JP6872032B2 - 組成物、及び、その組成物から形成された潤滑被膜層を備えた管用ねじ継手 - Google Patents
組成物、及び、その組成物から形成された潤滑被膜層を備えた管用ねじ継手 Download PDFInfo
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- JP6872032B2 JP6872032B2 JP2019548256A JP2019548256A JP6872032B2 JP 6872032 B2 JP6872032 B2 JP 6872032B2 JP 2019548256 A JP2019548256 A JP 2019548256A JP 2019548256 A JP2019548256 A JP 2019548256A JP 6872032 B2 JP6872032 B2 JP 6872032B2
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Images
Classifications
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Description
鋼管同士をねじ締めする際、ねじ締めを終了する最適なトルクがあらかじめ決められている。図1は、ショルダー部を有する管用ねじ継手をねじ締めした際の、管用ねじ継手の回転数とトルクとの関係を示す図である。図1を参照して、管用ねじ継手をねじ締めすれば、初めは、回転数に比例してトルクが上昇する。この時のトルクの上昇率は低い。さらにねじ締めをすれば、ショルダー部同士が接触する。この時のトルクを、ショルダリングトルクという。ショルダリングトルクに達した後、さらにねじ締めをすれば、再び回転数に比例してトルクが上昇する。この時のトルクの上昇率は高い。トルクが所定の数値(締結トルク)に達した時点で、ねじ締めは完了する。ねじ締めの際のトルクが、締結トルクに達していれば、金属シール部同士が適切な面圧で干渉し合う。この場合、管用ねじ継手の気密性が高まる。
本発明者らはさらに、組成物にCr2O3を適量含有させれば、オーバートルク性能が高まるだけでなく、耐焼付き性も高まることを見出した。
管用ねじ継手1は、ピン5及びボックス8を備える。図4は、本実施形態の管用ねじ継手の構成を示す図である。管用ねじ継手1は、鋼管2と、カップリング3とを備える。鋼管2の両端には外面に雄ねじ部4を有するピン5が形成される。カップリング3の両側には、内面に雌ねじ部7を有するボックス8が形成される。ピン5とボックス8とをねじ締めすることによって、鋼管2の端に、カップリング3が取り付けられる。図示していないが、相手部材が装着されていない鋼管2のピン5及びカップリング3のボックス8には、それぞれのねじ部を保護するため、プロテクター(図示せず)が装着される場合がある。
管用ねじ継手1は、ピン5及びボックス8の少なくとも一方の接触表面上に、潤滑被膜層21を備える。図6は、本実施形態による管用ねじ継手1の接触表面の断面図である。潤滑被膜層21は、後述の製造方法のとおり、潤滑被膜層21を形成するための組成物を、ピン5及びボックス8の少なくとも一方の接触表面上に塗布し、乾燥することで形成される。
潤滑被膜層21を形成するための組成物は、Cr2O3と、金属石鹸と、ワックスと、塩基性芳香族有機酸金属塩とを含有する。したがって、潤滑被膜層21も、Cr2O3と、金属石鹸と、ワックスと、塩基性芳香族有機酸金属塩とを含有する。組成物は、無溶剤型の組成物(つまり、上述の成分のみ含有)であっても、溶剤に溶解させた溶剤型の組成物であってもよい。溶剤型の組成物の場合、各成分の質量%とは、組成物の不揮発性成分の合計量(組成物に含まれる溶剤以外の全成分を合計した質量)を100%とした場合の質量%をいう。つまり、組成物中の各成分の含有量と、潤滑被膜層21中の各成分の含有量とは、同じである。
Cr2O3は、酸化クロム(III)ともいう。Cr2O3は、無機化合物である。Cr2O3の式量は151.99である。Cr2O3は、二クロム酸アンモニウム(重クロム酸アンモニウム)の熱分解により得られる。Cr2O3は、昇華精製により、暗緑色金属光沢の結晶となる。Cr2O3はきわめて安定で、石英より硬い。Cr2O3には、毒性や危険性はない。
金属石鹸は、脂肪酸のアルカリ金属以外の金属との塩である。金属石鹸を含有すれば、潤滑被膜層21の耐焼付き性と防錆性とが高まる。
ワックスとは、常温で固体、加熱すると液体となる有機物である。ワックスは、動物性、植物性、鉱物性及び合成ワックスからなる群から選択される1種又は2種以上である。動物性のワックスはたとえば、蜜蝋及び鯨蝋である。植物性のワックスはたとえば、木蝋、カルナバワックス、キャンデリラワックス及びライスワックスである。鉱物性のワックスはたとえば、パラフィンワックス、マイクロクリスタリンワックス、ペトロラタム、モンタンワックス、オゾケライト及びセレシンである。合成ワックスはたとえば、酸化ワックス、ポリエチレンワックス、フィッシャー・トロプッシュワックス、アミドワックス及び硬化ひまし油(カスターワックス)である。好ましくは、ワックスは、分子量150〜500のパラフィンワックスである。
塩基性芳香族有機酸金属塩は、芳香族有機酸と過剰のアルカリ(アルカリ金属又はアルカリ土類金属)とから構成される塩である。塩基性芳香族有機酸金属塩は、たとえば、常温でグリース状ないし半固体の物質である。塩基性芳香族有機酸金属塩では、アルカリの過剰分が、コロイド状微粒子の金属塩として油中に分散している。
組成物は、潤滑被膜層21の潤滑性をさらに高めるために、潤滑性粉末を含有してもよい。潤滑性粉末とは、潤滑性を有する添加剤の総称である。潤滑性粉末は、公知のものを使用できる。
(1)滑り易い特定の結晶構造、たとえば、六方晶層状結晶構造を有することにより潤滑性を示すもの(例えば、黒鉛、酸化亜鉛、窒化硼素)、
(2)結晶構造に加えて反応性元素を有することにより潤滑性を示すもの(例えば、二硫化モリブデン、二硫化タングステン、フッ化黒鉛、硫化スズ、硫化ビスマス)、
(3)化学反応性により潤滑性を示すもの(例えば、チオ硫酸塩化合物)、及び、
(4)摩擦応力下での塑性又は粘塑性挙動により潤滑性を示すもの(例えば、ポリテトラフルオロエチレン(PTFE)及びポリアミド)。
組成物は、揮発性有機溶剤を含有してもよい。常温で塗布を行う場合には、潤滑被膜層21の組成物成分の混合物に揮発性有機溶剤を添加し、組成物を調製する。揮発性有機溶剤は、潤滑油の基油とは異なり、潤滑被膜層形成工程で蒸発する。そのため、揮発性有機溶剤は、潤滑被膜中には実質的に残存しない。「揮発性」とは、被膜形態で室温〜150℃までの温度で蒸発傾向を示すことを意味する。しかしながら、本実施形態の潤滑被膜層21は粘稠液体又は半固体であってもよいので、若干の溶剤の残存は許容される。
組成物は、その他、公知の防錆添加剤、防腐剤、着色顔料等を含有してもよい。
潤滑被膜層21は、実際に使用されるまでの長期間に渡る防錆性を有する必要がある。そのため、組成物は、防錆添加剤を含有してもよい。防錆添加剤とは、耐食性を有する添加剤の総称である。防錆添加剤はたとえば、トリポリリン酸アルミニウム、亜燐酸アルミニム及びカルシウムイオン交換シリカからなる群から選ばれる1種又は2種以上を含有する。好ましくは、防錆添加剤は、カルシウムイオン交換シリカ及び亜燐酸アルミニウムからなる群から選ばれる少なくとも1種を含有する。防錆添加剤として、他に市販の反応撥水剤なども使用できる。
組成物はさらに、防腐剤を含有してもよい。防腐剤も、耐食性を有する添加剤の総称である。
本実施形態の管用ねじ継手1はさらに、ピン5及びボックス8の少なくとも一方の接触表面と潤滑被膜層21との間に、金属めっき層を備えてもよい。金属めっき層はたとえば、Cu、SnもしくはNi金属による単層めっき層、又はCu−Sn合金の単層めっき層、Cu層とSn層との2層めっき層、及び、Ni層、Cu層及びSn層による3層めっき層である。
本実施形態の管用ねじ継手1はさらに、潤滑被膜層21の下に、潤滑被膜層21と接触する表面を有する化成処理被膜を備えてもよい。化成処理被膜はたとえば、蓚酸塩化成処理被膜及び硼酸塩化成処理被膜である。
本実施形態の管用ねじ継手1はさらに、潤滑被膜層21と接触する表面が、ブラスト処理されている又は酸洗された表面であってもよい。
管用ねじ継手1の母材の組成は、特に限定されない。母材はたとえば、炭素鋼、ステンレス鋼及び合金鋼等である。合金鋼の中でも、Cr、Ni及びMo等の合金元素を含んだ二相ステンレス鋼及びNi合金等の高合金鋼は耐食性が高い。そのため、これらの高合金鋼を母材に使用すれば、硫化水素や二酸化炭素等を含有する腐食環境において、優れた耐食性が得られる。
以下、本実施形態による管用ねじ継手1の製造方法を説明する。
潤滑被膜層形成工程では、上述の組成物の構成成分の混合物を溶剤添加及び/又は加熱により液状化し、ピン5及びボックス8の少なくとも一方の接触表面上に塗布する。必要に応じて、接触表面上に塗布された組成物を乾燥して、潤滑被膜層21を形成する。潤滑被膜層21の性状は問わない。潤滑被膜層21の性状はたとえば、固体、粘稠液体、又は半固体である。
本実施形態による管用ねじ継手1の製造方法は、潤滑被膜層形成工程の前に、金属めっき層形成工程を備えてもよい。金属めっき層はたとえば、電気めっき処理、又は、衝撃めっき処理により形成できる。
電気めっき処理はたとえば、電気めっきにより、金属めっき層を形成する処理である。金属めっき層はたとえば、Zn合金めっき層である。Zn合金めっき層を形成する場合、電気めっき処理では、ピン5とボックス8の少なくとも一方の接触表面上に、電気めっき処理によりZn合金めっき層を形成してもよい。
衝撃めっき処理は、粒子と被めっき物を回転バレル内で衝突させるメカニカルプレーティングや、ブラスト装置を用いて粒子を被めっき物に衝突させる投射めっきにより実施することができる処理である。
ブラスト処理はたとえば、ブラスト装置を用いて粒子を被めっき物に衝突させる処理である。ブラスト処理はたとえば、サンドブラスト処理である。サンドブラスト処理は、ブラスト材(研磨剤)と圧縮空気とを混合して接触表面に投射する処理である。ブラスト材はたとえば、球状のショット材及び角状のグリッド材である。サンドブラスト処理により、接触表面の表面粗さを大きくできる。サンドブラスト処理は、周知の方法により実施できる。たとえば、コンプレッサで空気を圧縮し、圧縮空気とブラスト材を混合する。ブラスト材の材質はたとえば、ステンレス鋼、アルミ、セラミック及びアルミナ等である。サンドブラスト処理の投射速度等の条件は、適宜設定できる。
酸洗処理は、硫酸、塩酸、硝酸もしくはフッ酸等の強酸液に、接触表面を浸漬して接触表面を荒らす処理である。これにより、接触表面の表面粗さを大きくできる。酸洗処理はたとえば、化成処理である。
本実施形態による管用ねじ継手1の製造方法は、潤滑被膜層形成工程の前に、化成処理工程を備えてもよい。化成処理工程では、化成処理を実施して、潤滑被膜層21の下に、潤滑被膜層21と接触する表面を有する化成処理被膜を形成する。
試験番号1では、ピン表面及びボックス表面に対し、機械研削仕上げを行った。その上に、潤滑被膜層を形成するための組成物を常温(約20℃)でスプレー塗布して、潤滑被膜層を形成した。膜厚は、所定のスプレー圧力及び対象面までの距離から、単位面積及び単位時間当たりの塗布される組成物の重量とその比重を用いて、目標平均膜厚を算出し、その値が120〜150μmの範囲になるようにした。
試験番号2〜試験番号4では、ピン表面及びボックス表面に対し、機械研削仕上げを行った。ピン表面に対しては、75〜85℃の燐酸亜鉛用化成処理液中に10分間浸漬して、厚さ10μmの燐酸亜鉛被膜を形成した。ボックス表面に対しては、80〜95℃の燐酸マンガン用化成処理液中に10分間浸漬して、厚さ12μmの燐酸マンガン被膜を形成した。その上に、潤滑被膜層を形成するための組成物を常温(約20℃)でスプレー塗布して、潤滑被膜層を形成した。膜厚は、所定のスプレー圧力及び対象面までの距離から、単位面積及び単位時間当たりの塗布される組成物の重量とその比重を用いて、目標平均膜厚を算出し、その値が120〜150μmの範囲になるようにした。
試験番号5では、ピン表面に対し、機械研削仕上げを行った。75〜85℃の燐酸亜鉛用化成処理液中に10分間浸漬して、厚さ10μmの燐酸亜鉛被膜を形成した。その上に、潤滑被膜層を形成するための組成物を常温(約20℃)でスプレー塗布して、潤滑被膜層を形成した。膜厚は、所定のスプレー圧力及び対象面までの距離から、単位面積及び単位時間当たりの塗布される組成物の重量とその比重を用いて、目標平均膜厚を算出し、その値が120〜150μmの範囲になるようにした。
試験番号6及び試験番号7では、ピン表面及びボックス表面に対し、機械研削仕上げを行った。その後、ブラスト加工により表面粗さを形成した。その上に、潤滑被膜層を形成するための組成物を常温(約20℃)でスプレー塗布して、潤滑被膜層を形成した。膜厚は、所定のスプレー圧力及び対象面までの距離から、単位面積及び単位時間当たりの塗布される組成物の重量とその比重を用いて、目標平均膜厚を算出し、その値が120〜150μmの範囲になるようにした。
試験番号8では、ピン表面及びボックス表面に対し、機械研削仕上げを行った。ピン表面に対しては、75〜85℃の燐酸亜鉛用化成処理液中に10分間浸漬して、厚さ10μmの燐酸亜鉛被膜を形成した。ボックス表面に対しては、80〜95℃の燐酸マンガン用化成処理液中に10分間浸漬して、厚さ12μmの燐酸マンガン被膜を形成した。その上に、API規格ドープを刷毛で塗布した。API規格ドープとは、API Bul 5A2に準拠して製造された油井管用ねじ用コンパウンドグリースである。API規格ドープの組成はグリースを基材とし、黒鉛粉:18±1.0%、鉛粉:30.5±0.6%、及び銅フレーク:3.3±0.3%含有すると規定されている。なお、この成分範囲においては、油井管用ねじ用コンパウンドグリースは同等の性能を有すると理解されている。
試験番号9では、ピン表面及びボックス表面に対し、機械研削仕上げを行った。ピン表面に対しては、75〜85℃の燐酸亜鉛用化成処理液中に10分間浸漬して、厚さ10μmの燐酸亜鉛被膜を形成した。ボックス表面に対しては、80〜95℃の燐酸マンガン用化成処理液中に10分間浸漬して、厚さ12μmの燐酸マンガン被膜を形成した。その上に、潤滑被膜層を形成するための組成物を常温(約20℃)でスプレー塗布して、潤滑被膜層を形成した。膜厚は、所定のスプレー圧力及び対象面までの距離から、単位面積及び単位時間当たりの塗布される組成物の重量とその比重を用いて、目標平均膜厚を算出し、その値が120〜150μmの範囲になるようにした。試験番号9では、組成物中にCr2O3が含有されなかった。
試験番号10では、ピン表面及びボックス表面に対し、機械研削仕上げを行った。ピン表面に対しては、75〜85℃の燐酸亜鉛用化成処理液中に10分間浸漬して、厚さ10μmの燐酸亜鉛被膜を形成した。ボックス表面に対しては、80〜95℃の燐酸マンガン用化成処理液中に10分間浸漬して、厚さ12μmの燐酸マンガン被膜を形成した。その上に、潤滑被膜層を形成するための組成物を常温(約20℃)でスプレー塗布して、潤滑被膜層を形成した。膜厚は、所定のスプレー圧力及び対象面までの距離から、単位面積及び単位時間当たりの塗布される組成物の重量とその比重を用いて、目標平均膜厚を算出し、その値が120〜150μmの範囲になるようにした。試験番号10では、組成物の成分としてCr2O3の代わりにCaF2を含有させた。
耐焼付き性評価は、繰返し締結試験により行った。試験番号1〜試験番号10のピン及びボックスを用いて、室温(20℃)でねじ締め及びねじ戻しを繰り返し、耐焼付き性を評価した。締結トルクは24350N・mとした。ねじ締め及びねじ戻しを1回行うごとに、ピン表面及びボックス表面を目視により観察した。目視観察により、ねじ部及び金属シール部焼付きの発生状況を確認した。金属シール部は焼付き発生で試験終了とした。ねじ部は焼付きが軽微であり、ヤスリなどの手入れにより回復可能な場合には、焼付き疵を補修して試験を続行した。最大繰返し締結回数は15回とした。耐焼付き性の評価指標は、ねじ部で回復不可能な焼付き、及び、金属シール部で焼付きのいずれも発生しない最大の締結回数とした。結果を表3の「耐焼付き性(ねじ部で回復不可能な焼付き、及び、金属シール部で焼付きのいずれも発生しないで締結できた回数(回))」欄に示す。
試験番号1〜試験番号10のピン及びボックスを用いて、トルクオンショルダー抵抗ΔT’を測定した。具体的には、締付け速度10rpm、締付けトルク42.8kN・mでねじ締めを行った。ねじ締めの際にトルクを測定し、図7に示す様なトルクチャートを作成した。図7中のTsは、ショルダリングトルクを表す。図7中のMTVは、線分Lと、トルクチャートとが交わるトルク値を表す。線分Lは、ショルダリング後のトルクチャートにおける線形域の傾きと同じ傾きを持ち、同線形域と比べて回転数が0.2%多い直線である。通常、トルクオンショルダー抵抗ΔT’を測定する場合には、Ty(イールドトルク)を使用する。しかしながら、本実施例では、イールドトルク(ショルダリング後におけるトルクチャートにおける、線形域と非線形域との境界)が不明瞭であった。そのため、線分Lを用いて、MTVを規定した。MTVとTsとの差分を、本実施例のトルクオンショルダー抵抗ΔT’とした。オーバートルク性能は、試験番号8において、潤滑被膜層の代わりにAPI規格ドープを使用した際のトルクオンショルダー抵抗ΔT’の数値を基準(100)として、本実施例のトルクオンショルダー抵抗ΔT’との相対値として求めた。結果を表3に示す。
表1〜表3を参照して、試験番号1〜試験番号7の管用ねじ継手の潤滑被膜層を形成する組成物は、Cr2O3を有した。そのため、ねじ締め及びねじ戻しを10回繰り返しても、焼付きが発生せず、優れた耐焼付き性を示した。さらに、オーバートルク性能が100を超え、優れたオーバートルク性能を示した。
4 雄ねじ部
5 ピン
7 雌ねじ部
8 ボックス
10、13 金属シール部
11、12 ショルダー部
21 潤滑被膜層
Claims (11)
- 管用ねじ継手に潤滑被膜層を形成するための組成物であって、
Cr2O3と、
金属石鹸と、
ワックスと、
塩基性芳香族有機酸金属塩とを含有する、組成物。 - 請求項1に記載の組成物であって、
前記組成物の不揮発性成分の合計量に基づく質量%で、
Cr2O3:1〜20%、
金属石鹸:2〜30%、
ワックス:2〜30%、及び、
塩基性芳香族有機酸金属塩:20〜70%、を含有する、組成物。 - 請求項1又は請求項2に記載の組成物であってさらに、
潤滑性粉末を含有する、組成物。 - 請求項3に記載の組成物であって、
前記組成物の不揮発性成分の合計量に基づく質量%で、
潤滑性粉末:0.5〜20%、を含有する、組成物。 - 請求項3又は請求項4に記載の組成物であって、
前記潤滑性粉末が、黒鉛及びポリテトラフルオロエチレンからなる群から選ばれる1種以上である、組成物。 - 請求項1〜請求項5のいずれか1項に記載の組成物であってさらに、
揮発性有機溶剤を含有する、組成物。 - ピン及びボックスを備える管用ねじ継手であって、
前記ピン及び前記ボックスの各々は、ねじ部を有する接触表面を備え、
前記管用ねじ継手は、前記ピン及び前記ボックスの少なくとも一方の前記接触表面上であって、最表層として、請求項1〜請求項6のいずれか1項に記載の組成物からなる潤滑被膜層を備える、管用ねじ継手。 - 請求項7に記載の管用ねじ継手であってさらに、
前記管用ねじ継手は、前記ピン及び前記ボックスの少なくとも一方の前記接触表面と前記潤滑被膜層との間に、金属めっき層を備える、管用ねじ継手。 - 請求項7又は請求項8に記載の管用ねじ継手であってさらに、
前記潤滑被膜層の下に、前記潤滑被膜層と接触する表面を有する化成処理被膜を備える、管用ねじ継手。 - 請求項7又は請求項8に記載の管用ねじ継手であって、
前記潤滑被膜層と接触する表面は、ブラスト処理されている又は酸洗されている、管用ねじ継手。 - 請求項7〜10のいずれか1項に記載の管用ねじ継手であって、
前記接触表面はさらに、ねじ無し金属接触部を有する、管用ねじ継手。
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