CN103429773A - Ni-Fe-Cr系合金和以其镀敷的发动机阀 - Google Patents

Ni-Fe-Cr系合金和以其镀敷的发动机阀 Download PDF

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Publication number
CN103429773A
CN103429773A CN2012800109817A CN201280010981A CN103429773A CN 103429773 A CN103429773 A CN 103429773A CN 2012800109817 A CN2012800109817 A CN 2012800109817A CN 201280010981 A CN201280010981 A CN 201280010981A CN 103429773 A CN103429773 A CN 103429773A
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Prior art keywords
alloy
quality
mass
engine valve
resistance
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CN103429773B (zh
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乙部胜则
西村信一
中川健治
饭尾将波
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Nippon Forging Co ltd
Fukuda Metal Foil and Powder Co Ltd
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Fukuda Metal Foil and Powder Co Ltd
Nittan Valve Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3033—Ni as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
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    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
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    • B23K35/3093—Fe as the principal constituent with other elements as next major constituents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
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    • C—CHEMISTRY; METALLURGY
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Abstract

本发明提供一种具备耐冲击性、耐磨损性和耐高温腐蚀性，此外含有资源丰富而廉价的Fe的表面硬化合金。一种Ni-Fe-Cr系合金和以其进行了镀敷的发动机阀，其特征在于，含有Mo为0～20.0质量%，W为8.0～40.0质量%，Mo和W的合计量为20.0～40.0质量%，含有Fe为20.0～50.0质量%，Cr为12.0～36.0质量%，B为1.0～2.5质量%，余量由Ni和不可避免的杂质构成。上述的Ni-Fe-Cr系合金，此外，也可以含有从Co、Mn、Cu、Si、C中选择的元素，合计为15.0质量%以下，这时，优选Co为15.0质量%以下，Mn、Cu分别为5.0质量%以下，Si为2.0质量%以下，C为0.5质量%以下。

Description

Ni-Fe-Cr系合金和以其镀敷的发动机阀
技术领域
本发明涉及PTA堆焊、TIG堆焊，喷镀等的各种施工工艺所使用的表面硬化合金，涉及具备耐磨损性、耐冲击性和耐高温腐蚀性的Ni-Fe-Cr系合金，以其镀敷的发动机阀。
背景技术
历来，需要耐磨损性的发动机阀中，除了广泛使用Stellite（注册商标）所代表的Co-Cr-W-C系合金和Tribaloy（注册商标）所代表的Co-Mo-Si系合金等的Co基表面硬化合金以外，在一部分发动机阀中，Ni基表面硬化合金（专利文献1～3）和Fe基表面硬化合金（专利文献4～8）也得到应用或研究。
Co-Cr-W-C系合金，作为表面硬化合金虽然具备高的耐冲击性，但耐磨损性不充分，不能耐受长期的使用。Co-Mo-Si系合金，作为表面硬化合金虽然具备高的耐磨损性，但耐冲击性不充分，裂纹和伴随其发生的剥离成为问题。另外，Co-Cr-W-C系合金和Co-Mo-Si系合金由Co和Cr、W或Mo构成，不能将稀有金属的含量控制在低水平。
另一方面，与Co-Cr-W-C系合金和Co-Mo-Si系合金具备同等的特性的、以Ni和Fe为主成分的表面硬化合金（专利文献1～8）被开发/使用，但在使用环境严苛化的发动机阀中，存在不能全部满足耐磨损性、耐冲击性、耐高温腐蚀性的问题。
先行技术文献
专利文献
专利文献1：专利第3196381号公报
专利文献2：专利第3196389号公报
专利文献3：专利第3855257号公报
专利文献4：特开平11-310854号公报
专利文献5：特开平6-297188号公报
专利文献6：专利第3328753号公报
专利文献7：专利第3343576号公报
专利文献8：特公平6-38998号公报
以赋予耐磨损性、耐冲击性和耐高温腐蚀性为目的的表面硬化合金，目前在各种工业领域被广泛使用。但是，由于近年来环境意识的提高，工业设备的使用环境增加了严格度。随之而来的是，除了表面硬化合金也要求更高性能的材料以外，还要求矿物资源的有效利用和与之相伴而将稀有金属的使用量抑制得低的廉价的合金。特别是在发动机阀所使用的镀敷合金中，具备耐冲击性、耐磨损性和耐高温腐蚀性，此外利用资源丰富的廉价的合金的开发成为课题。
发明内容
在本发明中，为了进行具备耐冲击性、耐磨损性和耐高温腐蚀性，此外将稀有金属的含量控制在低水平，使资源丰富的Fe含有的表面硬化用合金的开发而研究合金组成时，设定下述的目标值，以使其全部满足为条件。
（目标值）
（1）摆锤冲击值     →4J/cm2以上
（2）洛氏硬度（C级）  →42以上
（3）磨损减量         →150μm以下
（4）Fe含量          →20质量%以上
还有，这里定义的稀有金属，为除去铁、铝、铜、锌、锡、金、银、汞、铅、硅、碳的金属，相当于本发明的金属元素是Ni、Cr、B、Mo、W、Mn、Co。
即，满足上述的目标（1）～（4）的本发明的Ni-Fe-Cr系合金（以下，称为“本发明合金”），其特征在于，含有Mo为0～20.0质量%、W为8.0～40.0质量%，Mo和W的合计量为20.0～40.0质量%，含有Fe为20.0～50.0质量%、Cr为12.0～36.0质量%、B为1.0～2.5质量%，余量由Ni和不可避免的杂质构成。在此，所谓不可避免的杂质，指不是有意添加，但因各原料的制造工序等而不可避免地混入的杂质，作为这样的杂质，可列举Mg、S、O、N、V、Zr、Sn等。而且，其总和通常在0.3质量%以下，不会对本发明的作用造成影响。
此外，本发明合金，其特征在于，在以上记述的Ni-Fe-Cr系合金中，含有从Co、Mn、Cu、Si、C中选择的元素，合计为15.0质量%以下，并且，Co为15.0质量%以下，Mn、Cu分别为5.0质量%以下，Si为2.0质量%以下，C为0.5质量%以下。
另外，本发明的发动机阀，其特征在于，镀敷或涂覆有具有所述组成的本发明合金，更优选的发动机阀，其特征在于，所述的本发明合金至少被镀敷或涂覆在表面与底座的接触面。
其次，阐述限定本发明合金的各成分范围的理由。
W和Mo固溶在构成基质（基体）的Ni或Fe固溶体中，提供耐磨损性/耐冲击性，并且其一部分与B形成金属间化合物而进一步有助于耐磨损性的提高，但W和Mo的合计量低于20.0质量%时，金属间化合物的结晶不充分，若超过40.0质量%，则金属间化合物大量形成，韧性（耐冲击性）大幅降低。因此，Mo和W的合计量定在20.0～40.0质量%的范围。还有，若W的含量低于8.0质量%，则金属间化合物的结晶不充分，因此W的含量优选为8.0～40.0质量%的范围，因为Mo比W向基质的固溶极限量小，所以将Mo的含量的上限定为20.0质量%。还有，Mo是任意成分，因此Mo的含量也可以是0质量%。
Fe是资源丰富而廉价的元素，有助于制品的低价格化。因此，优选Fe的含量尽可能多的方法，将其下限设定在20.0质量%。另一方面，Fe在Ni固溶体中固溶，但若超过50.0质量%，则冲击值、硬度和耐高温腐蚀性降低，因此Fe的含量定为20.0～50.0质量%的范围。
Cr在Ni或Fe固溶体中固溶，提供耐磨损性、耐冲击性、耐腐蚀性、耐氧化性。另外，Cr的一部分与B形成金属间化合物，分散在基体内，因此进一步有助于耐磨损性的提高。但是，含量低于12.0质量%时，得不到充分的耐磨损性、耐腐蚀性、耐氧化性，若超过36.0质量%，在金属组织中金属间化合物大量形成，韧性大幅降低，因此Cr的含量定在12.0～36.0质量%的范围。
B与W、Mo和Cr形成金属间化合物，提供耐磨损性，并且使熔液洁净化，使镀敷时的流动性良好，因此使PTA和TIG堆焊或喷镀等的施工操作性提高。但是，在低于1.0质量%的含量时，无法形成充分量的金属间化合物，除了耐磨损性降低以外，熔液的洁净化作用不充分。另外，若超过2.5质量%，则金属间化合物的量多，韧性（耐冲击性）大幅降低。因此，B的含量定在1.0～2.5质量%的范围。
本发明合金，作为不会对物性造成不良影响的添加元素，能够含有Co为15.0质量%以下，Mn、Cu分别为5.0质量%以下，Si为2.0质量%以下，C为0.5质量%以下，为了不使耐冲击性和耐磨损性受损，将Co、Mn、Cu、Si、C的合计量的上限值定为15.0质量%以下。
本发明合金，使Fe含有20质量%以上，是减少了稀有金属的使用量的合金，具有摆锤冲击值为4J/cm2以上，且硬度（HRC）为42以上的特性，此外，在后述的阀‐阀座磨损试验中，发动机阀和底座的磨损减厚量的合计低于150μm，除了发动机阀以外，还能够作为具备耐冲击性和耐磨损性的表面硬化合金，面向大范围的用途应用。
附图说明
图1是表示镀敷了本发明合金的发动机阀的一例的模式图。
图2是阀‐阀座磨损试验方法的概略图。
具体实施方式
将基础的Ni和作为添加成分的W、Mo、Fe、Cr、B以及根据需要添加的Co、Mn、Cu、C、Si，分别以达到规定的质量%的方式进行了调整、调合的基体金属，熔解炉中的坩埚内加热、熔融而成为液状的合金后，通过雾化法和熔融粉碎法使之成为粉末，在既定的模具中铸造而成为棒状和板状等，能够得到本发明合金。
特别是以雾化法制造的本发明合金，通过调整为适合于目标的施工方法的粒度，能够适用于PTA堆焊和喷镀等的表面改质施工，以连续铸造法制造的堆焊焊条能够适用于气体堆焊等的表面改质施工。另外，将该粉末至棒材在各种材质的发动机阀的表面施工，能够赋予发动机阀以耐磨损性。
实施例
熔炼如上述这样调整、调合的本发明的实施例合金和比较例合金，通过以下所示的方法，进行摆锤冲击值和洛氏硬度的测量和磨损试验。
（1）摆锤冲击试验；将具有各合金的调合组成的100g的基体金属，使用电炉在氩气流中加热至大约1600℃而使之熔化，在壳型铸模中进行铸造，进行机械加工，成为JIS Z2242：2005所述的试验片（无切口）。然后，使用摆锤冲击试验机，进行依据JIS Z2242：2005的冲击试验，测量冲击值。
（2）硬度测量；将通过与上述（1）相同方法熔炼的铸片机械加工成10×10×20mm的形状，露出平行面，并用240号的耐水砂纸对于该平行面上部进行湿式研磨，实施依据JIS Z2245：2005的洛氏硬度试验。还有，硬度测量按C级实施。
（3）磨损试验；将具有各合金的调合组成的100kg的基体金属，使用高频熔解炉在氩气流中加热到大约1600℃进行熔解，通过气体雾化法使之粉末化，以振捣筛机将粒度调整到80～350mesh。对于以Fe-Ni-Cr系耐热钢制作的发动机阀（伞直径约32mm，轴直径约6mm，全长约110mm）的表面（图1的符号2所示的部分）进行PTA堆焊，使该合金粉末成为规定形状而进行机械加工后，以图2所示的试验方法，实施阀‐阀座磨损试验。还有，以如下试验条件实施：阀座材使用Co-Mo-Cr系烧结材，凸轮转速3000rpm，阀转速20rpm，阀表面温度250～400℃，试验时间9小时，计算试验前后的阀门（阀）和阀底座（阀座）的磨损减量的合计值。
（评价标准）
○：阀与底座的磨损减量的合计低于100μm
△：阀与底座的磨损减量的合计在100μm以上，低于150μm
×：阀与底座的磨损减量的合计在150μm以上
表1中显示本发明的实施例，表2和表3中显示比较例。
[表1]
[表2]
Figure BDA0000374239860000062
[表3]
Figure BDA0000374239860000063
表2所示的比较例合金（a）～（i）是本发明的要求范围外组成的合金。合金（a）其Mo和W的合计低于要求范围的下限，合金（e）其Fe和Cr低于要求范围的下限，合金（g）其Cr高于要求范围的上限，B低于要求范围的下限，合金（i）其Co和Mn的合计高于要求范围的上限，均不满足硬度和磨损减量的目标值。合金（b）其W和B高于要求范围的上限，合金（c）其Mo和Si高于要求范围的上限，合金（d）其W和Mo的合计高于要求范围的上限，合金（h）其C高于要求范围的上限，冲击值均不满足目标值。合金（f）其Fe高于要求范围的上限，不满足冲击值和硬度的目标值。
表3所示的比较例合金（A）～（U），是现有的Co-Cr-W-C系合金（Stellite（注册商标））和Co-Mo-Si系合金（Tribaloy（注册商标）），或其他的专利文献所示的合金，均不满足Fe量、冲击值、硬度和磨损减量的某一个目标值。
相对于此，如表1所示，作为本发明合金的实施例1～12，冲击值、硬度和磨损减量均满足目标值，作为表面硬化合金具备适度的耐磨损性和充分的韧性。
（4）PTA堆焊试验；在上述（3）的磨损试验中，调查制作发动机阀时，堆焊时所形成的熔融池的流动状态，其结果是，确认到实施例合金的流动状态均非常良好，堆焊操作性优异。
（5）高温硫化腐蚀试验；使用实施例合金和比较例合金（A）、（C）的合金组成，将通过与上述（3）相同的方法制作的发动机阀，用硫化钠包裹，在850℃下保持2小时后，确认镀敷层的表面状态。其结果是，比较例合金（C）确认到硫化物的生成，但在实施例合金和比较例合金（A）中，未确认到硫化物的生成，具有优异的高温硫化腐蚀特性。
（7）热冲击试验；使用实施例合金和比较例合金（A）、（C）的合金组成，将通过与上述（3）相同的方法制作的发动机阀，以设定为400℃的电炉进行1小时热处理后，投入约20℃的水中进行急冷。其次使热处理温度再上升50℃，进行1小时的热处理后，进行水冷。使其反复至热处理温度达到650℃，调查650℃下的热处理后的水冷下，镀敷层是否产生裂纹和剥离，其结果是，比较例合金（C）确认到裂纹，但实施例合金和比较例合金（A）中未确认到裂纹，确认具备充分的热冲击特性。
产业上的可利用性
以上，由于本发明合金作为表面硬化合金而具备优异的耐磨损性和耐冲击特性，所以在将其进行了镀敷的发动机阀中，能够期待耐久性的提高。此外，本发明合金含有资源丰富而比较廉价的Fe达20质量%以上，因此能够将稀有金属的使用量控制在低水平，可以进行顾及到矿物资源的有效利用或环境的发动机阀的制造。
另外，本发明合金，不限定于镀敷用，也能够活用于通过在粉末冶金形成的烧结零件中复合添加而成为硬质粒子，从而形成耐磨损性良好的机械零件。
符号说明
1  发动机阀
2  表面（镀敷层）：和底座的接触面
3  加热燃烧器
4  阀
5  底座
6  冷却水
7  转子（径向旋转）
8  推杆（上下运动）

Claims (4)

1.一种Ni-Fe-Cr系合金，其特征在于，含有Mo为0～20.0质量%，W为8.0～40.0质量%，Mo和W的合计量为20.0～40.0质量%，并且，含有Fe为20.0～50.0质量%，Cr为12.0～36.0质量%，B为1.0～2.5质量%，余量由Ni和不可避免的杂质构成。
2.根据权利要求1所述的Ni-Fe-Cr系合金，其特征在于，含有合计为15.0质量%以下的从Co、Mn、Cu、Si、C中选择的元素，并且，Co为15.0质量%以下，Mn、Cu分别为5.0质量%以下，Si为2.0质量%以下，C为0.5质量%以下。
3.一种发动机阀，其特征在于，镀敷或涂覆有权利要求1或2所述的Ni-Fe-Cr系合金。
4.根据权利要求3所述的发动机阀，其特征在于，至少在表面与底座的接触面上镀敷或涂覆有所述Ni-Fe-Cr系合金。
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