Repair method and repair material

Abstract

A repair method that includes covering a damaged part of a member to be repaired with a repair material, and heating the repair material to a predetermined temperature to form an alloy layer. At least the surface of the member to be repaired is a first metal such as Cu. The repair material includes a second metal such as Sn. By the heating, the surface of the member to be repaired is integrally joined with a layer of an intermetallic compound and an alloy having a melting point higher than a melting point of either of the first metal or the second metal.

1 . A method for repairing a damaged part of a member to be repaired, the method comprising:
 covering a damaged part of a metal surface with a repair material; and   heating the repair material to a predetermined temperature to form an alloy layer,   wherein the alloy layer contains, as a principal phase, an intermetallic compound predominantly composed of a first metal and a second metal having a melting point higher than that of the first metal.   
     
     
         2 . The repair method according to  claim 1 ,
 wherein the first metal has Sn as a main component, and   the second metal is at least one alloy selected from the group consisting of a Cu—Ni alloy, a Cu—Mn alloy, a Cu—Al alloy, a Cu—Cr alloy and an Ag—Pd alloy.   
     
     
         3 . The repair method according to  claim 1 , wherein the metal surface is a metal having Sn as a main component, a metal having Ag as a main component, or a metal having Cu as a main component. 
     
     
         4 . The repair method according to  claim 1 , further comprising disposing an auxiliary material containing the first metal on a surface of the repair material and heating the auxiliary material after heating the repair material to the predetermined temperature to form the alloy layer. 
     
     
         5 . The repair method according to  claim 1 , wherein the repair material has a film layer containing the first metal as a metal powder and the second metal as an alloy powder. 
     
     
         6 . The repair method according to  claim 5 , wherein an auxiliary layer which contains the first metal is disposed on the film layer, and a side of the film layer and the auxiliary layer is abutted against a side of the damaged part. 
     
     
         7 . The repair method according to  claim 5 , wherein an auxiliary layer containing the first metal and the second metal is disposed on the film layer, and a side of the thick film layer and the auxiliary layer is abutted against a side of the damaged part, and
 wherein a content of the first metal in the auxiliary layer is larger than a content of the first metal in the film layer.   
     
     
         8 . The repair method according to  claim 5 , wherein the film layer further contains a reducing agent and a resin. 
     
     
         9 . The repair method according to  claim 5 , wherein the film layer is disposed on a substrate sheet. 
     
     
         10 . The repair method according to  claim 1 , wherein the repair material has a multilayer structure of a first layer including the first metal and a second layer including the second metal. 
     
     
         11 . The repair method according to  claim 1 , wherein the repair material has a multilayer structure of a foil or film made of the second metal and a film layer made of the first metal. 
     
     
         12 . The repair method according to  claim 1 , wherein the repair material has a multilayer structure of a foil or film made of the first metal and a film layer made of the second metal. 
     
     
         13 . The repair method according to  claim 1 , wherein the repair material has a multilayer structure of a foil or film made of the first metal and a foil or film made of the second metal. 
     
     
         14 . A repair material for repairing a damaged part of a metal surface, the repair material comprising:
 a first metal having Sn as a main component; and   at least one second metal selected from the group consisting of a Cu—Ni alloy, a Cu—Mn alloy, a Cu—Al alloy, a Cu—Cr alloy and an Ag—Pd alloy.   
     
     
         15 . The repair material according to  claim 14 , wherein the repair material further contains a binder resin. 
     
     
         16 . The repair material according to  claim 14 , wherein the repair material further contains a reducing agent. 
     
     
         17 . A method for repairing a damaged part of a member to be repaired, the method comprising:
 covering a damaged part of a surface predominantly composed of a first metal with a repair material; and   heating the repair material to a predetermined temperature to form an alloy layer,   wherein the repair material contains a second metal having a melting point higher than that of the first metal, and   the alloy layer contains, as a principal phase, an intermetallic compound of the first metal and the second metal.   
     
     
         18 . The repair method according to  claim 17 ,
 wherein the first metal is a metal having Sn as a main component, and   the second metal is at least one alloy selected from the group consisting of a Cu—Ni alloy, a Cu—Mn alloy, a Cu—Al alloy, a Cu—Cr alloy and an Ag—Pd alloy.   
     
     
         19 . A repair material for repairing a damaged part of a member to be repaired in which at least the surface is a low melting point metal having Sn as a main component, the repair material comprising at least one alloy selected from the group consisting of a Cu—Ni alloy, a Cu—Mn alloy, a Cu—Al alloy, a Cu—Cr alloy and an Ag—Pd alloy. 
     
     
         20 . A method for repairing a damaged part of a member to be repaired, the method comprising:
 covering a damaged part of a surface predominantly composed of a second metal with a repair material; and   heating the repair material to a predetermined temperature to form an alloy layer,   wherein the repair material contains a first metal having a melting point lower than that of the second metal, and   the alloy layer contains, as a principal phase, an intermetallic compound of the first metal and the second metal.   
     
     
         21 . The repair method according to  claim 20 ,
 wherein the first metal is a metal having Sn as a main component, and   the second metal is at least one alloy selected from the group consisting of a Cu—Ni alloy, a Cu—Mn alloy, a Cu—Al alloy, a Cu—Cr alloy and an Ag—Pd alloy.   
     
     
         22 . A repair material for repairing a damaged part of a member to be repaired in which at least the surface is at least one alloy selected from the group consisting of a Cu—Ni alloy, a Cu—Mn alloy, a Cu—Al alloy, a Cu—Cr alloy and an Ag—Pd alloy, the repair material comprising a metal having Sn as a main component.