CN103338879A - 用二氧化铈和/或氧化钇填充的粉末金属构件及其制造方法 - Google Patents

用二氧化铈和/或氧化钇填充的粉末金属构件及其制造方法 Download PDF

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CN103338879A
CN103338879A CN201180066677XA CN201180066677A CN103338879A CN 103338879 A CN103338879 A CN 103338879A CN 201180066677X A CN201180066677X A CN 201180066677XA CN 201180066677 A CN201180066677 A CN 201180066677A CN 103338879 A CN103338879 A CN 103338879A
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小丹尼斯·克里斯托弗森
杰瑞米·科斯
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Abstract

一种粉末金属构件由压实和烧结的粉末金属颗粒例如含铬的亚铁基金属制成并且具有多孔。烧结后，用相对较小的二氧化铈和/或氧化钇颗粒填充孔。然后构件被热处理，并且填充的二氧化铈和/或氧化钇的存在作为所需氧化物例如氧化铬在表面上形成的成核位置。在原始氧化物层被磨损或破坏的情况下，位于防护性氧化物层之下的填充颗粒在构件的整个寿命中保持有效性，由于填充颗粒的存在，新的防护性氧化物在这些区域形成。

Description

用二氧化铈和/或氧化钇填充的粉末金属构件及其制造方法
相关申请的交叉引用
本申请要求2010年12月3日提交的第61/419522号美国临时申请的优先权，其全部内容通过引用并入此处。
技术领域
本发明大体涉及粉末金属（PM）构件的制造，并且涉及用其它材料填充（impregnation）这些PM构件的孔。
背景技术
粉末金属（PM）构件这样制成：混合所需的粉末成分（预合金的、混合的或者两者皆有），将粉末混合物压实成为生压坯，然后将生压坯烧结以生成烧结的PM构件。
众所周知，烧结后用树脂或油填充PM构件的孔。
众所周知，用纳米二氧化铈薄层涂敷含铬的亚铁基熟料的表面，当暴露于高温或含水氧化环境时，纳米二氧化铈作为反应催化剂以在其表面生成防护性氧化铬。尽管有利，但若防护性氧化铬层被磨损或破坏，下面的基底材料就会被暴露出来，不需要的氧化物（例如Fe2O3和FeO）就会形成，因此使用纳米二氧化铈仅提供有限的防护。
发明内容
一种粉末金属构件由压实和烧结的特定材料制成并且带有预设数量的孔隙。该PM构件被铈和/或氧化钇颗粒填充。
一种制造PM构件的方法，包括用二氧化铈和/或氧化钇填充压实和烧结的PM构件。
在随后的热处理工艺中，填充的二氧化铈和/或氧化钇为防护性氧化物的形成提供成核位置。例如，当铬存在于PM材料中时，它可以有利地与二氧化铈和/或氧化钇的填充颗粒反应以形成氧化铬，同时还起到抑制不需要的氧化物形成（例如当铁也存在时，抑制氧化铁形成）的作用。其它氧化铬混合物也可以形成，其它防护性氧化物包括其它合金元素存在时的防护性氧化物也可以形成，例如钒、钨、钼和铝等的氧化物。
进一步的优点通过在原始防护性氧化物层在构件外表面上形成之后用二氧化铈和/或氧化钇颗粒填充PM构件来实现。在原始防护性氧化物层被磨损或破坏的情况下，存在于孔中位于防护性氧化物层之下的填充颗粒对于防护性氧化物的继续形成有效，并且因此保持在孔中的二氧化铈和/或氧化钇为PM构件提供再生或自修复防护性氧化物，而不像非PM构件上的涂层。因此，用二氧化铈和/或氧化钇填充在热处理过程中提供即时的有益效果并且随后在构件的整个寿命中提供耐蚀性的持续效果。
作为填充工艺的一部分，二氧化铈和/或氧化钇可以被包含在载体（例如油、水或其它液体）中，或者甚至包含在树脂中。例如使用油将具有如下优点：除了当掺入二氧化铈和/或氧化钇时该组合物在PM构件的整个寿命中具有持久耐蚀性的额外优点，还提供带有已知优点（例如自润滑特性）的油填充。载体（油或水）还可以增加填充颗粒的移动性并且从而增强它们的有效性。此外，当颗粒包含在作为载体的油中时，目前用于油填充的相同填充技术和设备仍然可以有利地使用，并且因此唯一增加的成本是额外的颗粒填充材料。
填充的二氧化铈和/或氧化钇颗粒的尺寸比PM构件的孔的尺寸相对较小。为了实现良好的分布、覆盖性以及作为防护性氧化物层形成的成核位置的有效性，选择纳米颗粒作为填充颗粒是有利的。
结合优选实施例的具体描述，本发明的上述及其他特征和优点将会更加容易理解。附图详情如下。
附图说明
图1是根据本发明制备的填充后的粉末金属构件的示意图；
图2是图1的区域2的放大示意图；以及
图3是PM填充工艺的示意图。
具体实施方式
用比粉末金属（PM）构件孔隙小的二氧化铈（CeO2）和/或氧化钇（Y2O3）颗粒填充PM构件。在填充工艺中，构件的暴露表面也被二氧化铈和/或氧化钇涂敷。在随后的热处理过程中，至少位于PM构件表面或其附近的填充颗粒发生反应从而为至少在其表面形成防护性氧化物（例如氧化铬）提供成核位置，同时起到抑制某些不需要的氧化物（例如Fe2O3）形成的作用。通过用这些氧化物催化剂颗粒填充PM构件（而不是例如简单地涂敷构件），一小部分在热处理过程中没有反应的填充颗粒保留在构件的孔中位于防护性氧化物层下方，预备在构件的使用寿命后期原始防护性氧化物层被磨损或破坏的情况下活化，从而继续形成防护性氧化物（例如氧化铬）。在这种情况下，位于暴露的被磨损或破坏的涂敷区域附近的填充二氧化铈和/或氧化钇可以移动到这些区域以便快速重建这些区域的防护性氧化表皮。当填充颗粒位于流动载体（例如油）中时，对于移动性尤其有帮助。因此，这些颗粒的填充对耐蚀性提供持久的自修复效应，这是用例如二氧化铈简单涂敷非粉末金属物品表面无法实现的。
图1示意性地示出典型的PM构件10，可以理解为该PM构件10可以具有任意尺寸、形状或形态，并且由多个粉末金属颗粒13制成，该多个粉末金属颗粒13被压实从而为构件提供所需形状并且随后被烧结以使金属颗粒13彼此结合。该PM构件10将具有一个或多个暴露的表面12，并且由于构件本质上由粉末金属技术制成，将在构件表面上和整个本体中都具有一定数量的孔隙（也就是说，在组成PM构件的被压实和烧结的金属颗粒之间存在间隙网络）。孔的尺寸取决于压实、材料、密度、烧结、合金、添加剂等。相应地，将基于PM构件的特性对填充颗粒14设置尺寸和进行选择，以便实现有效的颗粒填充。填充工艺在PM构件烧结之后进行，因此二氧化铈和/或钇填充颗粒14没有被烧结并且因而不会彼此结合或者与PM构件10的金属颗粒13结合。填充颗粒的尺寸可以变化，只要它们相对较小并且可以渗入PM构件的孔16中。所有填充颗粒14可以具有同一尺寸，或者可以混合不同尺寸的颗粒以实现所需尺寸范围。填充颗粒14可以全部是铈，全部是钇或者两者混合，并且可以添加或不添加其它颗粒，包括其它反应性金属氧化物颗粒和填料。基于作为成核位置的铈和/或钇颗粒的存在而形成的防护性氧化物18在图1和2中示意性地示出为18。如图2所示，防护性氧化物层18将位于暴露的表面12上，并且当条件适于防护性氧化物在孔中形成（例如孔暴露于氧化环境）时也可以存在于至少一些内孔16中。
可以通过多种方式实现颗粒对PM构件10的填充，包括使用油作为颗粒的载体。该工艺在图3中示出，其中PM构件被置于真空环境中，空气被抽出孔外而油和油中承载的二氧化铈和/或氧化钇颗粒被吸入孔中并且覆盖构件的暴露表面。水或其它介质例如树脂，也可以用于替代油。使用油具有如下有益效果：除了掺入颗粒以在构件的整个寿命中提供持久的耐蚀性，还提供具有已知优点（例如自润滑轴承表面）的油填充。此外，当PM构件表面磨损且露出下面的材料时，保留在孔中的填充颗粒可以显露出来并且有利地反应以在表面需要的位置形成和补充防护性氧化物涂层以便持续防护，即使在磨损状况下。该优点只能通过使用PM构件以及纳米颗粒的填充实现。还应注意到，填充工艺可以在一个或多个阶段进行。例如，可以在使用颗粒和可选载体（例如水）对构件进行第一阶段填充之后进行热处理，此时一些或全部载体被汽化。然后可以进行至少第二阶段填充操作，此时载体（例如油）可以被填充到孔中，或者作为随后将随构件保持一段时间的唯一载体，或者补偿在此前的热处理操作中汽化的载体。
用颗粒填充PM构件10的进一步优点是，如果暴露于氧化环境，作为颗粒存在结果形成的防护性氧化物涂层18不只出现在构件外表面上，还可以进一步延伸到构件的孔中，该处附近的颗粒将如它们位于表面上一样以同样的方式反应，充当有利的防护性氧化物形成的催化剂并且避免不需要的氧化物形成。这与非PM构件不同，非PM构件中只有外表面可以用这种颗粒层涂覆，该颗粒层不穿透表面。
用于PM构件的材料13可以变化。一个典型实施例利用包含至少铬的亚铁基粉末金属材料13（例如不锈钢或工具钢粉末），当热处理时它在二氧化铈和/或氧化钇存在的情况下有利地反应，贯穿防护性氧化铬涂层形成过程。得益于该颗粒填充的其它合金、预合金以及混合物被本发明考虑在内，并且包含在公开范围内。例如，当铬作为合金元素存在时，可以形成氧化铬的各种混合物。二氧化铈和/或氧化钇存在时可以形成的其它防护性氧化物的例子包括钒、钨、钼以及铝等的氧化物，当这些元素作为合金元素被包含在内时。也可以形成这些各种防护性氧化物的混合物。
关于颗粒14的具体尺寸没有限制，只要它们不大于孔16的尺寸并且能够填充在用二氧化铈和/或氧化钇材料处理的特定PM构件中。例如，二氧化铈和/或氧化钇颗粒14的标称尺寸可以在1纳米至250微米范围内，并且更优选1纳米至100纳米，而孔16的标称尺寸可以在1微米至250微米范围内。颗粒的尺寸可以是一致的，或者具有一定尺寸范围也是有利的。二氧化铈和/或氧化钇颗粒可以单独使用，或者和作为填料或作为功能性颗粒的其它颗粒结合（例如其它氧化物催化剂或填料）。
上述说明本质上是示例而非限制。所公开实施例的各种修改和变化对于本领域技术人员是显而易见的，并且包含在本发明范围内。本发明由所附权利要求限定。

Claims (21)

1.一种由金属粉末颗粒制成的粉末金属构件，该金属粉末颗粒被压实和烧结以便颗粒彼此结合并且该构件是多孔的；并且包括填充在构件的孔中的二氧化铈或氧化钇中至少一种的未烧结颗粒。
2.如权利要求1所述的构件，其特征在于，二氧化铈和氧化钇中至少一种的未烧结颗粒是纳米颗粒。
3.如权利要求2所述的构件，其特征在于，未烧结的纳米颗粒位于填充在孔中的油载体中。
4.如权利要求2所述的构件，其特征在于，未烧结的纳米颗粒位于填充在孔中的树脂载体中。
5.如权利要求2所述的构件，其特征在于，纳米颗粒具有1至100纳米范围的标称尺寸。
6.如权利要求5所述的构件，其特征在于，孔具有1至250微米范围的标称尺寸。
7.如权利要求1所述的构件，其特征在于，所述填充颗粒具有大体一致的尺寸。
8.如权利要求1所述的构件，其特征在于，所述填充颗粒具有不同的尺寸。
9.如权利要求1所述的构件，其特征在于，所述构件由含铬的亚铁基粉末金属材料制成。
10.如权利要求1所述的构件，其特征在于，所述构件由粉末金属成分构成，该粉末金属成分包括以下元素中的至少一种：铬、钒、钨、钼和铝。
11.如权利要求9所述的构件，其特征在于，所述构件和所述填充颗粒被热处理并且包括形成在所述构件的暴露表面上的氧化铬层。
12.如权利要求1所述的构件，其特征在于，防护性氧化物层形成于构件的外表面上，并且至少一些所述填充颗粒位于所述构件的所述孔中的所述防护性氧化物层下方。
13.如权利要求12所述的构件，其特征在于，所述防护性氧化物位于至少一些所述孔的壁上。
14.一种制造粉末金属构件的方法，包括：
制备压实且烧结的构件，该构件具有多孔性以及相关联的孔和暴露表面；以及
烧结后用二氧化铈和氧化钇颗粒中的至少一种填充所述孔并且涂敷所述表面。
15.如权利要求14所述的方法，其特征在于，所述填充颗粒是纳米颗粒。
16.如权利要求14所述的方法，其特征在于，包括热处理烧结和填充的构件。
17.如权利要求16所述的方法，其特征在于，构件由含铬粉末金属制成，该含铬粉末金属与二氧化铈和氧化钇中的至少一种反应以形成至少位于所述暴露表面上的氧化铬层。
18.如权利要求17所述的方法，其特征在于，氧化铬形成于至少一些孔中。
19.如权利要求16所述的方法，其特征在于，构件由粉末金属成分构成，该粉末金属成分包括以下组分中的至少一种：铬、钒、钨、钼和铝。
20.如权利要求19所述的方法，其特征在于，形成至少一种所述组分的防护性氧化物。
21.如权利要求14所述的构件，其特征在于，当填充到孔中时至少一种二氧化铈和氧化钇颗粒包含在油、水或树脂载体中。
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