JP2020033634A - 表面硬化材料の製造方法 - Google Patents
表面硬化材料の製造方法 Download PDFInfo
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Abstract
Description
(1)表面に窒素が固溶された鉄鋼材料を、塩化物を含む溶融物に650℃〜900℃の範囲内で浸漬する浸漬ステップと、
浸漬した前記鉄鋼材料を、マルテンサイト変態が開始する下部臨界冷却速度以上の冷却速度にて、マルテンサイト変態開始温度以下まで冷却する冷却ステップと、
を含む、表面硬化材料の製造方法;
(2)表面に窒素が固溶された鉄鋼材料は、表層として鉄窒素化合物層を更に含む、上記(1)に記載の表面硬化材料の製造方法;
(3)表面に窒素が固溶された鉄鋼材料は、表面に炭素も固溶されている、上記(1)又は(2)に記載の表面硬化材料の製造方法;
(4)鉄鋼材料を窒化処理することにより、表面に窒素を固溶する窒化処理ステップを更に含む、上記(1)又は(2)に記載の表面硬化材料の製造方法;
(5)前記窒化処理が、ガス窒化処理、ガス軟窒化処理、プラズマ窒化処理、又は塩浴軟窒化処理である、上記(4)に記載の表面硬化材料の製造方法;
(6)前記窒化処理ステップの前に、鉄鋼材料に浸炭処理を施す浸炭処理ステップを更に含む、上記(4)又は(5)に記載の表面硬化材料の製造方法;
(7)表面に窒素を固溶する(前記窒化処理を行う)鉄鋼材料が、質量%で、
Cを0.01%以上1.5%以下、
Siを3%以下、
Mnを2%以下、
Cr、Mo、Cu及びNiを合計で5%以下、
Nb、Ti、V及びBを合計で1%以下、
Pを0.1%以下、
Sを0.05%以下、
Feを70.0%以上99.5%以下
の範囲内で含む、上記(1)〜(6)のいずれかに記載の表面硬化材料の製造方法;
(8)表面に窒素を固溶する(前記窒化処理を行う)鉄鋼材料が、質量%で、
Cを0.01%以上1.5%以下、
Siを3%以下、
Mnを2%以下、
Cr、Mo、Cu及びNiを合計で5%以下、
Nb、Ti、V及びBを合計で1%以下、
Pを0.1%以下、
Sを0.05%以下
の範囲内で含み、Feおよび不可避不純物を残部として更に含む、上記(1)〜(6)のいずれかに記載の表面硬化材料の製造方法。
表面に窒素が固溶された鉄鋼材料は、次に塩化物を含む溶融物に浸漬される。この浸漬ステップにより、より多くの、表面に固溶された窒素を深くまで浸透させることができ、かつ、表層が酸化されるのを防ぐことができるため、後述の冷却ステップにより、深い位置まで表面強度も向上させることができるようになる。溶融物に含まれる塩化物としては、例えば、NaCl、KCl、BaCl2等を挙げることができるがこれらに限定されるものではない。これらの塩化物は、1種を単独で用いてもよいが、2種以上を混合して用いてもよい。溶融物には、Na、K、Ba等の、硝酸金属塩および/または炭酸金属塩が含まれていてもよいが、含まれていなくてもよい。溶融物に浸漬する温度(浸漬温度)は、通常、650℃以上900℃以下の範囲内である。この温度範囲に限定した理由は、この温度範囲で浸漬しないと、表面硬化材料における表面硬度を深い位置まで十分に高めることができないからである。溶融物に浸漬する時間は、表面に窒素を固溶するための鉄鋼材料の種類、浸漬温度等によって異なるが、通常、5分間以上60分間以下であり、好ましくは5分間以上30分間以下である。
浸漬ステップで浸漬した上記鉄鋼材料を急冷することにより、表面部にマルテンサイト変態を生じさせ、深い位置まで硬質な表面を有する表面硬化材料を製造することができる。冷却(急冷)の条件としては、マルテンサイト変態が開始する(生じる)下部臨界冷却速度以上の冷却速度であれば特に制限されるものではないが、上部臨界冷却速度以上の冷却速度であることが好ましい。下部臨界冷却速度及び上部臨界冷却速度は、浸漬する上記鉄鋼材料の組成によって異なるが、一般的に、20℃/秒〜30℃/秒以上である。なお、冷却する温度としては、マルテンサイト変態開始温度以下であれば特に制限されるものではない。また、冷却(急冷)方法は、特に制限されるものではないが、水、塩水、ポリマー分散水溶液、油、塩浴、鉛浴などの冷却媒体に浸漬することが好ましい。冷却ステップを行った後、冷却した上記鉄鋼材料に対し、水洗したり、水洗後さらに焼き戻しを行ったりしてもよい。焼き戻しを行うことにより、靭性を向上させた表面硬化材料を製造することが可能となる。焼き戻しは、通常行われる条件で行うことができる。焼き戻しの温度及び時間等の条件は、冷却した上記鉄鋼材料の組成や使用用途により異なるが、例えば、150℃以上180℃以下の範囲内の温度、及び、60分間以上90分間以下の範囲内の時間等を挙げることができる。
(1)試験片1
機械構造用炭素鋼鋼材S45Cを850℃にて4時間の焼鈍を行い、機械加工により、直径20mm×長さ50mmに成形し、試験片1を作製した。
(2)試験片2
板厚1mmの自動車用極軟鋼薄鋼板SPCCを70mm×150mmに切断し、試験片2を作製した。
(3)試験片3
S10Cを900℃で4時間の焼鈍を行い、機械加工により、直径20mm×長さ50mmに成形し、試験片3を作製した。
(4)試験片4
S55Cを850℃で4時間の焼鈍を行い、機械加工により、直径20mm×長さ50mmに成形し、試験片4を作製した。
(5)試験片5及び試験片6
SCM420を850℃で4時間の焼鈍を行い、機械加工により、直径20mm×長さ50mmに成形し、試験片5を作製した。この試験片を、プロパン変成ガス(RXガス)及びプロパンエンリッチガスを注入しながら浸炭炉内にて、930℃で180分間浸炭処理を行った。その後、850℃まで温度を下げてから油冷(焼入れ)を行い、有効硬化層深さ(550HV)が0.8mmとなるように焼き戻しを行い、表面を機械研磨して直径20mm×長さ50mmに成形し、表面に浸炭層を備えた試験片6を作製した。なお、有効硬化層深さは、JIS G 0557:2006における「鋼の浸炭硬化層深さ測定方法」に基づき測定した。
(6)試験片7
SCM440を球状化焼鈍し、機械加工により、直径20mm×長さ50mmに成形し、試験片を作製した。
試験片1を塩浴軟窒化剤(パーカー熱処理工業製;NS−2)に浸漬し、570℃で120分間塩浴軟窒化処理を行った。塩浴軟窒化処理を行った試験片1を、光学顕微鏡及びEPMA分析により観察したところ、鉄窒素化合物層が表面から約15μmの厚さで、鉄窒素化合物層の下に窒素拡散層が約200μmの厚さで、複合層が形成されているのが確認できた。塩浴軟窒化処理を行った試験片1を、塩化物金属塩を含む塩浴剤に浸漬し、600℃〜1000℃で30分間塩浴加熱を行った。塩浴剤としては、600℃又は650℃で加熱する場合には、パーカー熱処理工業製GS540(融点540℃)を使用し、800〜1000℃で加熱する場合には、パーカー熱処理工業製GS660(融点660℃)を使用した。塩浴加熱を行った後、試験片1を20〜30℃の5%NaCl水溶液中に浸漬して冷却し(以下、「水冷」という)、No.1〜5の評価材料を作製した。この際の冷却速度は、概ね170℃/秒であった。
試験片1に対してプラズマ窒化処理を行い、プラズマ窒化処理を行った試験片1を、光学顕微鏡及びEPMA分析により観察した。なお、プラズマ窒化処理は、炉内のN2ガスとH2ガスの体積比が1:4となるように調整し、3torrに減圧して570℃で6時間行った。光学顕微鏡の観察の結果、鉄窒素化合物層が表面において不連続に形成し、また、窒素拡散層が鉄窒素化合物層の下あるいは表面から約200μmの厚さで形成されているのが確認できた。プラズマ窒化処理を行った試験片1の表面を機械研磨して、表面に不連続に形成した僅かな鉄窒素化合物層を除去し、上述と同様に、塩浴剤への浸漬及び水冷を行い、No.6〜10の評価材料を作製した。
No.1〜10の評価材料の特性(表面酸化、断面硬さ)を評価した。表面酸化は、水冷時に試験片1の表面から酸化物等の剥離や脱落の有無と、各評価材料を金属顕微鏡により断面観察(観察倍率500倍)した場合における、表面の酸化スケールの厚さと、を確認し、評価した。剥離や脱落がなく、酸化スケールの厚さが2μm未満である場合は実用化レベルと判断し、表面酸化が「無」と評価した。その他の場合、すなわち、剥離や脱落が確認された場合、又は酸化スケールの厚さが2μm以上である場合は、表面酸化が「有」と評価した。
断面硬さは、各評価材料を切断した後、断面を機械研磨により鏡面仕上げし、続いて、微小硬さ試験機(マイクロビッカース)を用いて、測定荷重0.3kgfにて、表面から深さ300μmの位置における微小硬さ(HV)を測定した。
これらの結果を表2に示す。
上述と同様に塩浴軟窒化処理を行った試験片1又は6を、光学顕微鏡及びEPMA分析により観察した。光学顕微鏡の観察の結果、鉄窒素化合物層が表面から約15μmの厚さで、鉄窒素化合物層の下に窒素拡散層が約200μmの厚さで形成されているのが確認できた。
塩浴軟窒化処理を行った試験片6に対し、800℃で5分間または30分間塩浴加熱を行った後、30〜40℃のコールドクエンチ油(出光製;ダフニーマスタークエンチA)中に浸漬して冷却し(以下、「油冷」という)、No.11及び12の評価材料を作製した。この際の冷却速度は、概ね約100℃/秒であった。
また、塩浴軟窒化処理を行った試験片1又は6を、電気炉内において800℃で5分間または30分間加熱した(電気炉加熱)。加熱後、試験片1又は6を水冷または油冷し、No.13〜15の評価材料を作製した。
塩浴軟窒化処理した試験片6を、高周波電源装置(最大出力:30kW、周波数:70kHz)を用いて800℃で0.5〜5分間加熱した(IH)。加熱後、試験片6を油冷し、No.16〜18の評価材料を作製した。
No.11〜18の評価材料に対し、上述の同様に特性の評価を行った。その結果を表3に示す。
上述と同様に、塩浴軟窒化処理を行った試験片1〜7を、光学顕微鏡及びEPMA分析により観察した。光学顕微鏡の観察の結果、鉄窒素化合物層が表面から約15μmの厚さで、鉄窒素化合物層の下に窒素拡散層が約200μmの厚さで形成されているのが確認できた。塩浴軟窒化処理を行った試験片1〜7に対し、850℃で5分間塩浴加熱を行った後、水冷又は油冷し、No.19及びNo.21〜26の評価材料を作製した。また、塩浴軟窒化処理を行った試験片6に対し、850℃で5分間塩浴加熱を行った後、20℃の部屋に放置し、20℃になるまで冷却し、No.20の評価材料を作製した。この際の冷却速度は、概ね約10℃/秒であった。No.19〜26の評価材料に対し、上述の同様に特性の評価を行った。その結果を表4に示す。
Claims (5)
- 表面に窒素が固溶された鉄鋼材料を、塩化物を含む溶融物に650℃〜900℃の範囲内で浸漬する浸漬ステップと、
浸漬した前記鉄鋼材料を、マルテンサイト変態が開始する下部臨界冷却速度以上の冷却速度にて、マルテンサイト変態開始温度以下まで冷却する冷却ステップと、
を含む、表面硬化材料の製造方法。 - 表面に窒素が固溶された鉄鋼材料は、表層として鉄窒素化合物層を更に含む、請求項1に記載の表面硬化材料の製造方法。
- 鉄鋼材料を窒化処理することにより、表面に窒素を固溶する窒化処理ステップを更に含む、請求項1又は2に記載の表面硬化材料の製造方法。
- 表面に窒素が固溶された鉄鋼材料は、表面に炭素も固溶されている、請求項1又は2に記載の表面硬化材料の製造方法。
- 前記窒化処理ステップの前に、鉄鋼材料に浸炭処理を施す浸炭処理ステップを更に含む、請求項3に記載の表面硬化材料の製造方法。
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