, it may be set to 460 to 600° C., preferably set to 470 to 550° C. Thus, Al and Cu can be well joined, and since both Cu and Cu cannot be joined, the dividing (removing) can be easily done. Two plural layer clad materials can be manufactured from one composite slab by dividing, so that productivity can be enhanced.
Note that, although a specific illustration is omitted, in a case where a plate member of an aluminum alloy whose front face or back face is anodized is adopted instead of the removing member 106, the dividing can be easily done like the removing member 106. Thus, two plates of plural layer clad materials composed of Al and Cu were manufactured.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-113979 | Jun 2018 | JP | national |
| 2018-113980 | Jun 2018 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/011075 | 3/18/2019 | WO | 00 |
