CN101461030A - 螺旋伞齿轮组的表面处理 - Google Patents

螺旋伞齿轮组的表面处理 Download PDF

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CN101461030A
CN101461030A CNA2007800096924A CN200780009692A CN101461030A CN 101461030 A CN101461030 A CN 101461030A CN A2007800096924 A CNA2007800096924 A CN A2007800096924A CN 200780009692 A CN200780009692 A CN 200780009692A CN 101461030 A CN101461030 A CN 101461030A
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gear
layer
anticorrosion layer
scuff
resistant coating
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CN101461030B (zh
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伊丽莎白·P·库克
瑞安·D·埃文斯
加里·L·多尔
兰迪·P·克鲁泽
卡尔·R·里包多
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Timken Co
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Abstract

公开一种向基材提供防磨损和耐蚀性能的基材(例如齿轮组中的齿轮)处理方法。该方法包括向基材提供耐磨层和耐蚀层。将所述耐磨层施加到齿轮上，接着将所述耐蚀层施加到该耐磨层上。可替换地，设置耐蚀层，接着在该耐蚀层上形成耐磨层。

Description

螺旋伞齿轮组的表面处理
相关申请交叉引用
本申请要求在2006年3月23日提交的美国专利申请60/785,298的优先权，在此将该专利申请参引到本申请中。
关于联邦资助的研究或发展的声明
本发明主要涉及齿轮的表面处理，并特别地涉及齿轮(尤其是螺旋伞齿轮组)的耐蚀以及耐磨的表面处理。
背景技术
齿轮组通常用于传递能量。齿轮组中的齿轮通常由钢制成，该钢可以是硬化钢。齿轮组会遇到对齿轮工作寿命有不利影响的物理状况(干运转状况、存在砂粒等)。齿轮组还会遇到同样对齿轮工作寿命有不利影响的腐蚀状况。
本领域向钢合金部件提供耐蚀性能的现有技术是设置铬或镍合金的厚(即20微米或以上)涂层。(铬或镍合金的较薄涂层(即小于3微米)在ASTM B117盐雾测试中可提供不到24小时的耐蚀性能。)该工艺提供非常有效的耐蚀性能。但是，这种涂层太厚从而会导致部件尺寸改变，因而需要重新设计部件。另外，虽然这些厚涂层在高载荷以及有滑动速度的情况下不会产生微量磨损，但是由于存在断裂和剥离现象，使得其不适于用作耐磨涂层。
本领域向钢合金部件提供耐磨性能的现有技术是设置MC/aC:H(纳米晶金属碳化物/非晶态碳氢化合物的混合物)或氮化铬涂层。但是，这些涂层无论是通过物理气相沉积(PVD)实现还是通过化学气相沉积(CVD)实现，都会产生大量贯穿涂层延伸到基材的针孔。虽然在涂层沉积过程中形成针孔的原因还未完全清楚，但针孔是钢合金基材上的物理气相沉积(PVD)涂层及化学气相沉积(CVD)涂层的固有特性。涂层中出现的针孔能导致电化腐蚀，这会使钢合金基材以超过其未涂覆状态的速度腐蚀。
发明内容
简而言之，本发明描述了一种向例如伞齿轮等钢合金部件提供耐磨性能及耐蚀性能的双重或双成分涂层。双成分涂层包括：(a)在钢合金基材上施加镍或镍合金的薄层(即大约3微米以下)，并在镍或镍合金的涂层上施加氮化铬或MC/aC:H的薄层(即大约3微米以下)；或者(b)在钢合金基材上施加氮化铬或MC/aC:H的薄层(即大约3微米以下)，并在氮化铬或MC/aC:H的涂层上施加镍或镍合金的薄层(即大约3微米以下)。在第一种方式中，将耐蚀层施加到基材上而将耐磨层施加到耐蚀层上。在第二种方式中，将耐磨层施加到基材上而将耐蚀层施加到耐磨层上。
公开一种向基材提供防磨损以及耐腐蚀性能的基材(诸如齿轮组的齿轮等)处理方法。该方法包括向基材提供防磨层以及耐蚀层。将防磨层施加到齿轮上，接着将耐蚀层施加到耐磨层上部。可替换地，将耐蚀层施加到齿轮上，接着在耐蚀层上形成耐磨层。
附图说明
图1是螺旋伞齿轮组的透视图；
图2是本发明的耐磨/耐蚀双成分涂层处理的示意图；
图3包括显示耐蚀层效果的照片；以及
图4包括涂覆有耐磨层的试样件和未涂覆的试样件的照片，以证明耐磨层不能提供耐蚀性能。
在全部附图中使用一致的附图标记。
具体实施方式
下面以示例方式而非限制方式对本发明进行详细描述。该描述将使本领域的普通技术人员能够清楚地制造和使用本发明，并说明了本发明的若干实施方式、改型、变型、替代方案以及应用，包括我们目前认为的本发明的最佳实施模式。另外，应当理解，本发明的应用并不限于下面描述中所说明的或附图中所图示的部件配置和结构详图。本发明具有其它实施方式并能通过各种方式得以实现或实施。同样，应当理解，本文所使用的措词以及术语都是为说明目的而不应视为限制。
参照图1，众所周知，齿轮组包括一对齿轮G1和G2，每个齿轮包括轮齿T以及轮齿之间的齿槽R。众所周知，齿轮对的轮齿彼此啮合，使得驱动轮带动从动轮转动。图1中所示的齿轮组包括螺旋伞齿轮组。可以看到，轮齿的顶端边缘成斜面(也就是说在俯视图中齿轮的轮廓是梯形)。另外，轮齿T是螺旋型而非直线型。尽管图示本发明为用于螺旋伞齿轮组，但是应当理解，该处理方法可应用于其它齿轮，并且实际上可应用于其它类型的基材(即轴承等)。
为了向齿轮提供防磨损以及耐蚀性能，在一说明性示例中，在齿轮上形成耐磨层，接着在耐磨层上形成耐蚀层以提供耐蚀性能。
耐磨层能够是例如：(1)复合材料涂层，其包括纳米晶金属碳化物以及非晶态碳氢化合物基(即MC/aC:H)(例如Timken公司的ES300涂层)；(2)双层系统，其包括MC/aC:H以及含有非晶态碳氢化合物(aC:H)的非金属(或无金属物)；(3)双层系统，其包括氮化铬以及非晶态碳氢化合物(aC:H)；(4)非晶态碳氢化合物(aC:H)单层，其也可包括硅，(4)碳化硼或碳化硼以及金属(例如钛、钨、钽或铬)；(5)金属氮化物(例如氮化钛或氮化铬)涂层；或(6)金属碳化物(例如碳化钛)。耐磨层优选地具有3微米或3微米以下的厚度。
耐蚀层既能够对齿轮本身进行表面处理也能够对耐磨涂层进行表面处理。可替代地，耐蚀层能够位于耐磨涂层之下(即将耐蚀层施加到齿轮上而将耐磨涂层施加到耐蚀层上)。能够提供耐蚀性能的表面处理的示例包括氮、铬或其它金属(例如镍)的离子注入。离子注入能够通过等离子体渗氮、等离子体浸没离子注入(PIII)或传统的离子注入工艺实现。假如耐蚀层是涂层，则该涂层是例如使用电解或无电镀(自动催化)工艺形成的如镍钴(NiCo)、镍硼(NiB)或镍磷(NiP)化合物等镍或镍合金。还能够使用镍锌(NiZn)合金(例如美国专利No.5352046所公布的镍锌(NiZn)合金，在此引入该专利作为参考，且该镍锌(NiZn)合金可由Timken公司的名为
Figure A200780009692D00071
的产品得到)。还能够使用通过阳极处理形成氧化物相的金属，例如钽(Ta)、铬(Cr)、铝(Al)、铌(Nb)或钛(Ti)。另外，环氧树脂、石油镏出物、聚甲基丙烯酸甲酯(PMMA)、普通润滑添加剂、稀土元素或密封剂(例如可从Henkel 
Figure A200780009692D00072
或得到的
Figure A200780009692D00074
产品)也可起到提供耐蚀性能的作用。连二磷酸盐(HyPO4)也能起到同样的作用。另外，化学转化层既能够施加到齿轮基材上也能够施加到耐磨层上。可以在如MC/aC:H或氮化铬等耐磨涂层上进行铬离子注入以向涂层中的针孔所暴露的钢合金区域提供耐蚀性能。
表面处理方法(例如通过等离子体浸没离子注入(PIII)、物理气相沉积(PVD)、化学气相沉积(CVD)等进行离子注入)的优点是不改变齿轮的表面形状。这对于例如必须精密监测和保持公差的齿轮组而言是非常重要的。如果使用涂层，涂层厚度优选为5微米或5微米以下。
在一说明性示例中，对齿轮镀以非电解镍镀层从而提供耐蚀性能。接着将MC/aC:H(例如碳化钨/非晶态碳氢化合物的混合物WC/aC:H)耐磨涂层施加到非电解镍镀层上。在本例中，外层提供耐磨性能而内层提供耐蚀性能。尽管外部耐磨层可能具有针孔，但位于耐磨层与齿轮(即基材)之间的耐蚀层将阻止腐蚀性元素接触齿轮基材从而防止腐蚀齿轮。通常需要至少20微米厚的非电解镍镀涂层才能提供ASTM B117盐雾测试48小时后第一次出现可视腐蚀迹象所代表的有效耐蚀性能。该涂层对于大多数应用场合来说过厚且不耐磨损。另外，如上所述，其在载荷下会发生断裂。由于镍层将由MC/aC:H涂层覆盖，所以我们的双成分涂层仅需要非常薄(即小于大约3微米)的镍层，而且仅需在MC/aC:H涂层中的气泡附近设置双成分涂层。
在又一说明性示例中，将耐磨层施加到齿轮(即基材)上，接着将耐蚀(或密封剂)层施加到耐磨层上。在本例中，耐磨层能够是氮化铬或MC/aC:H或aC:H层，而耐蚀层能够是非电解镍镀层。可替代地，耐磨层可同时包括MC/aC:H和aC:H成分。在本变型中，将无金属非晶态碳氢化合物(aC:H)施加到纳米晶金属碳化物/非晶态碳氢化合物的混合层(MC/aC:H)上。在本例中，密封剂(耐蚀)层实际上是牺牲层。当将密封剂(耐蚀)层施加到耐磨层上时，密封剂(耐磨材料)将填充针孔，如图2所示。由于密封剂层可能不是耐磨层，因此密封剂层可磨损至耐磨层的位置。但是，填充针孔的密封剂将留在针孔内，从而堵塞或封闭针孔。由于密封剂堵塞或封闭了针孔，腐蚀性元素将不能渗入到耐磨层，从而向钢合金基材提供了耐蚀性能。利用牺牲耐蚀层，通过模型或软性的相对部运转齿轮来清除牺牲层，从而保证将耐蚀层嵌入(或填充)耐磨涂层中的所有针孔。在本例中，一旦将耐蚀层磨损完，双成分涂层的厚度将与耐磨层的厚度大致相等。但是，双成分涂层将同时提供耐磨性能和耐蚀性能。
在第三示例中，用转化为铬涂层的氮化铬层(例如通过物理气相沉积(PVD)方法沉积)涂覆齿轮。接着，对涂层的外部铬层进行阳极处理以形成铬氧化物层。基于未知的原因，经过阳极处理的铬之类涂层(其含有针孔)表现出足以提供比带有针孔的纯铬层更高的耐蚀程度。
在另一示例中，通过等离子体浸没离子注入(PIII)将铬离子注入到钢合金表面从而在齿轮上形成耐蚀层，然后在已处理的齿轮表面上施加纳米晶金属碳化物/非晶态碳氢化合物的混合物、含硅非晶态碳氢化合物和/或无金属非晶态碳氢化合物或氮化铬的耐磨层。
在另一示例中，将非电解镍镀层施加到齿轮表面上，接着将耐磨涂层施加到镍层上。但是，在施加耐磨涂层之前，用铬、镍或氩离子轰击镍层，以提高层密度并实现对钢合金表面更加均匀的覆盖。
如上概述的方法提出了两种向钢合金基材(如钢合金齿轮)提供耐蚀性能和耐磨性能的方法。在第一种方式中，耐蚀层位于耐磨层之下。此处，耐蚀层包括通过湿化学方法或铬注入法施加的薄(即小于大约3微米)镍层，其中铬注入法是通过离子注入或等离子体浸没离子注入(PIII)来实施的。耐磨层包括：(1)通过例如反应磁控溅射来施加的MC/aC:H薄(即小于大约3微米)层；(2)通过例如反应磁控溅射来施加的氮化铬薄(即小于大约3微米)层；(3)通过例如等离子体增强化学气相沉积(CVD)来施加的Si-aC:H薄(即小于大约3微米)层；(4)通过例如反应磁控溅射和化学气相沉积(CVD)来施加的MC/aC:H和aC:H双成分薄(即小于大约3微米)层；或(5)通过例如磁控溅射来施加的碳化硼薄(即小于大约3微米)层。
在第二种方法中，耐磨层位于耐蚀层之下。此处，耐蚀层用作填充耐磨层中的针孔或裂缝的密封剂。在该方法中，耐磨层与刚才上文所述的相同。耐蚀层包括非电解镍镀层、环氧树脂、润滑添加剂、聚合物密封剂以及
Figure A200780009692D00091
图3示出了3个环，一个涂覆镍锌、一个涂覆硬铬、一个未涂覆。将从Timken公司得到的
Figure A200780009692D00092
用作镍锌涂层。图3说明了与镀铬或未涂覆的情况相比，镍基耐蚀涂层的效果。在ASTM B117盐雾腐蚀测试24小时之后，涂覆有AquaSpexx的环上未出现锈迹(AquaSpexx涂层本身具有“彩虹状”黄绿色外观)，而在铬涂覆环和标准环上可清晰地观察到红色的锈迹。
图4示出了盐雾腐蚀测试对涂覆碳化钨/非晶态碳氢化合物的混合物(WC/aC:H)涂层的钢合金试样件和未涂覆试样件的影响。碳化钨/非晶态碳氢化合物的混合物(WC/aC:H)涂层使用的是从Timken公司得到的ES300。如图4所示，涂覆ES300的试样件和未涂覆试样件都具有大量的锈迹。图4中的图像说明耐磨层不能保护合金不受腐蚀。也就是说，耐磨层不是耐蚀层。耐蚀性能是由涂层的第二成分——形成于基材上的镍层提供的(既可以位于耐磨层上也可以位于耐磨层之下)，其更不容易受到腐蚀的侵害。如上所述，如果将耐蚀层施加到耐磨层上，耐蚀层会磨损，使得全部涂层的厚度与耐磨层的厚度大致相等。但是，耐蚀镍将填充或堵塞耐磨层中的针孔。
由于在不背离本发明范围的情况下能够在上述结构中做出各种改型，因此上述说明中所描述的或附图中所示的所有内容都应理解为说明性而非某种意义的限制。

Claims (18)

1.一种向基材(例如齿轮)提供防磨损和耐蚀性能的方法，该方法包括向所述基材提供防磨层和耐蚀层。
2.如权利要求1所述的方法，包括：首先将所述防磨层施加到所述基材上，接着将所述耐蚀层施加到该防磨层上。
3.如权利要求2所述的方法，其中所述防磨层包括腐蚀性元素能够渗入的裂缝和孔等；所述耐蚀层填充该裂缝和孔等。
4.如权利要求3所述的方法，其中所述耐蚀层是牺牲层，该方法进一步包括磨损该耐蚀层的步骤，从而将除填充所述裂缝和孔等之外的耐蚀层从所述防磨层除去。
5.如权利要求1所述的方法包括：首先将所述耐蚀层施加到基材上，接着将所述防磨层施加到该耐蚀层上。
6.如权利要求1所述的方法，其中所述防磨层包括从包含纳米晶金属碳化物/非晶态碳氢化合物的混合物、无金属非晶态碳氢化合物、含硅非晶态碳氢化合物、碳化硼、金属氮化物及其组合的组中选择的涂层。
7.如权利要求1所述的方法，其中所述防磨层包括表面处理；该表面处理选自：渗碳、渗氮、氮碳共渗、碳氮共渗和等离子体浸没离子注入方法。
8.如权利要求1所述的方法，其中所述耐蚀层包括聚合物(聚甲基丙烯酸甲酯、聚四氟乙烯等)、阳极化金属、润滑添加剂膜及其衍生物(例如化学转化层)和它们的组合。
9.如权利要求1所述的方法，其中所述耐蚀层包括含有磷、硼、钴、钨、钍、锌及其组合的镍合金。
10.一种具有表面的齿轮，其改进包括在所述齿轮表面上有耐蚀层和防磨层。
11.如权利要求10所述的齿轮，其中所述防磨层位于该齿轮表面上，而所述耐蚀层位于该防磨层上。
12.如权利要求11所述的齿轮，其中所述防磨层包括腐蚀性元素能够渗入的裂缝和孔等；所述耐蚀层填充该裂缝和孔等。
13.如权利要求12所述的齿轮，其中所述耐蚀层是牺牲层，对其进行磨损使得该耐蚀层填充缝隙和孔等并将残余的耐蚀层基本全部去除。
14.如权利要求10所述的齿轮，其中所述耐蚀层位于所述齿轮表面上，而所述防磨层位于该耐蚀层上。
15.如权利要求10所述的齿轮，其中所述防磨层包括从包含纳米晶金属碳化物/非晶态碳氢化合物的混合物、无金属非晶态碳氢化合物、含硅非晶态碳氢化合物、碳化硼、金属氮化物及其组合的组中选择的涂层。
16.如权利要求10所述的齿轮，其中所述耐磨层包括表面处理；该表面处理选自：渗碳、渗氮、氮碳共渗、碳氮共渗和等离子体浸没离子注入方法。
17.如权利要求10所述的齿轮，其中所述耐蚀层包括聚合物(聚甲基丙烯酸甲酯、聚四氟乙烯等)、阳极化金属、润滑添加剂膜及其衍生物(例如化学转化层)和它们的组合。
18.如权利要求10所述的齿轮，其中所述耐蚀层包括含有磷、硼、钴、钨、钍、锌及其组合的镍合金。
CN2007800096924A 2006-03-23 2007-03-23 耐磨耐蚀涂层 Expired - Fee Related CN101461030B (zh)

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CN106795631A (zh) * 2014-06-04 2017-05-31 普莱克斯S.T.技术有限公司 用于动态接合承载表面的液密低摩擦涂层体系
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CN105065626A (zh) * 2015-07-08 2015-11-18 盐城市禾鼎机械有限公司 高传动效能的节能发动机驱动齿轮及其表面处理方法
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CN105695991A (zh) * 2016-02-01 2016-06-22 成都布雷德科技有限公司 一种耐蚀抗磨多层涂镀层
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TWI788140B (zh) * 2021-12-13 2022-12-21 揚博科技股份有限公司 抗蝕磁力輪

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JP2009531536A (ja) 2009-09-03
EP2002460A2 (en) 2008-12-17
DE602007007194D1 (de) 2010-07-29
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CN101461030B (zh) 2013-04-17
WO2007109784A2 (en) 2007-09-27

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