JP7014420B2

JP7014420B2 - Abrasion resistant composite material and its manufacturing method

Info

Publication number: JP7014420B2
Application number: JP2018122769A
Authority: JP
Inventors: 伸碩栗林; 秀一澁谷; 忠徳永; 和章小松原; 亮窪田
Original assignee: 株式会社ティクスTsk
Priority date: 2018-06-28
Filing date: 2018-06-28
Publication date: 2022-02-01
Anticipated expiration: 2038-06-28
Also published as: JP2020002427A

Description

本発明は、掘削用ビット等に用いる耐摩耗性・耐食性部材用複合材料、及びその製造方法に関係する。 The present invention relates to a composite material for wear-resistant and corrosion-resistant members used for excavation bits and the like, and a method for manufacturing the same.

石油、天然ガス、地熱等のエネルギー開発に用いる掘削用ビットには、岩石を掘削するだけでなく、掘削した穴径を保持する特性が必要となる。図１Ａは典型的な掘削用ビット（トリコンビット）の外見写真、図１Ｂはその部分的拡大写真である。掘削用トリコンビットのビットゲージ部２は、岩石から掘削荷重７及び抗壁圧力８を受け、岩石との摩擦で摩耗する事によって掘削穴の径が細径化する。これは次に使用するビットを短時間に損傷させて、掘削効率の低下を招く。また抗壁圧力８はビットカッターが抜け落ちる方向に作用するのでベアリング３及びシール４がダメージを受ける。その結果としてビットの取り換えを要する場合には膨大な費用を要し、それは掘削費用の高騰に繋がる。従ってビットの摩耗対策は最重要課題である。 The excavation bit used for energy development such as oil, natural gas, and geothermal must have the property of not only excavating rock but also maintaining the diameter of the excavated hole. FIG. 1A is an external photograph of a typical excavation bit (tricon bit), and FIG. 1B is a partially enlarged photograph thereof. The bit gauge portion 2 of the excavation tricon bit receives an excavation load 7 and an anti-wall pressure 8 from the rock, and wears due to friction with the rock, so that the diameter of the excavation hole is reduced. This damages the next bit to be used in a short time, resulting in a decrease in excavation efficiency. Further, since the anti-wall pressure 8 acts in the direction in which the bit cutter comes off, the bearing 3 and the seal 4 are damaged. As a result, if the bit needs to be replaced, it costs a huge amount of money, which leads to an increase in excavation cost. Therefore, measures against bit wear are the most important issue.

ビットの耐摩耗性の向上のため、通常、超硬チップの埋め込みや超硬（溶融タングステンを含む）粒子の溶接肉盛が行われているが、それでは十分とは言えず、超高圧のダイヤモンド焼結体を用いる場合もある。本願の発明者等は、ダイヤモンド複合材料を開発して実用化した（特許文献１）。これは超硬合金中にダイヤモンド粒を分散させた耐摩耗に優れた複合材料である。しかし複合材料チップの耐摩耗性が優れていても、チップが埋め込まれた母材（鋼材）５が摩耗すると、チップは歯槽膿漏のように脱落するので、母材の耐摩耗性も同様に重要となる。 In order to improve the wear resistance of the bit, carbide chips are usually embedded and carbide (including fused tungsten) particles are welded and built up, but this is not sufficient and ultra-high pressure diamond firing is performed. Carbide may be used. The inventors of the present application have developed and put into practical use a diamond composite material (Patent Document 1). This is a composite material with excellent wear resistance in which diamond grains are dispersed in cemented carbide. However, even if the composite material chip has excellent wear resistance, when the base material (steel material) 5 in which the chip is embedded wears, the chip falls off like alveolar pyorrhea, so that the wear resistance of the base material also has the same. It will be important.

母材の耐摩耗性を向上させるため、鋼材の表面を硬化することが行われ、通常、溶射、溶接の手法により１～３ｍｍ厚程度の硬装施工が行われる。例えば特許文献２には、耐摩耗性に優れたれたＷＣサーメットのウォームスプレー法による溶射施工により、気孔率が１．５％以下、粒子径が５μｍ以下で、ＨＶ１０５０～１１５０である溶射ロールを得ることが開示されている。しかし、１０～４０％の金属炭化物（ＷＣ）を分散しているものの気孔も含むため、重荷重で衝撃のある耐摩耗用途には向いていない。特許文献３にはダイヤモンドと樹脂の複合材料について開示されているが、金属ベースではないので重荷重で衝撃のある耐摩耗用途には使用できない。また、特許文献１に記載されているように、超硬合金中にダイヤモンド粒子を分散し加圧焼結する方法もあるが、超高圧法による超砥粒チップは極めて高価で、形状の制約があり、サイズの大きな物は作製できないことから本用途には向いていない。また、メッキ処理によるダイヤ砥粒の貼り付けの例（ダイヤモンド電着被膜）もあるが、接合強度が弱く、多孔質であるため、主に砥石用として用いられ、重荷重で衝撃のある耐摩耗用途には向いていない。その他にも、表面に数μｍ程度の高硬度の薄膜コーティングを行う研究は多くされており、例えば特許文献４には、ダイヤモンド被膜の成型方法が開示されているが、得られる膜厚が薄いため、重荷重の衝撃のある耐摩耗硬装用途には向いていない。 In order to improve the wear resistance of the base metal, the surface of the steel material is hardened, and usually, hard mounting with a thickness of about 1 to 3 mm is performed by a thermal spraying or welding method. For example, in Patent Document 2, a sprayed roll having a porosity of 1.5% or less, a particle size of 5 μm or less, and an HV of 1050 to 1150 is obtained by thermal spraying of WC cermet having excellent wear resistance by a worm spray method. Is disclosed. However, it is not suitable for wear-resistant applications with heavy load and impact because it contains pores although it is dispersed with 10 to 40% of metal carbide (WC). Patent Document 3 discloses a composite material of diamond and resin, but since it is not a metal base, it cannot be used for wear-resistant applications with heavy load and impact. Further, as described in Patent Document 1, there is also a method of dispersing diamond particles in a cemented carbide and performing pressure sintering, but the cemented carbide chip by the ultrahigh pressure method is extremely expensive and has shape restrictions. However, it is not suitable for this application because it is not possible to manufacture large-sized products. There is also an example of attaching diamond abrasive grains by plating (diamond electrodeposition coating), but since the bonding strength is weak and porous, it is mainly used for grindstones, and it is wear resistant under heavy load and impact. Not suitable for use. In addition, there are many studies in which a thin film coating having a high hardness of about several μm is applied to the surface. For example, Patent Document 4 discloses a method for forming a diamond coating, but the obtained film thickness is thin. , Not suitable for wear-resistant and hard-wearing applications with heavy impact.

特許５０７６０４４号公報（米国特許第７６３７９８１号明細書）Japanese Patent No. 5076044 (US Pat. No. 7,637,981) 特許第５０１３３６４号公報Japanese Patent No. 5013364 特許第３４９０９７８号公報Japanese Patent No. 3490978 特許第４３５８５０９号公報Japanese Patent No. 4358509 国際公開第２０１７／１３０２８３号International Publication No. 2017/130283

本発明の目的は、耐摩耗性・耐食性に優れ、かつ母材の硬装施工にも適用可能な広いサイズで、あるいは任意の形状をニヤネット（Near Net、Near Net Shapeとも言い、追加加工の不要な完成品に近い状態という意味）に作製できる複合材料、それを用いた部材、及びその製造方法を提供することにある。 An object of the present invention is to have a wide size that is excellent in wear resistance and corrosion resistance and that can be applied to hard mounting of a base material, or an arbitrary shape is also called a near net (Near Net or Near Net Shape), and no additional processing is required. It is an object of the present invention to provide a composite material that can be produced in a state close to that of a finished product, a member using the composite material, and a method for producing the same.

通常、溶射、溶接の手法により厚さ１～３ｍｍ程度の硬装施工が行われるが、この中に超砥粒を分散させることができれば、ビットの母材としても使用できる耐摩耗性材料を実現することが可能となる。しかしながら、発明者等の知る限り、溶射、溶接で超砥粒を分散させた事例はない。砥粒を溶射、硬装に用いるのが不可能であった理由として、施工（溶射、溶接）中に超砥粒が熱により炭素に変質する、または超砥粒の比重が軽く表面に浮き上るため半溶融にならない、さらに施工物に付着しない（濡れない）等が考えられる。このため、従来技術ではＷＣを主とする金属炭化物を自溶性合金中へ分散したものが主で、ＷＣを４０％程度まで溶融して緻密化処理が可能であったが、これ以上のＷＣを添加する場合は高速プラズマ等の溶射処理で行う必要があった。しかし溶射処理は微少な気泡が含まれるため緻密化処理はできず、耐衝撃性が得られなかった。 Normally, hard mounting with a thickness of about 1 to 3 mm is performed by thermal spraying and welding, but if superabrasive grains can be dispersed in this, a wear-resistant material that can also be used as a base material for bits will be realized. It becomes possible to do. However, as far as the inventor and others know, there is no case where the superabrasive particles are dispersed by thermal spraying or welding. The reason why it was impossible to use the abrasive grains for spraying and hardening is that the superabrasive grains are transformed into carbon by heat during construction (spraying, welding), or the specific gravity of the superabrasive grains lightly rises to the surface. Therefore, it is possible that it does not become semi-melted and does not adhere to the work (does not get wet). For this reason, in the prior art, metal carbides mainly composed of WC are mainly dispersed in a self-soluble alloy, and WC can be melted to about 40% for densification treatment. When it was added, it was necessary to perform thermal spraying treatment such as high-speed plasma. However, since the thermal spraying treatment contained minute bubbles, the densification treatment could not be performed, and impact resistance could not be obtained.

そこで発明者等は、特許文献１に記載した超硬合金（ＷＣ－Ｃｏ）とダイヤモンド粒子の焼結体であるダイヤモンド複合材料において、ＷＣの一部または全部をＣｏまたはＮｉを含む自溶性合金に置き換え、ダイヤモンド及び／またはｃＢＮ（立方晶窒化ホウ素）を自溶性合金中に分散させることを目指し研究を行った。自溶性合金は高硬度、低融点で半溶融域が広く、本研究目的に適している。 Therefore, the inventors have made a part or all of WC into a self-soluble alloy containing Co or Ni in the diamond composite material which is a sintered body of cemented carbide (WC-Co) and diamond particles described in Patent Document 1. Research was conducted with the aim of replacing and dispersing diamond and / or cBN (cubic boron nitride) in a self-soluble alloy. The self-soluble alloy has high hardness, low melting point and wide semi-melting range, and is suitable for the purpose of this research.

ダイヤモンドを自溶性合金のような金属材料に分散させるために必要な条件としては以下の条件が考えられる。
（１）ダイヤモンドが真空、雰囲気中の熱処理で変質しないこと。即ち短時間かつ１１００℃以下であること。なおダイヤモンドの代わりにｃＢＮを用いる場合には、短時間かつ１２００℃以下であること。
（２）ダイヤモンドと硬質金属の混合粉末が偏析なく型に充填されること。
（３）ダイヤモンドが混合粉末中で移動（浮き上がり）しないこと。
（４）混合粉末が熱処理（焼結温度）条件で、施工物表面に強固に付着すること。付着が不十分であると、混合物が焼結収縮して端面が捲れたり、亀裂が発生する。
（５）完全に焼結すること（気泡が含まれないこと）。この場合、厚み方向だけの収縮となる。 The following conditions can be considered as the conditions necessary for dispersing diamond in a metal material such as a self-soluble alloy.
(1) Diamond does not deteriorate due to heat treatment in a vacuum or atmosphere. That is, it should be 1100 ° C or lower for a short time. When cBN is used instead of diamond, the temperature should be 1200 ° C or lower for a short time.
(2) The mixed powder of diamond and hard metal is filled in the mold without segregation.
(3) Diamond does not move (float) in the mixed powder.
(4) The mixed powder firmly adheres to the surface of the work piece under heat treatment (sintering temperature) conditions. If the adhesion is insufficient, the mixture is sintered and shrunk, the end face is rolled up, and cracks are generated.
(5) Completely sintered (does not contain air bubbles). In this case, the contraction occurs only in the thickness direction.

本発明による硬装施工は、目的施工物の形状より少し大きい雌型のカーボン製の型９と、目的施工物の形状より少し小さい金属母材５を用いて作製する（図２Ａ）。そしてカーボン型と金属母材との隙間にダイヤモンドまたはｃＢＮの超砥粒と自溶性合金の混合粉末１０を十分に充填し、これを自溶性合金が焼結収縮を始める温度の近傍下の温度で十分保持する。混合粉末にはダイヤモンドまたはｃＢＮの他、金属炭化物等を超砥粒として加えてもよい。母材表面にＮｉロー等９００℃程度の融点の低融点材料を微量塗布すればさらに好結果が得られる。また、自溶性合金は固相～液相の半溶融域が広く、適度な粘性を有するのでこのような用途に好適である。充填した混合粉末は硬く固まり（仮焼結）、同時に鋼材の鉄との拡散結合により強く保持される。次にカーボン型枠９を外して仮焼結体と母材の鋼材を適正温度（１１００℃以下。超砥粒がｃＢＮの場合には１２００℃以下）で焼結する。仮焼結を行わず一度に焼結温度まで加熱すると、型９と充填物１０が付着して取出しができず破損する。また型９のリサイクルもできないので仮焼結の工程が必要となる。 The rigid construction according to the present invention is produced by using a female carbon mold 9 that is slightly larger than the shape of the target construction and a metal base material 5 that is slightly smaller than the shape of the target construction (FIG. 2A). Then, the gap between the carbon mold and the metal base material is sufficiently filled with the mixed powder 10 of diamond or cBN superabrasive grains and the self-soluble alloy, and this is filled at a temperature near the temperature at which the self-soluble alloy starts sintering shrinkage. Hold enough. In addition to diamond or cBN, metal carbides and the like may be added to the mixed powder as superabrasive particles. Further better results can be obtained by applying a small amount of a low melting point material having a melting point of about 900 ° C. such as Ni raw on the surface of the base material. Further, the self-soluble alloy has a wide semi-melting range from the solid phase to the liquid phase and has an appropriate viscosity, so that it is suitable for such an application. The filled mixed powder is hard and solidified (temporarily sintered), and at the same time, it is strongly held by the diffusion bond of the steel material with iron. Next, the carbon form 9 is removed, and the temporary sintered body and the steel material of the base material are sintered at an appropriate temperature (1100 ° C. or lower. When the superabrasive grains are cBN, 1200 ° C. or lower). If the mold 9 and the filling material 10 adhere to each other and cannot be taken out and are damaged if they are heated to the sintering temperature all at once without performing temporary sintering. Moreover, since the mold 9 cannot be recycled, a temporary sintering process is required.

前述の分散条件を満たすためには、カーボン型９と母材金属５の間に０．３ｍｍ以上の隙間（空間）を設けて、混合粉末１０を充填する必要がある。隙間がこれ以上狭いと、粉末を充填することが難しくなる。また母材金属５の表面は清浄な状態に保つことが、強固に付着させるためには重要である。自溶性合金としてはコルモノイ（登録商標）、またはヘガネス社の１３５５を用いるのが好適である。型の材料は熱伝導が良いカーボンが最適である。また、カーボン型９は簡単に取り外しが可能である。図２Ｂはこのようにして試作した、母材金属の左端部に硬装を形成した試験片の外観写真（左）及び断面写真（右）を示す。 In order to satisfy the above-mentioned dispersion condition, it is necessary to provide a gap (space) of 0.3 mm or more between the carbon mold 9 and the base metal 5 and fill the mixed powder 10. If the gap is narrower than this, it becomes difficult to fill the powder. Further, it is important to keep the surface of the base metal 5 in a clean state in order to firmly adhere it. As the self-soluble alloy, Colmonoy (registered trademark) or 1355 manufactured by Höganäs is preferably used. The best material for the mold is carbon, which has good thermal conductivity. Further, the carbon type 9 can be easily removed. FIG. 2B shows an external photograph (left) and a cross-sectional photograph (right) of the test piece having a hard covering formed on the left end portion of the base metal, which was prototyped in this way.

母材金属と仮焼結体は拡散結合で強く保持されているので、焼結収縮は厚み方向に制限される。従って、通常の焼結に比べると厚み収縮率は大きくなるが、充填時の厚みに比例して焼結されるので、硬装の厚みは収縮率×充填厚みとなる。充填厚みは均等なため、焼結後の寸法のバラツキはプラスマイナス０．１ｍｍ以下に収まり、ニヤネットの製作が可能となる。 Since the base metal and the tentative sintered body are strongly held by the diffusion bond, the sintering shrinkage is limited in the thickness direction. Therefore, although the thickness shrinkage rate is larger than that of normal sintering, since sintering is performed in proportion to the thickness at the time of filling, the thickness of the hardened body is the shrinkage rate × the filling thickness. Since the filling thickness is uniform, the variation in dimensions after sintering is within plus or minus 0.1 mm, and it is possible to manufacture a grinnet.

表１に従来の溶射施工と本発明による施工との比較を示す。

Table 1 shows a comparison between the conventional thermal spraying construction and the construction according to the present invention.

本発明による方法により、母材金属の表面に超砥粒（ダイヤモンドまたはｃＢＮ）－自溶性合金の複合材料による任意の形状の硬装を施工することが可能になった。この複合材料には各種の金属炭化物等の材料を高精度に複合添加することも可能である。このため、超砥粒の量、粒度等の調整を最適化すれば、多様な用途において優れた耐摩耗部材が提供できる。また施工に際しては、投入した原材料の粉末のほぼ１００％が硬装となるため、溶射のような付着歩留まりロスが無く、材料歩留まりに特に優れている。 According to the method according to the present invention, it has become possible to apply a rigid body of any shape to the surface of the base metal with a composite material of superabrasive grains (diamond or cBN) -self-soluble alloy. It is also possible to add various materials such as metal carbides to this composite material with high accuracy. Therefore, by optimizing the adjustment of the amount and particle size of the superabrasive grains, it is possible to provide an excellent wear-resistant member in various applications. Further, in the construction, since almost 100% of the raw material powder put in is hardened, there is no adhesion yield loss such as thermal spraying, and the material yield is particularly excellent.

本発明による硬装または施工物は、前述のダイヤモンド複合材料（特許文献１）に比べると、地が超硬合金から硬質金属になり靱性・耐衝撃が強化される効果がある。本発明によるダイヤモンドやｃＢＮの超砥粒を含んだ硬装材料は画期的な材料であり、また広い面積に被覆出来るので、従来の硬装よりも耐摩耗性を強化することができる。本発明による硬装を掘削用ビットに適用した場合には、超砥粒、ＷＣ粒子を含んだ凸状の広い鑢面を形成するので、坑壁研削力を従来よりも強化することができる。それにより抗壁の面圧が低減され、ベアリング保護とシールの強化を図ることができる。 Compared to the above-mentioned diamond composite material (Patent Document 1), the hardened or constructed material according to the present invention has an effect that the ground is changed from a cemented carbide to a hard metal and the toughness and impact resistance are enhanced. The hardened material containing diamond and cBN superabrasive grains according to the present invention is an epoch-making material and can cover a wide area, so that the wear resistance can be enhanced as compared with the conventional hardened material. When the hard fitting according to the present invention is applied to the excavation bit, a wide convex file surface containing superabrasive particles and WC particles is formed, so that the grinding force of the well wall can be strengthened as compared with the conventional case. As a result, the surface pressure of the anti-wall is reduced, and bearing protection and sealing can be strengthened.

さらに、本発明によれば、型によって任意の形状、大きさの施工物が作製できる。また、製作後の寸法のバラツキはプラスマイナス０．１ｍｍ以下に収まるため、ニヤネットの硬装施工が可能となる。これにより、施工物を作製するための加工費の大幅削減を図ることができる。この利点のため、耐摩耗性をそれほど必要としない用途の場合には、ダイヤモンドやｃＢＮを粉末に混合せずに金属炭化物を超砥粒とした硬装として、多様な用途に用いることが可能である。 Further, according to the present invention, a work piece having an arbitrary shape and size can be manufactured depending on the mold. In addition, since the variation in dimensions after production is within plus or minus 0.1 mm, it is possible to perform hard mounting of the grinette. As a result, it is possible to significantly reduce the processing cost for producing the work. Because of this advantage, in the case of applications that do not require much wear resistance, it can be used in various applications as a hardened body with metal carbide as superabrasive grains without mixing diamond or cBN with powder. be.

掘削用ビットの全体外見写真（左）と拡大外見写真（右）である。The whole appearance photograph (left) and the enlarged appearance photograph (right) of the excavation bit. 掘削用ビットの模式的断面図である。It is a schematic sectional view of a bit for excavation. 本発明による施工物を作製するための方法を示す模式的断面図である。It is a schematic cross-sectional view which shows the method for making the construction | structure by this invention. 本発明により作製した試験的施工物の概観写真（左）と断面写真（右）である。It is an overview photograph (left) and a cross-sectional photograph (right) of the experimental construction piece produced by this invention. 本発明により作製したシャフト型の形状の施工物の模式的断面図（左）と焼結施工後の外見写真（中）、及びその後センタレス加工を行った外観写真（右）である。It is a schematic cross-sectional view (left) of a shaft-shaped structure produced by the present invention, an appearance photograph (middle) after sintering, and an external photograph (right) after which centerless processing is performed. 本発明により作製したスリーブ円筒型の形状の施工物の模式的断面図（左）と焼結施工後の外見写真（右）である。It is a schematic cross-sectional view (left) and the appearance photograph (right) after the sintering construction of the sleeve cylindrical-shaped construction piece produced by this invention. 本発明により作製した鼓型ロール形状の施工物の模式的断面図（左）と焼結施工後の外見写真（中）、（右）である。It is a schematic cross-sectional view (left) and the appearance photograph (middle), (right) after the sintering construction of the drum-shaped roll-shaped construction piece produced by this invention. 本発明により作製した掘削用ビット（中）と、作製前の母材（左）、及び施工物の断面写真（右）である。It is a bit for excavation (middle) manufactured by this invention, a base material (left) before manufacturing, and a cross-sectional photograph (right) of a construction. ６０～８０μm径のダイヤモンド粒を含んだ複合材料の１ｍｍ厚の層を施工した試作品の断面の組織写真である。It is a microstructure photograph of a cross section of a prototype in which a 1 mm thick layer of a composite material containing diamond grains having a diameter of 60 to 80 μm was constructed. ３０～４０μm径のｃＢＮ粒を含んだ複合材料の１ｍｍ厚の層を施工した試作品の断面の組織写真である。It is a microstructure photograph of a cross section of a prototype in which a 1 mm thick layer of a composite material containing cBN grains having a diameter of 30 to 40 μm was constructed.

（実施例１）
本発明の方法による施工の予備試作として、種種の形状の回転体の母材の表面にダイヤモンド粒を含んだ硬装を形成した。図３Ａ、３Ｂ、３Ｃはそれぞれ、シャフト型の形状、スリーブ円筒型の形状、鼓型ロール形状の母材上の施工物の模式的断面図（左）と焼結施工後の外見写真（中、右）である。シャフト型の例では硬装を形成後、センタレス加工も問題なく行えることが確認され、いずれの形状でも、均一な硬装が母材の表面に強固に形成されることが分かった。 (Example 1)
As a preliminary trial production of the construction by the method of the present invention, a hard covering containing diamond grains was formed on the surface of the base material of a rotating body having a different shape. FIGS. 3A, 3B, and 3C are a schematic cross-sectional view (left) of a structure on a base metal having a shaft shape, a sleeve cylindrical shape, and a drum-shaped roll shape, respectively, and an external photograph after sintering (middle, Right). In the case of the shaft type, it was confirmed that centerless processing could be performed without any problem after forming the hard metal, and it was found that a uniform hard metal was firmly formed on the surface of the base material in any shape.

（実施例２）
本発明の方法によりビットカッターの模型を試作した。図４に示すように、ビットカッターの母材（鉄）のゲージ部に、深さ２ｍｍの凹状スリットを放射状に加工形成し、その上にカーボンの型を被せた。その隙間の空間に平均径が３０μｍのダイヤモンドで超硬合金粒を包んだ複合粒子（特許文献５）４０重量％と、残りが自溶性合金ヘガネス１３５５から成る混合物を充填した。そして、全体を加熱炉中で９５０℃で６０分保持して仮焼きを行った。その後型を外し、１０３０℃で３０分間焼結を行い、硬質層が形成された部材を得た（図４（中））。図４（右）の切断面写真が示すように、緻密な硬質層（上端部）が母材に固着して形成されていることが分かる。 (Example 2)
A model of a bit cutter was prototyped by the method of the present invention. As shown in FIG. 4, a concave slit having a depth of 2 mm was radially formed on the gauge portion of the base material (iron) of the bit cutter, and a carbon mold was placed on the concave slit. The space between the gaps was filled with a mixture consisting of 40% by weight of composite particles (Patent Document 5) in which cemented carbide grains were wrapped with diamond having an average diameter of 30 μm, and the rest consisting of the self-soluble alloy Heganez 1355. Then, the whole was kept in a heating furnace at 950 ° C. for 60 minutes for temporary baking. After that, the mold was removed and sintering was performed at 1030 ° C. for 30 minutes to obtain a member having a hard layer formed (FIG. 4 (middle)). As shown in the photograph of the cut surface in FIG. 4 (right), it can be seen that the dense hard layer (upper end portion) is fixed to the base metal and formed.

（実施例３）
図５は、φ２５ｍｍの鉄丸棒の外周に、６０～８０μm径のダイヤモンド粒を含んだ複合材料の１ｍｍ厚の硬質層を施工した試作品の、表面硬装部の断面組織の拡大写真である。ダイヤモンド粒は複合材料中に１０体積％含まれている。ダイヤモンド粒が比較的均一に分散していることが分かる。 (Example 3)
FIG. 5 is an enlarged photograph of the cross-sectional structure of the surface hardened portion of a prototype in which a 1 mm thick hard layer of a composite material containing diamond grains having a diameter of 60 to 80 μm is applied to the outer circumference of a φ25 mm iron round bar. .. Diamond grains are contained in the composite material in an amount of 10% by volume. It can be seen that the diamond grains are relatively uniformly dispersed.

（実施例４）
図６は、同様なφ２５ｍｍの鉄丸棒の外周に、ダイヤモンド粒の代わりに３０～４０μm径のｃＢＮ粒を含んだ複合材料の１ｍｍ厚の、硬質層を施工した試作品の表面硬装部の断面組織の拡大写真である。ｃＢＮ粒は複合材料中に１０体積％含まれている。この場合もｃＢＮ粒は比較的均一に分散していることが分かる。 (Example 4)
FIG. 6 shows the surface hardened portion of the prototype in which a 1 mm thick hard layer of a composite material containing cBN grains having a diameter of 30 to 40 μm instead of diamond grains was applied to the outer circumference of a similar iron round bar having a diameter of 25 mm. It is an enlarged photograph of the cross-sectional structure. The cBN grains are contained in the composite material in an amount of 10% by volume. In this case as well, it can be seen that the cBN grains are relatively uniformly dispersed.

なお、上記記載は実施例についてなされたが、本発明はそれに限定されず、本発明の精神と添付の請求の範囲の範囲内で種々の変更、及び修正をすることができることは当業者に明らかである。 Although the above description has been made for Examples, it is clear to those skilled in the art that the present invention is not limited thereto and various changes and modifications can be made within the scope of the spirit of the present invention and the appended claims. Is.

本発明による耐摩耗性・耐食性複合材料は、石油、天然ガス、地熱等のエネルギー開発に用いる掘削用ビット、その他の掘削用工具の耐摩耗部材として利用が可能である。また、母材の表面を広く覆うように形成して、母材の硬装施工へも応用が可能である。さらに、部材をニヤネットに作製できるので、従来よりも複雑な任意の形状の硬装施工物、例えば、内燃機関の各種弁、ロッカーアーム、あるいはバルブ装置用のボールバルブの球、ゲートバルブ等への応用が可能である。 The wear-resistant / corrosion-resistant composite material according to the present invention can be used as a wear-resistant member for excavation bits and other excavation tools used for energy development such as petroleum, natural gas, and geothermal energy. In addition, it can be formed so as to widely cover the surface of the base material, and can be applied to hard mounting of the base material. Furthermore, since the member can be manufactured in a near net, it can be applied to a rigid construction object having an arbitrary shape, which is more complicated than the conventional one, for example, various valves of an internal combustion engine, a rocker arm, a ball of a ball valve for a valve device, a gate valve, or the like. It can be applied.

１ビット、
２ゲージ部
３ベアリング
４シール部
５母材
７掘削荷重
８側壁からの面圧
９型
１０混合粉末 1 bit,
2 Gauge part 3 Bearing 4 Seal part 5 Base material 7 Excavation load 8 Surface pressure from side wall 9 Type 10 Mixed powder

Claims

自溶性合金単独の粉末または自溶性合金ベースの混合粉末に、超砥粒の粉末をさらに混合した材料粉末の焼結体の任意の形状の層が、鉄系金属の母材の表面に完成品に近い状態に接合された耐摩耗性複合材料。 A layer of any shape of the sintered body of the material powder, which is a mixture of the powder of the self-soluble alloy alone or the mixed powder of the self-soluble alloy base, and the powder of superabrasive grains, is formed on the surface of the base metal of the iron-based metal. Abrasion resistant composite material joined in a state close to.

前記超砥粒がダイヤモンド粒である請求項１に記載の耐摩耗性複合材料。 The wear-resistant composite material according to claim 1, wherein the superabrasive grains are diamond grains.

前記超砥粒が前記耐摩耗性複合材料中に１～３０体積％含まれる請求項１または２に記載の耐摩耗性複合材料。 The wear-resistant composite material according to claim 1 or 2, wherein the superabrasive grains are contained in the wear-resistant composite material in an amount of 1 to 30% by volume.

前記粉末の層の厚さが０．２ｍｍ以上である請求項１～３のいずれか１項に記載の耐摩耗性複合材料。 The wear-resistant composite material according to any one of claims 1 to 3, wherein the powder layer has a thickness of 0.2 mm or more.

請求項１～４のいずれか１項に記載の耐摩耗性複合材料を用いた掘削用の部材または工具、バルブ装置用の部材、内燃機関用の部材。 A member or tool for excavation using the wear-resistant composite material according to any one of claims 1 to 4, a member for a valve device, and a member for an internal combustion engine.

鉄系金属の母材と該母材を覆うように配置された型との隙間に、自溶性合金単独の粉末または自溶性合金をベースとした混合粉末に超砥粒をさらに混合した材料粉末を充填する工程と、
前記材料粉末を、真空または非酸化性雰囲気中で焼結収縮を始める温度未満の温度に所定の時間保持して仮焼結させ、前記母材の表面に仮焼結体を強固に拡散接合させる工程と、
前記型を取りはずした後、非酸化性雰囲気中で本焼結を行う工程と
を含む耐摩耗性複合材料の製造方法。 In the gap between the base material of the iron-based metal and the mold arranged so as to cover the base material, a material powder obtained by further mixing superabrasive grains with a powder of a self-soluble alloy alone or a mixed powder based on the self-soluble alloy is placed. The filling process and
The material powder is temporarily sintered by holding it at a temperature lower than the temperature at which sintering shrinkage begins in a vacuum or a non-oxidizing atmosphere for a predetermined time, and the temporary sintered body is firmly diffused and bonded to the surface of the base material. Process and
A method for producing a wear-resistant composite material, which comprises a step of performing main sintering in a non-oxidizing atmosphere after removing the mold.

前記超砥粒がダイヤモンド粒であり、前記焼結温度が１１００℃以下である、請求項６に記載の方法。 The method according to claim 6, wherein the superabrasive grains are diamond grains and the sintering temperature is 1100 ° C. or lower.

前記超砥粒がｃＢＮ粒であり、前記焼結温度が１２００℃以下である、請求項６または７に記載の方法。 The method according to claim 6 or 7, wherein the superabrasive grains are cBN grains and the sintering temperature is 1200 ° C. or lower.

前記超砥粒が前記耐摩耗性複合材料中に１～３０体積％含まれる請求項６～８のいずれか１項に記載の方法。 The method according to any one of claims 6 to 8, wherein the superabrasive grains are contained in the wear-resistant composite material in an amount of 1 to 30% by volume.

前記型がカーボンである請求項６～９のいずれか１項に記載の方法。 The method according to any one of claims 6 to 9, wherein the mold is carbon.

前記母材と前記型との隙間が０．３ｍｍ以上である請求項６～１０のいずれか１項に記載の方法。 The method according to any one of claims 6 to 10, wherein the gap between the base material and the mold is 0.3 mm or more.

前記本焼結後の前記耐摩耗性複合材料の形状の寸法のバラツキが±０．１ｍｍ以下の完成品に近い状態である、請求項６～１１のいずれか１項に記載の方法。 The method according to any one of claims 6 to 11, wherein the dimensional variation in the shape of the wear-resistant composite material after the main sintering is close to a finished product of ± 0.1 mm or less.