CN110226032A - 钢制燃料压送配管的制造方法 - Google Patents
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Abstract
本发明提供对腐蚀性燃料具有高耐性的高品质的钢制的燃料压送配管的制造方法。其特征在于,分选出钢制的管材的管内周面的初始瑕疵(微细裂纹或褶皱瑕疵、焊接缺陷部等)超过预先设定的阈值的管材和不超过阈值的管材,并在通过机械切削去除了不超过阈值的管材的内周面的初始瑕疵之后,对该管材的内周面实施镀Ni等表面处理。
Description
技术领域
本发明涉及将汽油直喷发动机***或柴油发动机***中的燃料向发动机供给的配管的制造方法,涉及例如通过拉伸管加工等去除内表面产生的微细裂纹或褶皱瑕疵等而实施内表面处理,制造耐腐蚀性优异的高品质的钢制燃料压送配管的方法。
背景技术
在上述的汽油直喷发动机***或柴油发动机***中使用的燃料压送配管中,作为具有耐压性、气密性及耐腐蚀性等各种性能的规格,采用最多的是对不锈钢系的材料实施各种塑性加工(管端成形加工、弯曲加工等)或接合加工(钎焊加工等)而形成制品的燃料压送配管。
此外,近年来,在汽油直喷发动机***中,提出了采用比上述的不锈钢系配管廉价的低碳钢等钢系配管的燃料压送配管(参照专利文献1)。特别是为了获得对腐蚀性燃料的高耐性,该钢制的燃料压送配管是实施了对腐蚀性燃料耐性优异的内表面处理和/或外表面处理的配管,例如是在钢制配管内表面形成Ni镀层,并且在上述Ni镀层上设置有由Zn镀层或Zn基合金镀层构成的防锈覆膜层的配管、在钢制配管外表面形成有Zn镀层或Zn基合金镀层的配管等。
但是,在上述钢制的燃料压送配管中,存在以下所示的问题点。
即,在上述钢制的燃料压送配管使用例如拉伸管材的情况下,在管内周面存在拉伸管时所产生的初始瑕疵(微细裂纹或褶皱瑕疵等),另外,在焊接管的情况下,在管内周面存在因焊接不良等而产生的初始瑕疵(焊接缺陷部等)。在这样的管内周面的缺陷、特别是在存在微细裂纹或褶皱瑕疵、焊接缺陷部的状态下实施了上述的内表面处理(例如镀Ni等)的情况下,镀覆液未浸透到该微细裂纹或褶皱瑕疵、焊接缺陷部的内部,微细裂纹或褶皱瑕疵、焊接缺陷部的部位未完全地被实施表面处理而成为缺陷,特别是存在无法获得对腐蚀性燃料的耐性而不得已产生腐蚀、锈的问题。
现有技术文献
专利文献
专利文献1:日本特开2012-26357号公报
发明内容
发明所要解决的课题
本发明是鉴于上述现有技术的问题点而完成的,提供一种在将汽油直喷发动机***或柴油发动机***中的燃料向发动机供给的钢制的配管中,不存在管内周面所产生的初始瑕疵(微细裂纹或褶皱瑕疵、焊接缺陷部等),对腐蚀性燃料具有高耐性的高品质的钢制的燃料压送配管的制造方法。
用于解决课题的技术方案
本发明的钢制的燃料压送配管的制造方法是在钢制的管材的内周面具有防锈覆膜层的钢制的燃料压送配管的制造方法,其特征在于,分选出该管材的管内周面的初始瑕疵(微细裂纹、褶皱瑕疵、焊接缺陷部等)超过预先设定的阈值的管材和不超过该阈值的管材,并在通过机械切削去除了不超过阈值的管材的内周面的初始瑕疵后,对该管材的内周面实施表面处理(例如镀Ni等)。另外,将超过阈值的管材作为不合格品进行处理。也可以在决定该阈值时,使用统计的方法算出预计的最大损伤深度,将该最大损伤深度作为阈值。
另外,作为去除管材的管内周面的初始瑕疵(微细裂纹、褶皱瑕疵、焊接缺陷部等)的方法使用的机械切削的方法,优选采用利用用于深孔加工的枪管钻加工机的方法。
并且,作为管内周面的初始瑕疵的检测手段,优选采用超声波探伤方法。
发明效果
根据本发明的钢制的燃料压送配管的制造方法,发挥以下优异的效果:通过检测或预测拉伸管材、半无缝管、焊接管等管材的管内周面的初始瑕疵(微细裂纹、褶皱瑕疵、焊接缺陷部等),并通过机械切削去除该检测值不超过预先确定的阈值的管材的内周面,从而获得上述初始瑕疵被完全去除,并且管内周面的平滑度提高,管内周面的表面处理的耐腐蚀性提高,对腐蚀性燃料具有高耐性的高品质的钢制的燃料压送配管。
另外,通过管材的管内周面的初始瑕疵(微细裂纹或褶皱瑕疵、焊接缺陷部等)的去除部件使用用于深孔加工的枪管钻加工机,由于刀具的直进性良好,因此能够在管材的管轴方向及圆周方向上均匀地切削,能够完全去除初始瑕疵。
附图说明
图1是表示用于实施本发明方法的钢制燃料压送配管的制造工序的一个例子的框图。
图2是表示在图1所示的钢制燃料压送配管制造工序中的管材的初始瑕疵去除工序中使用的枪管钻加工机的概略图。
具体实施方式
本发明的钢制的燃料压送配管的制造方法如图1的制造工序的一个例子所示,首先,作为被加工管,在管材制造工序1中制造作为配管母材的管材。作为管材制造工序1,例如是拉伸管工序、焊接管制造工序等。作为在管材制造工序1中制造的管材,是例如使用机械构造用碳素钢钢管STKM材、SCM材、STK材、STS材等低碳钢或合金钢,外径为10~30mm、内径为5~20mm的钢制管材等。
接着,作为配管母材的接收检查,在管材的探伤工序2中,利用探伤机对该管材的管内周面进行探伤,检测初始瑕疵(微细裂纹、褶皱瑕疵、焊接缺陷部等)。接着,在管材的分选工序3中,分选出在所述探伤工序中检测出的检测值超过预先确定的阈值的管材和不超过该阈值的管材。关于初始瑕疵(微细裂纹、褶皱瑕疵、焊接缺陷部等)的阈值,将其基准值设定为例如深度150μm,将超过该阈值的管材作为不合格品进行处理,将不超过该阈值的管材向接下来的初始瑕疵去除工序4输送。另外,关于阈值,根据管材的种类、内径、壁厚、微细裂纹或褶皱瑕疵、焊接缺陷部等的大小等来决定。
在初始瑕疵去除工序4中,将不超过阈值的管材以阈值以上的大小机械切削内周面,由此去除初始瑕疵。作为去除不超过该阈值的管材的管内周面的初始瑕疵(微细裂纹、褶皱瑕疵、焊接缺陷部等)的方法所使用的机械切削的方法,使用基于图2所示的用于深孔加工的枪管钻加工机7的方法。在该深孔加工中使用的枪管钻加工机7是使安装于主体部7-1的切削工具7-2一边旋转一边压入固定于夹具(省略图示)的管材而进行切削加工的方式。由于该加工是使用了被称为所谓的枪管钻的重视孔的直进性的工具的施工方法,因此用于深孔加工的枪管钻加工机7适合作为管材的管内周面的初始瑕疵的去除部件。
在初始瑕疵去除工序4中,利用用于深孔加工的枪管钻加工机7被去除了管内周面的初始瑕疵的不超过阈值的管材接着在表面处理工序5中,对该管材的内表面实施镀Ni等表面处理。此时,表面处理沿着该管材的内表面实施,但在上述初始瑕疵去除工序4中被去除了管内周面的初始瑕疵的管材的情况下,由于在其内表面没有微细裂纹或褶皱瑕疵、焊接缺陷部等,所以不带有镀覆液的部位完全不存在,对内表面整体可靠地实施表面处理。因此,可知在表面处理工序5中对管内周面实施了镀Ni等表面处理的制品通过充分保持对于腐蚀性燃料的防锈力,完全不会产生腐蚀或锈,耐腐蚀性优异。
[实施例1~6]
在管材制造工序1中,将通过拉伸管装置制造的外径为15.6mm、内径为9.8mm的钢制拉伸管材(试样No.1~6)用作配管母材,对于各拉伸管材,在探伤工序2中利用探伤机对该拉伸管材的管内周面进行探伤而检测出初始瑕疵(微细裂纹或褶皱瑕疵、焊接缺陷部等)之后,在拉伸管材的分选工序3中,分选出在上述探伤工序2中被检测出的检测值超过预先设定的阈值(150μm)的拉伸管材和不超过该阈值的拉伸管材,在接下来的初始瑕疵去除工序4中,利用用于深孔加工的枪管钻加工机7切削不超过上述阈值的各拉伸管材的内周面。此时的内周面的切削量为0.2mm(片厚)。接着,在表面处理工序5中,对切削了上述内周面的各拉伸管材的管内周面实施无电解镀Ni处理,形成膜厚3~5μm的Ni-P(无电解Ni)镀层。
将以下述要领进行本实施例的钢制拉伸管材的耐腐蚀性试验的结果示于表1。
耐腐蚀性试验:
将腐蚀性燃料(包含20%乙醇混合燃料(汽油)、有机酸500ppm、水分5%、氯10ppm)封入在整个管内表面实施了镀Ni的各钢制拉伸管材内,确认了在温度100℃下放置1000小时时的管内的腐蚀状况。耐腐蚀评价是通过目视及实体显微镜对红锈的有无进行确认而判定的。
[现有例1~3]
使用与实施例1~6相同的外径15.6mm、内径9.8mm的钢制拉伸管材,在拉伸管后对管内周面不实施机械切削而对各拉伸管材的内周面实施与实施例1~6相同的无电解镀Ni处理,形成膜厚3~5μm的Ni-P(无电解Ni)镀层,将利用与实施例1~6同样的方法进行耐腐蚀性试验的结果一并示于表1。
根据表1的结果,确认了以下的内容:在拉伸管后对管内周面进行探伤,对未超过预先设定的阈值的拉伸管材的内周面进行机械切削而去除之后,形成了无电解Ni镀层的实施例1~6的本发明的钢制拉伸管材,在管的内部均未确认到红锈的产生,具有优异的耐腐蚀性。
另一方面可判断出,对于现有例1~3,均在拉伸管材的内周面发现红锈的产生,与本发明的钢制拉伸管材相比耐腐蚀性差。
[表1]
耐腐蚀性试验结果 ○:无红锈产生 ×:有红锈产生
[实施例7~12]
在管材制造工序1中,将通过焊接管制造装置制造的外径为15.9mm、内径为9.9mm的钢制焊接管材(试样No.7~12)用作配管母材,焊接缺陷的深度调查预先通过统计的方法应去除的深度,根据该预想的最大损伤深度来设定管内表面的切削量,以预先设定的切削量的阈值(150μm)的切削量,利用用于深孔加工的枪管钻加工机7对内周面进行切削。此时的内周面的切削量为0.2mm(片厚)。接着,在表面处理工序5中,对切削了上述内周面的各焊接管材的管内周面实施无电解镀Ni处理,形成了膜厚3~5μm的Ni-P(无电解Ni)镀层。
将以与实施例1相同的要领进行本实施例中的钢制焊接管材的耐腐蚀性试验的结果示于表2。
[现有例4~6]
使用与实施例7~12相同的外径为15.9mm、内径为9.9mm的钢制焊接管材,在管材制造后对管内周面不实施机械切削而对各焊接管材的内周面实施与实施例7~12相同的无电解镀Ni处理,形成膜厚3~5μm的Ni-P(无电解Ni)镀层,将以与实施例1~6同样的方法进行耐腐蚀性试验的结果一并示于表2。
根据表2的结果,确认了以下的内容:在本实施例中,通过统计的方法预先设定焊接管制造后的焊接缺陷部的深度,以预先设定的阈值以上对焊接管材的内周面通过机械切削而去除之后,形成了无电解Ni镀层的实施例7~12的本发明的焊接管材,在管的内部均没有被确认到红锈的产生,具有优异的耐腐蚀性。另一方面可判断出,对于现有例4~6,均在焊接管材的内周面发现红锈的产生,与本发明的钢制焊接管材相比耐腐蚀性差。
[表2]
耐腐蚀性试验结果 ○:无红锈产生 ×:有红锈产生
附图标记说明
1 管材制造工序
2 探伤工序
3 分选工序
4 初始瑕疵去除工序
5 表面处理工序
6 制品
7 枪管钻加工机
7-1 主体部
7-2 切削工具
Claims (4)
1.一种钢制的燃料压送配管的制造方法,该钢制的燃料压送配管在钢制的管材的内周面具有防锈覆膜层,其特征在于,
分选出该管材的初始瑕疵超过预先设定的阈值的管材和不超过该阈值的管材,并在通过机械切削去除了不超过阈值的管材的内周面的初始瑕疵之后,对该管材的内周面实施表面处理。
2.一种钢制的燃料压送配管的制造方法,该钢制的燃料压送配管在钢制的管材的内周面具有防锈覆膜层,其特征在于,
对该管材的内周面进行探伤而检测初始瑕疵,分选出该检测值超过预先设定的阈值的管材和不超过该阈值的管材,并在通过机械切削去除了不超过阈值的管材的内周面的初始瑕疵之后,对该管材的内周面实施表面处理。
3.根据权利要求1或2所述的钢制的燃料压送配管的制造方法,其特征在于,
所述管材的管内周面的初始瑕疵通过用于深孔加工的枪管钻加工机去除。
4.根据权利要求1~3中任一项所述的钢制的燃料压送配管的制造方法,其特征在于,
所述表面处理为镀Ni。
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EP3591213A1 (en) | 2020-01-08 |
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