CN107709616A - 涂层结构、叶轮、压缩机、金属组件的制造方法、叶轮的制造方法及压缩机的制造方法 - Google Patents

涂层结构、叶轮、压缩机、金属组件的制造方法、叶轮的制造方法及压缩机的制造方法 Download PDF

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CN107709616A
CN107709616A CN201580081249.2A CN201580081249A CN107709616A CN 107709616 A CN107709616 A CN 107709616A CN 201580081249 A CN201580081249 A CN 201580081249A CN 107709616 A CN107709616 A CN 107709616A
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impeller
manufacture method
magnesium
chemical conversion
compressor
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南部崇
安秉
安秉一
新井贵
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Mitsubishi Heavy Industries Engine and Turbocharger Ltd
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Abstract

本发明的涂层结构具备：化学转化层(11)，其以覆盖由作为主成分含有镁的镁合金构成的叶轮主体(10)的表面的方式，通过化学转化处理所形成，且具有预先设定的范围内的膜厚；及电镀层(12)，其以覆盖化学转化层(11)的方式形成。

Description

涂层结构、叶轮、压缩机、金属组件的制造方法、叶轮的制造方 法及压缩机的制造方法
技术领域
该发明涉及一种涂层结构、叶轮、压缩机、金属组件的制造方法、叶轮的制造方法及压缩机的制造方法。
背景技术
发动机及涡轮等构成各种机械等的部件中，为了实现轻量化，进行将部件的材质从铝合金转换为镁合金的处理。
当由镁合金形成部件时，与由铝合金形成部件的情况相比，腐蚀量变多。于是，为了提高由镁合金构成的母材的耐蚀性，通过化学转化处理来覆盖母材的表面。而且，也进行对母材的表面用树脂来涂覆的处理。
但是，例如，当在发动机中由镁合金来形成进行排气再循环(EGR：Exhaust GasRecirculation)的组件时，因在排气再循环过程中通过被冷凝的水分有时可能会导致化学转化处理层及树脂涂层被侵蚀。其结果，组件中出现冲蚀及腐蚀。
于是，在由镁合金形成的组件中，希望进一步提高耐蚀性。
例如，专利文献1中公开有对由镁合金构成的母材实施镍基电镀的结构。通过对表面实施电镀，与化学转化处理及树脂涂层相比，可获得更高的耐蚀性。
在此，在专利文献1中所公开的结构中，在对母材实施镍基电镀处理之前，进行化学蚀刻等预处理。这种预处理是为了提高母材与电镀膜之间的粘附性而进行。
现有技术文献
专利文献
专利文献1：日本特开2003-73843号公报
发明内容
发明要解决的技术课题
于是，成为母材的镁合金中，为了进一步提高强度，添加添加物等进行改变镁合金的组成的处理。但是，根据为了提高强度而镁合金中所添加的添加物的成分等，即使进行化学蚀刻等预处理，有时也不能获得母材与电镀膜之间的充分的粘附性。
该发明的目的在于提供一种提高由镁合金构成的母材与由镍基合金构成的电镀层之间的粘附性而能够获得高耐蚀性及耐冲蚀性，并且提高可靠性的涂层结构、叶轮、压缩机、金属组件的制造方法、叶轮的制造方法及压缩机的制造方法。
用于解决技术课题的方法
根据该发明所涉及的第一方式，涂层结构具备以覆盖由作为主成分含有镁的镁合金构成的母材的表面的方式形成且由磷酸盐覆膜构成的化学转化层。该涂层结构还具备以覆盖所述化学转化层的方式形成且由镍基合金构成的电镀层。
根据这种结构，通过由磷酸盐覆膜构成的化学转化层与由镍基合金构成的电镀层良好地粘附，因此能够提高可靠性。通过具备这种电镀层，能够获得高耐蚀性及耐冲蚀性。
根据该发明所涉及的第二方式，涂层结构中，第一方式的涂层结构中的电镀层可以由镍磷合金形成。
通过如此设置化学转化层，尤其能够有效地提高镁合金与电镀层之间的粘附性。
根据该发明所涉及的第三方式，涂层结构中，第一或第二方式的涂层结构中的母材含有a原子％的锌，且以合计含有b原子％的选自由钆、铽、铥及镥构成的组中的至少一种元素。该涂层结构中，剩余部分由镁构成。a及b满足下述式(1)～(3)。而且涂层结构可以具有选自由镁和稀土元素的化合物；镁和锌的化合物；锌和稀土元素的化合物；及镁、锌、稀土元素的化合物构成的析出物组中的至少一种析出物。
(1)0.2≤a≤5.0
(2)0.5≤b≤5.0
(3)0.5a-0.5≤b
在由这种合金构成的母材中，即便欲使用电镀层直接包覆母材，粘附性也会变差。在该情况下，通过介隔基于化学转化处理的化学转化层，能够有效地提高母材与电镀层之间的粘附性，因此能够提高可靠性。而且，通过化学转化处理层能够提高耐蚀性。并且，通过电镀层也能够提高耐蚀性及耐冲蚀性。
根据该发明所涉及的第四方式，叶轮具有第一至第三方式中的任一个涂层结构。
由此，能够提高镁合金的耐蚀性、耐冲蚀性。因此，将由镁合金来形成叶轮而设为轻量，从而能够有效地提高使用叶轮的压缩机的动作响应。
根据该发明所涉及的第五方式，压缩机具备第四方式的叶轮。
由此，当由镁合金形成了叶轮时，能够提高叶轮的耐蚀性、耐冲蚀性。因此，将叶轮设为轻量，从而能够有效地提高使用叶轮的压缩机的动作响应。
根据该发明所涉及的第六方式，金属组件的制造方法包括通过以覆盖由作为主成分含有镁的镁合金构成的母材的表面的方式进行化学转化处理而形成化学转化层的工序。该金属组件的制造方法还包括以覆盖所述化学转化层的方式形成由镍基合金构成的电镀层的工序。
由此，由镍基合金构成的电镀层良好地粘附于母材，因此能够提高可靠性。而且，通过具备电镀层，能够获得高耐蚀性及耐冲蚀性。
根据该发明所涉及的第七方式，叶轮的制造方法包括第六方式中的金属组件的制造方法。
由此，能够提高镁合金的耐蚀性、耐冲蚀性。因此，由镁合金来形成叶轮而设为轻量，从而能够有效地提高使用叶轮的压缩机的动作响应。
根据该发明所涉及的第八方式，压缩机的制造方法包括第七方式中的叶轮的制造方法。
由此，能够将叶轮进行轻量化，从而能够有效地提高使用叶轮的压缩机的动作响应。
发明效果
根据上述的涂层结构、叶轮及压缩机，提高由镁合金构成的母材与由镍基合金构成的电镀层之间的粘附性，从而变得能够获得高耐蚀性及耐冲蚀性并且提高可靠性。
附图说明
图1是表示该发明的实施方式中的压缩机的概略结构的图。
图2是表示该发明的实施方式中的涂层结构的剖视图。
图3是该发明的实施方式中的叶轮的制造方法的流程图。
符号说明
1-压缩机，2-壳体，3-叶轮，4-旋转轴，5-涡轮，10-叶轮主体，11-化学转化层，12-电镀层。
具体实施方式
图1是表示该发明的实施方式中的压缩机的概略结构的图。
该实施方式中的压缩机例如为对内燃机进行增压的增压器中所设置的离心压缩机。
如图1所示，例如发动机中所使用的压缩机1通过叶轮(金属组件)3在壳体2内旋转而对壳体2内所送入的流体AR进行压缩。在此，关于叶轮3的形状及压缩机1的结构，并无任何限定。
叶轮3配置于壳体2内，对成为压缩对象的气体等流体AR进行压缩。叶轮3与被壳体2内所设置的轴承6以旋转自如的方式支撑的旋转轴4设置成一体。旋转轴4通过根据排气G旋转的涡轮5而绕其中心轴被旋转驱动。由此，叶轮3与旋转轴4一同旋转，并对流过壳体2内的流体AR进行压缩。
该实施方式中的压缩机1装配有进行排气再循环(EGR：Exhaust GasRecirculation)的系统，有时吸进包括含有冷凝水分的排气的空气。
图2是表示该发明的实施方式中的涂层结构的剖视图。图3是该发明的实施方式中的叶轮的制造方法的流程图。
如图2所示，叶轮3具备叶轮主体(母材)10、化学转化层11及电镀层12。如图3所示，该叶轮3的制造方法，首先进行形成叶轮主体10的工序(步骤S01)，然后进行形成化学转化层11的工序(步骤S02)，然后进行形成电镀层12的工序(步骤S03)。
叶轮主体10由镁合金构成。形成该叶轮主体10的镁合金含有：锌(Zn)；及选自由钆(Gd)、铽(Tb)、铥(Tm)及镥(Lu)构成的组中的至少一种元素，剩余部分由镁(Mg)构成。
在此，锌(Zn)的含量a(原子％)优选设为0.2≤a≤3.0。而且，选自由钆(Gd)、铽(Tb)、铥(Tm)及镥(Lu)构成的组中的至少一种元素的含量b(原子％)优选设为0.5≤b≤5.0。在此，进而，优选满足0.5a-0.5≤b这一关系。
当添加钆(Gd)时，进一步优选的上限含量小于3原子％。而且，钆(Gd)的含量与锌(Zn)的含量之比尤其优选为2:1或与其接近的比例。
通过设为这种含量比，尤其能够提高高强度、高韧性。
若要形成叶轮主体10，则通过溶解由前述组成构成的镁合金，并浇铸于模具，而形成镁合金铸造物。
该镁合金铸造物中析出有选自由镁(Mg)和稀土元素的化合物；镁(Mg)和锌(Zn)的化合物；锌(Zn)和稀土元素的化合物；及镁(Mg)、锌(Zn)、稀土元素的化合物构成的析出物组中的至少一种析出物。
接着，对镁合金铸造物实施溶体化处理。在该溶体化处理中，残留前述的至少一种析出物。
然后，对镁合金铸造物进行机械加工，得到规定形状的叶轮主体10。
作为该机械加工，例如能够利用挤出、ECAE(等径角挤压(equal-channel-angular-extrusion))加工法；轧制、拉拔、锻造及它们的重复加工；FSW(搅拌摩擦焊接)等伴随塑性变形的加工。
该塑性加工可以是轧制、挤出、ECAE、拉拔加工及锻造中的单独一种，也可以是它们的组合。
化学转化层11以覆盖叶轮主体10的表面的方式形成。化学转化层11例如由磷酸盐覆膜构成。磷酸盐覆膜由磷酸铁、磷酸锰及磷酸锌等磷酸盐构成。这种磷酸盐覆膜通过如下方式形成：清洗叶轮主体10后，在含有磷酸盐的水溶液中以规定时间浸渍成为母材的叶轮主体10。
由磷酸盐覆膜构成的化学转化层11至少在母材10的表面存在细微的凹凸等时，可以形成为以完全覆盖它们的程度的厚度。关于这种由磷酸盐覆膜构成的化学转化层11，若其膜厚过厚，则重量增加，对叶轮3旋转时的动作造成较恶劣的影响。
于是，由磷酸盐覆膜构成的化学转化层11优选形成为，其膜厚为0.5μm以上且5μm以下，更优选为2μm以上且5μm以下。
这种化学转化层11可以形成为多次重复进行形成磷酸盐覆膜的处理而将磷酸盐覆膜层叠为多层。
电镀层12以覆盖化学转化层11的方式形成。电镀层12为通过非电解电镀处理形成的由镍基合金构成的电镀膜。若举出具体例，则作为形成电镀层12的镍基合金，优选使用镍磷合金。
由镍磷合金构成的电镀层12形成为，其膜厚为10μm以上且30μm以下，更优选为15μm以上且30μm以下。
这种由镍基合金构成的电镀层12通过如下方式形成：将在表面形成有化学转化层11的母材即叶轮主体10以规定时间浸渍于电镀液而实施非电解电镀。
根据上述实施方式，具备：化学转化层11，其以覆盖由镁合金构成的叶轮主体10的表面的方式，通过化学转化处理所形成，且具有预先设定的范围内的膜厚；及电镀层12，其以覆盖化学转化层11的方式形成。根据这种结构，通过化学转化层11而电镀层12良好地粘附。通过具备这种电镀层12，能够具有高耐蚀性。
在具有这种涂层结构的叶轮3及具备有叶轮3的压缩机1中，通过由镁合金来形成叶轮3，能够具有高粘附性、耐蚀性，并且能够提高叶轮3及压缩机1的动作响应。
而且，化学转化层11为磷酸盐覆膜，电镀层12由镍磷合金形成。
由此，尤其能够有效地提高镁合金与电镀层12之间的粘附性。
而且，叶轮主体10含有锌(Zn)；及选自由钆(Gd)、铽(Tb)、铥(Tm)及镥(Lu)构成的组中的至少一种元素，剩余部分由镁(Mg)构成。而且，叶轮主体10具有选自由镁(Mg)和稀土元素的化合物；镁(Mg)和锌(Zn)的化合物；锌(Zn)和稀土元素的化合物；及镁(Mg)、锌(Zn)、稀土元素的化合物构成的析出物组中的至少一种析出物。
在由这种合金构成的叶轮主体10中，即便欲使用电镀层12直接包覆叶轮主体10，耐蚀性也会变差。在该情况下，通过介隔基于化学转化处理的化学转化层11，能够有效地提高叶轮主体10与电镀层12之间的粘附性。实施例
接着，关于如前述的涂层结构，确认了耐蚀性及有无发生冲蚀，因此示出其结果。
[母材]
首先，将含有2原子％的Gd及1原子％的Zn且剩余部分由Mg及不可避免的杂质构成的镁合金投入于真空熔炼炉而进行了溶解。
接着，将已加热溶解的材料放入模具内而进行铸造，以制作出由镁合金构成的150mm×60mm的长方形状的母材。
[表面处理]
清洗制作出的母材后，实施了如以下的表面处理。
(实施例1)
在母材的表面制膜磷酸盐覆膜后，实施了基于镍磷合金的电镀。
关于磷酸盐覆膜，在磷酸盐处理液中以规定时间浸渍母材，得到了膜厚3μm的磷酸盐覆膜。
基于镍磷合金的电镀,使用电镀浴实施了电镀处理。由此,得到了膜厚15μm的电镀层。
(比较例1)
不对母材实施表面处理而直接将母材作为试验片。
(比较例2)
在与实施例相同的条件下，在母材上仅形成了磷酸盐覆膜。
(比较例3)
对母材实施了树脂涂层。
树脂涂层中，使用Si系树脂，并通过涂抹在母材表面形成了树脂涂层。
(比较例4)
在与实施例相同的条件下，在母材上形成了磷酸盐覆膜之后，在与比较例3相同的条件下，实施了树脂涂层。
(比较例5)
在与实施例相同的条件下，对母材仅实施了基于镍磷合金的电镀处理。
(比较例6)
在与比较例3相同的条件下，对母材实施了树脂涂层后，在与实施例相同的条件下，实施了基于镍磷合金的电镀处理。
[膜的粘附性]
关于以前述的方式准备的实施例1及比较例1～6的试验片，首先，通过目视确认了对通过表面处理形成的膜对母材的粘附性。
将其结果示于表1中。
[表1]
其结果，关于实施例1及比较例2～5，在母材上形成有基于各自的表面处理的膜。
相对于此，对母材实施了树脂涂层后实施了基于镍磷合金的电镀处理的比较例6，确认到对实施了树脂涂层的母材进行电镀处理时所生成的电镀层的剥离。
[耐蚀性]
接着，对良好地形成膜的实施例1及比较例1～5，进行基于依照JIS标准“H 8502”的盐水喷雾循环试验的盐水喷雾试验，验证了耐蚀性。
分别对实施例1及比较例1～5，通过目视观察及测量腐蚀减量来确认试验片表面上所发生的腐蚀缺陷的状况，来进行了盐水喷雾试验后的评价。
其结果，如表1所示，在实施例1中，尤其未确认到腐蚀的发生。
相对于此，在母材其本身即比较例1中，整体确认到腐蚀。而且，在仅设置有磷酸盐覆膜的比较例2中，确认到腐蚀量多于比较例1。在仅基于树脂涂层的比较例3中，也确认到腐蚀量多于比较例1。
在设置有磷酸盐覆膜及树脂涂层的比较例4中，未确认到基于盐水喷雾试验的腐蚀。
在仅实施了基于Ni-P合金的电镀的比较例5中，确认到因盐水喷雾试验而电镀膜的剥离。
[耐冲蚀性]
接着，对在盐水喷雾试验中未确认到膜的剥离的实施例1及比较例1～4，进行在压缩机的入口加入水滴等的耐冲蚀试验，控制水滴量并且验证了有无发生冲蚀。
分别对实施例1及比较例1～4，通过以目视确认试验片表面来进行了有无发生冲蚀的评价。
其结果，如表1所示，在实施例1中，未确认到冲蚀的发生。
相对于此，在比较例1～4中分别确认到冲蚀的发生。
如此，仅设置有磷酸盐覆膜及基于Ni-P合金的电镀层的实施例1确认到膜的粘附性、耐蚀性及耐冲蚀性较高。
(其他实施方式)
该发明并不限定于上述实施方式，在不脱离该发明的宗旨的范围内，能够变更设计。
例如，在上述实施方式中，作为具有涂层结构的金属组件，例示了压缩机1用叶轮3。但是，并不限定于叶轮，能够使用于作为母材具备镁合金的其他各种金属部件。
而且，在上述实施方式中，例示了增压器的压缩机，但也能够适用于增压器以外的压缩机的叶轮。
而且，在上述实施方式中，例示了在磷酸盐覆膜上仅层叠1层由镍磷合金形成的电镀层的情况。但是，基于镍磷合金的电镀层并不限定于1层，也可以设置多层。例如，也可以在磷酸盐覆膜上层叠由镍磷合金构成的第一电镀层后，层叠同样由镍磷合金构成的第二电镀层。
当如此设置第一电镀层及第二电镀层时，与以1层来形成镍磷合金的电镀层的情况相比，能够使第一电镀层的膜厚变薄。因此，能够提高第一电镀层对磷酸盐覆膜的粘附性。
而且，形成第一电镀层及第二电镀层的镍磷合金的组成并不限定于相同组成的镍磷合金。例如，可以对第一电镀层使用对磷酸盐覆膜的粘附性高于第二电镀层的镍磷合金。
工业实用性
通过设置以覆盖由镁合金构成的母材的表面的方式，通过化学转化处理所形成，且具有预先设定的范围内的膜厚的化学转化层，能够提高电镀层的粘附性、耐蚀性。
权利要求书(按照条约第19条的修改)
1.一种涂层结构，其具备：
化学转化层，其作为主成分含有镁，且以覆盖由含有选自由钆、铽、铥及镥构成的组中的至少一种元素的镁合金构成的母材的表面的方式形成且由磷酸盐覆膜构成；及
电镀层，其以覆盖所述化学转化层的方式形成且由镍基合金构成。
2.根据权利要求1所述的涂层结构，其中，
所述电镀层由镍磷合金形成。
3.根据权利要求1或2所述的涂层结构，其中，
所述母材，
含有a原子％的锌，以合计含有b原子％的选自由钆、铽、铥及镥构成的组中的至少一种元素，剩余部分由镁构成，且a及b满足下述式(1)～(3)，
并且，具有选自由镁和稀土元素的化合物；镁和锌的化合物；锌和稀土元素的化合物；及镁、锌、稀土元素的化合物构成的析出物组中的至少一种析出物：
(1)0.2≤a≤5.0；
(2)0.5≤b≤5.0；
(3)0.5a-0.5≤b。
4.一种叶轮，其具有权利要求1～3中任一项所述的涂层结构。
5.一种压缩机，其具备权利要求4所述的叶轮。
6.一种金属组件的制造方法，其包括：
通过以覆盖由作为主成分含有镁的镁合金构成的母材的表面的方式进行化学转化处理而形成化学转化层的工序；及
以覆盖所述化学转化层的方式形成由镍基合金构成的电镀层的工序。
7.一种叶轮的制造方法，其包括权利要求6所述的金属组件的制造方法。
8.一种压缩机的制造方法，其包括权利要求7所述的叶轮的制造方法。

Claims (8)

1.一种涂层结构，其具备：
化学转化层，其以覆盖由作为主成分含有镁的镁合金构成的母材的表面的方式形成且由磷酸盐覆膜构成；及
电镀层，其以覆盖所述化学转化层的方式形成且由镍基合金构成。
2.根据权利要求1所述的涂层结构，其中，
所述电镀层由镍磷合金形成。
3.根据权利要求1或2所述的涂层结构，其中，
所述母材，
含有a原子％的锌，以合计含有b原子％的选自由钆、铽、铥及镥构成的组中的至少一种元素，剩余部分由镁构成，且a及b满足下述式(1)～(3)，
并且，具有选自由镁和稀土元素的化合物；镁和锌的化合物；锌和稀土元素的化合物；及镁、锌、稀土元素的化合物构成的析出物组中的至少一种析出物：
(1)0.2≤a≤5.0；
(2)0.5≤b≤5.0；
(3)0.5a-0.5≤b。
4.一种叶轮，其具有权利要求1～3中任一项所述的涂层结构。
5.一种压缩机，其具备权利要求4所述的叶轮。
6.一种金属组件的制造方法，其包括：
通过以覆盖由作为主成分含有镁的镁合金构成的母材的表面的方式进行化学转化处理而形成化学转化层的工序；及
以覆盖所述化学转化层的方式形成由镍基合金构成的电镀层的工序。
7.一种叶轮的制造方法，其包括权利要求6所述的金属组件的制造方法。
8.一种压缩机的制造方法，其包括权利要求7所述的叶轮的制造方法。
CN201580081249.2A 2015-10-01 2015-10-01 涂层结构、叶轮、压缩机、金属组件的制造方法、叶轮的制造方法及压缩机的制造方法 Pending CN107709616A (zh)

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