CN110382726A - 斜圈弹簧用线材和斜圈弹簧 - Google Patents

斜圈弹簧用线材和斜圈弹簧 Download PDF

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Publication number
CN110382726A
CN110382726A CN201780088212.1A CN201780088212A CN110382726A CN 110382726 A CN110382726 A CN 110382726A CN 201780088212 A CN201780088212 A CN 201780088212A CN 110382726 A CN110382726 A CN 110382726A
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China
Prior art keywords
coil spring
mass
canted coil
wire rod
hard layer
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Pending
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CN201780088212.1A
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English (en)
Inventor
赤田匠
泉田宽
细江晃久
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Sumitomo Corp
Sumitomo Electric Industries Ltd
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Sumitomo Corp
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Publication of CN110382726A publication Critical patent/CN110382726A/zh
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
    • B32B15/015—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium the said other metal being copper or nickel or an alloy thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/043—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
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    • C—CHEMISTRY; METALLURGY
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    • C—CHEMISTRY; METALLURGY
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    • C22C38/00—Ferrous alloys, e.g. steel alloys
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    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
    • C—CHEMISTRY; METALLURGY
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    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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Abstract

一种斜圈弹簧用线材，所述斜圈弹簧用线材包含：芯线，所述芯线由具有珠光体结构的钢构成；铜镀层，所述铜镀层覆盖所述芯线的外周表面并由铜或铜合金构成；和硬质层，所述硬质层邻近所述铜镀层的外周设置并且具有高于所述铜镀层的硬度。构成所述芯线的所述钢含有0.5质量％以上且1.0质量％以下的碳、0.1质量％以上且2.5质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。

Description

斜圈弹簧用线材和斜圈弹簧
技术领域
本发明涉及一种斜圈弹簧用线材和斜圈弹簧。本申请要求基于2017年3月10日提交的日本专利申请号2017-045720的优先权，该日本专利申请中所记载的所有内容通过引用并入本文中。
背景技术
已知斜圈弹簧为各自具有其中线材(金属线)以与垂直于轴向的平面成一定角度卷绕的结构的螺旋弹簧(例如，参考专利文献1)。这样的斜圈弹簧具有在垂直于轴向方向的方向上的一定位移范围内弹簧载荷保持基本恒定的性质(非线性)。由导电材料制造的斜圈弹簧例如可以作为触点部件使用。作为构成用于触点部件的斜圈弹簧的材料，通常使用铍铜。从同时实现高水平的强度和导电性的观点考虑，铍铜适合作为构成斜圈弹簧的材料。
然而，铍铜中含有的铍是昂贵的材料。另外，铍是具有高环境影响的材料。因此，期望开发一种铍铜的替代材料用作构成斜圈弹簧的材料。
为了解决这一问题，提出了一种斜圈弹簧用线材和通过卷绕所述线材而得到的斜圈弹簧，在所述斜圈弹簧用线材中将由奥氏体不锈钢构成的芯线和由诸如铜或铜合金构成的、单独设置而作为外层的构件一体化而形成包层线(例如，参考专利文献2)。
现有技术文献
专利文献
专利文献1：日本特开平4-107331号公报
专利文献2：日本特开2012-248495号公报
发明内容
技术方案
根据本发明的斜圈弹簧包含由具有珠光体结构的钢构成的芯线、覆盖所述芯线的外周表面并由铜或铜合金构成的铜镀层、和邻近所述铜镀层的外周设置并且具有高于所述铜镀层的硬度的硬质层。所述钢含有0.5质量％以上且1.0质量％以下的碳、0.1质量％以上且2.5质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
附图说明
图1为显示垂直于斜圈弹簧用线材的纵向的横截面的示意性横截面图。
图2为显示铜镀层和硬质层之间的边界区域的结构的示意性横截面图。
图3为显示斜圈弹簧的结构的示意图。
图4为说明制造斜圈弹簧用线材和斜圈弹簧的方法的流程图。
图5为说明制造斜圈弹簧用线材和斜圈弹簧的方法的示意性横截面图。
图6为说明制造斜圈弹簧用线材和斜圈弹簧的方法的示意性横截面图。
图7显示转动弯曲疲劳实验的结果。
图8显示转动弯曲疲劳实验的结果。
图9显示应力循环次数和电导率之间的关系
图10显示应力循环次数和电导率之间的关系。
具体实施方式
[本公开要解决的问题]
发明人进行的研究已经揭示了专利文献2中记载的斜圈弹簧具有弹簧载荷对在垂直于轴向的方向上的位移基本恒定的位移范围即非线性区域窄的问题。此外，在具有导电性的斜圈弹簧中，导电性稳定也很重要。
因此，本发明的目的在于提供一种斜圈弹簧用线材和斜圈弹簧，所述线材由铍铜的替代材料构成、具有宽的非线性区域、并且能够实现稳定的导电性。
[本公开的有益效果]
根据所述斜圈弹簧用线材，可以提供一种斜圈弹簧用线材，所述线材由铍铜的替代材料构成、具有宽的非线性区域、并且能够实现稳定的导电性。
[本发明的实施方式的说明]
首先列出并解释本发明的实施方式。根据本发明的斜圈弹簧用线材包含由具有珠光体结构的钢构成的芯线、覆盖所述芯线的外周表面并且由铜或铜合金构成的铜镀层、和邻近所述铜镀层的外周设置并且具有高于所述铜镀层的硬度的硬质层。所述钢含有0.5质量％以上且1.0质量％以下的碳、0.1质量％以上且2.5质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
在根据本发明的斜圈弹簧用线材中，使用由具有珠光体结构和适当的成分组成的钢构成的高强度芯线，由此能够确保宽的非线性区域。芯线的外周表面覆盖有由铜或铜合金构成的、具有良好的导电性的铜镀层。
由此，确保高导电性。
根据本发明的斜圈弹簧用线材不是通过将芯线与作为外层的单独设置的构件一体化而形成的包层线，而是具有铜镀层设置在芯线的外周表面上的结构。本发明人的研究表明，在由包层线得到的斜圈弹簧中，当施加载荷时发生外层相对于芯线移位的现象。这种现象是非线性区域变窄的主要因素。与此相对，在根据本发明的斜圈弹簧用线材中，所述线材包含设置在芯线的外周表面上的铜镀层，抑制了该现象的发生，从而能够确保宽的非线性区域。
根据本发明的斜圈弹簧用线材进一步包含邻近铜镀层的外周设置的硬质层。在斜圈弹簧的使用状态下，在越靠近外周表面的位置重复施加越大的应力。本发明人的研究表明，重复的应力可能导致铜镀层的疲劳破坏，从而降低导电性。与此相对，具有高于铜镀层的硬度的硬质层邻近铜镀层的外周设置，即设置在起作用的应力大的一侧，因此，可以抑制由于铜镀层的疲劳破坏而导致的导电性降低。这使得能够实现稳定的导电性。
如上所述，在根据本发明的斜圈弹簧用线材中，可以提供一种斜圈弹簧用线材，所述线材由铍铜的替代材料构成、具有宽的非线性区域、并且能够实现稳定的导电性。
在斜圈弹簧用线材中，所述钢可以进一步含有选自由0.1质量％以上且0.4质量％以下的镍、0.1质量％以上且1.8质量％以下的铬、0.1质量％以上且0.4质量％以下的钼、和0.05质量％以上且0.3质量％以下的钒构成的组中的一种以上的元素。即使使用由具有这种成分组成的钢构成的芯线，也可以提供一种斜圈弹簧用线材，所述线材由铍铜的替代材料构成并且能够实现宽的非线性区域。
下面将说明构成芯线的钢的成分组成限于上述范围的原因。
碳(C)：0.5质量％以上且1.0质量％以下
碳是一种极大地影响具有珠光体结构的钢的强度和弹性极限的元素。从实现足以作为用于斜圈弹簧用线材的芯线的强度和弹性极限的观点考虑，碳含量需要为0.5质量％以上。较高的碳含量导致韧性降低，从而可能使得加工芯线变得困难。从确保足够的韧性的观点考虑，碳含量需要为1.0质量％以下。从进一步提高强度和弹性极限的观点考虑，碳含量优选为0.6质量％以上，更优选为0.8质量％以上。从提高韧性以易于加工的观点考虑，碳含量优选为0.95质量％以下。
硅(Si)：0.1质量％以上且2.5质量％以下
硅是在钢的精炼中作为脱氧剂添加的元素。为了实现其作为脱氧剂的功能，硅含量需要为0.1质量％以上，优选为0.12质量％以上。另外，硅在钢中作为形成碳化物的元素，并且具有抑制由于加热导致的软化的性质(抗软化性)。从在卷绕线材后进行的应变消除热处理中抑制软化的观点考虑，硅含量优选为0.8质量％以上，并且可以为1.8质量％以上。过量添加硅会导致韧性降低。从确保足够的韧性的观点考虑，硅含量需要为2.5质量％以下，优选为2.3质量％以下，并且可以为2.2质量％以下。从重视韧性的观点考虑，硅含量可以为1.0质量％以下。
锰(Mn)：0.3质量％以上且0.9质量％以下
与硅一样，锰是在钢的精炼中作为脱氧剂添加的元素。为了实现其作为脱氧剂的功能，锰含量需要为0.3质量％以上。
过量添加锰会导致韧性和热加工中的可加工性降低。因此，锰含量需要为0.9质量％以下。
不可避免的杂质
在制造芯线的工序中，磷(P)和硫(S)不可避免地混入构成芯线的钢中。过量存在的磷和硫导致晶界偏析和夹杂物的形成，从而降低钢的性能。因此，磷含量和硫含量各自优选为0.025质量％以下。不可避免的杂质的总含量优选为0.3质量％以下。
镍(Ni)：0.1质量％以上且0.4质量％以下
镍的添加抑制拉伸芯线的过程中芯线的断裂和卷绕过程中线材的断裂。从可靠地发挥该功能的观点考虑，可以以0.1质量％以上的量添加镍。如果以超过0.4质量％的量添加镍，则镍的上述效果饱和。另外，如果以超过0.4质量％的量添加作为昂贵元素的镍，则芯线的制造成本增加。因此，镍的添加量优选为0.4质量％以下。
铬(Cr)：0.1质量％以上且1.8质量％以下
铬在钢中作为形成碳化物的元素，并且有助于通过形成微细的碳化物而形成较微细的金属微结构和在加热时抑制软化。从可靠地发挥该效果的观点考虑，铬可以以0.1质量％以上、0.2质量％以上或0.5质量％以上的量添加。过量添加铬会导致韧性降低。因此，铬的添加量优选为1.8质量％以下。在硅和钒共存时，通过添加铬得到的效果特别显著。因此，优选将铬与这些元素一起添加。
钼(Mo)：0.1质量％以上且0.4质量％以下
钼的添加能够提高弹性极限。从可靠地发挥该效果的观点考虑，可以以0.1质量％以上的量添加钼。如果以大于0.4质量％的量添加钼，则钼的效果饱和。另外，如果作为昂贵元素的钼的添加量超过0.4质量％，则芯线的制造成本增加。因此，钼的添加量优选为0.4质量％以下。
钒(V)：0.05质量％以上且0.3质量％以下
钒在钢中作为形成碳化物的元素，并且有助于通过形成微细的碳化物而形成较微细的金属微结构和在加热时抑制软化。从可靠地发挥该效果的观点考虑，可以以0.05质量％以上的量添加钒。过量添加钒会导致韧性降低。从确保足够的韧性的观点考虑，添加的钒的量优选为0.3质量％以下。在硅和铬共存时，通过添加钒得到的效果特别显着。因此，优选将钒与这些元素一起添加。
在斜圈弹簧用线材中，所述钢可以具有1.35质量％以上且2.3质量％以下的硅含量。硅含量为1.35质量％以上抑制应变消除热处理中的软化。硅含量为2.3质量％以下引起抑制韧性的降低。
在斜圈弹簧用线材中，所述钢可以含有0.6质量％以上且1.0质量％以下的碳、0.12质量％以上且0.32质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
在斜圈弹簧用线材中，所述钢可以含有0.6质量％以上且1.0质量％以下的碳、0.7质量％以上且1.0质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
在斜圈弹簧用线材中，所述钢可以含有0.55质量％以上且0.7质量％以下的碳、1.35质量％以上且2.3质量％以下的硅、0.3质量％以上且0.9质量％以下的锰、0.2质量％以上且1.8质量％以下的铬、和0.05质量％以上且0.30质量％以下的钒，剩余部分为铁和不可避免的杂质。
当将具有这种成分组成的钢用作构成芯线的钢时，可以更可靠地得到宽的非线性区域。
在斜圈弹簧用线材中，硬质层可以具有300HV以上的硬度。在这种情况下，可以更可靠地实现稳定的导电性。
在斜圈弹簧用线材中，硬质层可以具有比铜镀层的硬度高50HV以上的硬度。在这种情况下，可以更可靠地实现稳定的导电性。硬质层可以具有为芯线的硬度以下。
在斜圈弹簧用线材中，硬质层的厚度对铜镀层的厚度之比可以为1/10以上且小于1。即，(硬质层的厚度)/(铜镀层的厚度)的值可以为1/10以上且小于1。当该比例为1/10以上时，可以更可靠地实现稳定的导电性。当该比例小于1时，可以避免生产效率的降低。在将镀层用作硬质层的情况下，使用小于1的比例能够抑制由于在形成硬质层时氢的进入而导致的韧性的降低。该比例优选为1/3以上。该比例优选为3/4以下。
在斜圈弹簧用线材中，硬质层可以是镀层。在这种情况下，可以容易地形成硬质层。
在斜圈弹簧用线材中，硬质层可以是镍层或铬层。作为构成硬质层的材料，可以使用具有良好强度和良好导电性的镍或铬。硬质层特别优选为镍层。使用镍层作为硬质层有助于在硬质层上形成金层或银层作为镀层。
斜圈弹簧用线材可以具有900MPa以上且3000MPa以下的拉伸强度。在900MPa以上的拉伸强度下，容易得到足够的抗永久形变性(耐へたり性)。在3000MPa以下的拉伸强度下，容易确保足够的韧性。斜圈弹簧用线材优选具有1500MPa以上的拉伸强度。斜圈弹簧用线材优选具有2500MPa以下的拉伸强度。
斜圈弹簧用线材可以具有15％IACS以上(根据国际退火铜标准(IACS)；(3.87×108/Ω·m以上))且50％IACS以下(1.29×109/Ω·m以下)的电导率。在这种情况下，可以得到能够制造适用于触点部件的斜圈弹簧的斜圈弹簧用线材。斜圈弹簧用线材优选具有25％IACS以上的电导率。斜圈弹簧用线材优选具有40％IACS以下的电导率。
在斜圈弹簧用线材中，可以在铜镀层和硬质层之间设置有含有构成铜镀层的金属元素和构成硬质层的金属元素的合金区域。在这种情况下，可以得到铜镀层和硬质层牢固地结合在一起的斜圈弹簧用线材。
在斜圈弹簧用线材中，硬质层可以是镍层，并且合金区域可以含有铜和镍。在这种情况下，可以得到包含牢固地结合在一起的铜镀层和硬质层的斜圈弹簧用线材。
在斜圈弹簧用线材中，在硬质层上以包含斜圈弹簧用线材的外周表面的方式设置有金层、银层或锡层。在这种情况下，当斜圈弹簧作为触点部件使用时，可以减小接触电阻。
在斜圈弹簧用线材中，芯线和铜镀层之间的界面处的氧浓度可以为10质量％以下。在这种情况下，可以更可靠地得到宽的非线性区域。
在斜圈弹簧用线材中，铜镀层可以具有10μm以上且65μm以下的厚度。当铜镀层具有10μm以上的厚度时，容易得到足够的导电性。当铜镀层具有65μm以下的厚度时，容易得到高强度和高弹性极限。由此，容易得到宽的非线性区域。
从得到更宽的非线性区域的观点考虑，铜镀层可以具有50μm以下的厚度。
在斜圈弹簧用线材中，芯线可以具有0.05mm以上且2.0mm以下的直径。在这种情况下，可以得到特别适合用于斜圈弹簧的制造的斜圈弹簧用线材。
根据本发明的斜圈弹簧由斜圈弹簧用线材构成。因为根据本发明的斜圈弹簧由根据本发明的斜圈弹簧用线材构成，因此可以提供由铍铜的替代材料构成并且具有宽非线性区域和稳定的导电性的斜圈弹簧。
[本发明的实施方式的具体说明]
在下文中，将参考附图说明根据本发明的实施方式的斜圈弹簧用线材和斜圈弹簧。在附图中，使用相同的附图标记表示相同或等同的部分，并且不重复说明。
如图1所示，根据本实施方式的斜圈弹簧用线材1包含芯线10、铜镀层20、硬质层30和表面层40。芯线10由具有珠光体结构的钢构成。铜镀层20覆盖芯线10的外周表面11并设置为与外周表面11接触。铜镀层20由铜或铜合金构成。作为铜合金，例如可以使用铜和选自由锌、锡、磷和铁构成的组中的至少一种金属的合金。
邻近铜镀层20的外周设置硬质层30。将硬质层30设置为与铜镀层20的外周表面21接触以覆盖外周表面21。硬质层30具有高于铜镀层20的硬度。
邻近硬质层30的外周设置表面层40。将表面层40设置为与硬质层30的外周表面31接触以覆盖外周表面31。将表面层40设置为包含斜圈弹簧用线材1的外周表面。也就是说，将表面层40设置为斜圈弹簧用线材1的最外表面。表面层40为金层、银层或锡层。斜圈弹簧用线材1具有垂直于线材的纵向的圆形横截面。
构成芯线10的钢含有0.5质量％以上且1.0质量％以下的碳、0.1质量％以上且2.5质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
如图2所示，在铜镀层20和硬质层30之间设置有含有构成铜镀层20的金属元素和构成硬质层30的金属元素的合金区域50。合金区域50设置在铜镀层20和硬质层30之间的界面处，也就是说，铜镀层20和硬质层30设置为彼此接触以在它们之间的界面处形成合金区域。
如图3所示，根据本实施方式的斜圈弹簧2由根据本实施方式的斜圈弹簧用线材1形成。斜圈弹簧2为螺旋弹簧，并且具有斜圈弹簧用线材1以与垂直于轴向的平面成一定角度卷绕的结构。斜圈弹簧2以在垂直于轴向的方向上施加载荷的方式使用。
根据本实施方式的斜圈弹簧用线材1和斜圈弹簧2各自包含由具有珠光体结构和适当的成分组成的钢构成的高强度芯线10。由此，可以确保宽的非线性区域。芯线10具有由具有良好导电性的铜或铜合金构成的铜镀层20覆盖的外周表面11。由此，确保高导电性。
斜圈弹簧用线材1和斜圈弹簧2各自不是通过将芯线与作为外层的单独设置的构件一体化而形成的包层线，而是具有铜镀层20设置在芯线10的外周表面11上的结构。这抑制当施加载荷时发生作为外层的铜镀层20相对于芯线10移位的现象。由此，可以确保宽的非线性区域。
斜圈弹簧用线材1和斜圈弹簧2各自包含邻近铜镀层20的外周设置的硬质层30。具有高于铜镀层20的硬度的硬质层30邻近铜镀层20的外周设置，即设置在起作用的应力大的一侧；因此，可以抑制由于铜镀层20的疲劳破坏而导致的导电性降低。这使得能够实现稳定的导电性。
如上所述，斜圈弹簧用线材1和斜圈弹簧2为由铍铜的替代材料构成的、具有宽的非线性区域、并且能够实现稳定的导电性的斜圈弹簧用线材和斜圈弹簧。
在根据本实施方式的斜圈弹簧用线材1和斜圈弹簧2中，合金区域50设置在铜镀层20和硬质层30之间。虽然合金区域50的形成不是必需的，但是合金区域50的存在将铜镀层20和硬质层30牢固地结合在一起。
在斜圈弹簧用线材1和斜圈弹簧2各自的硬质层30上以包含斜圈弹簧用线材1和斜圈弹簧2各自的外周表面的方式设置有表面层40。虽然表面层40的形成不是必需的，但是当斜圈弹簧2作为触点部件使用时，表面层40的存在能够减小接触电阻。
在各斜圈弹簧用线材1和斜圈弹簧2中，构成芯线10的钢可以进一步含有选自由0.1质量％以上且0.4质量％以下的镍、0.1质量％以上且1.8质量％以下的铬、0.1质量％以上且0.4质量％以下的钼、和0.05质量％以上且0.3质量％以下的钒构成的组中的一种以上的元素。另外，在使用具有这样的成分组成的芯线10的情况下，斜圈弹簧用线材1和斜圈弹簧2由铍铜的替代材料构成，并且可以得到宽的非线性区域。
在各斜圈弹簧用线材1和斜圈弹簧2中，构成芯线10的钢可以具有1.35质量％以上且2.3质量％以下的硅含量。1.35质量％以上的硅含量引起抑制由于应变消除热处理而导致的软化。2.3质量％以下的硅含量引起抑制韧性的降低。
在各斜圈弹簧用线材1和斜圈弹簧2中，构成芯线10的钢可以含有0.6质量％以上且1.0质量％以下的碳、0.12质量％以上且0.32质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
在各斜圈弹簧用线材1和斜圈弹簧2中，构成芯线10的钢可以含有0.6质量％以上且1.0质量％以下的碳、0.7质量％以上且1.0质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
在各斜圈弹簧用线材1和斜圈弹簧2中，构成芯线10的钢可以含有0.55质量％以上且0.7质量％以下的碳、1.35质量％以上且2.3质量％以下的硅、0.3质量％以上且0.9质量％以下的锰、0.2质量％以上且1.8质量％以下的铬、和0.05质量％以上且0.30质量％以下的钒，剩余部分为铁和不可避免的杂质。
当将具有这样的成分组成的钢用作构成芯线10的钢时，可以更可靠地得到宽的非线性区域。
在各斜圈弹簧用线材1和斜圈弹簧2中，芯线10和铜镀层20之间的界面处的氧浓度优选为10质量％以下。在这种情况下，可以更可靠地得到宽的非线性区域。芯线10和铜镀层20之间的界面处的氧浓度例如可以通过如下方式来测定：在斜圈弹簧用线材1的垂直于纵向的横截面中，通过能量色散X射线光谱法(EDS)对包含芯线10和铜镀层20之间的界面的、具有300μm边长的正方形区域进行定量分析。
硬质层30优选具有300HV以上的硬度。在这种情况下，可以更可靠地实现稳定的导电性。硬质层30优选具有比铜镀层20高50HV以上的硬度。在这种情况下，可以更可靠地实现稳定的导电性。硬质层30可以具有小于等于芯线10的硬度。硬度(维氏硬度)的测定可以在载荷为50g、保持时间为10秒的条件下进行。硬质层30可以具有例如1μm以上且50μm以下的厚度。
硬层30的厚度对铜镀层20的厚度之比优选为1/10以上且小于1。在该比例为1/10以上时，可以更可靠地实现稳定的导电性。在该比例小于1时，可以避免生产效率的降低。
硬质层30优选为镀层。在这种情况下，可以容易地形成硬质层30。
硬质层30优选为镍层或铬层。作为构成硬质层30的材料，优选使用具有良好强度和良好导电性的镍或铬。
硬质层30特别优选为镍层。通过镀敷可以容易地形成镍层或铬层。也就是说，硬质层30可以为镍镀层或铬镀层。
斜圈弹簧用线材1优选具有900MPa以上且3000MPa以下的拉伸强度。在拉伸强度为900MPa以上时，容易得到足够的抗永久形变性。在拉伸强度为3000MPa以下时，容易确保足够的韧性。
斜圈弹簧用线材1和斜圈弹簧2各自优选具有15％IACS以上且50％IACS以下的电导率。在这种情况下，斜圈弹簧2适合作为触点部件。
当硬质层30为镍层时，合金区域50优选含有铜和镍。当硬质层30为镍层时，合金区域50优选为铜镍合金区域。在这种情况下，铜镀层20和硬质层30牢固地结合在一起。
在各斜圈弹簧用线材1和斜圈弹簧2中，铜镀层20优选具有10μm以上且65μm以下的厚度。当铜镀层20具有10μm以上的厚度时，容易得到足够的导电性。当铜镀层20具有65μm以下的厚度时，容易得到高强度和高弹性极限。由此，容易得到宽的非线性区域。
在斜圈弹簧用线材1中，芯线10优选具有0.05mm以上且2.0mm以下的直径。在这种情况下，可以得到特别适合用于斜圈弹簧的制造的斜圈弹簧用线材。
以下将说明制造斜圈弹簧用线材1和斜圈弹簧2的方法的一个例子。如图4所示，在根据本实施方式的用于制造斜圈弹簧用线材1和斜圈弹簧2的方法中，首先进行原料钢丝准备步骤作为步骤(S10)。在该步骤(S10)中，准备作为芯线10的钢丝。具体而言，准备一种钢丝，其由含有0.5质量％以上且1.0质量％以下的碳、0.1质量％以上且2.5质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰且剩余部分为铁和不可避免的杂质的钢构成。构成钢丝的钢还可以进一步含有选自由0.1质量％以上且0.4质量％以下的镍、0.1质量％以上且1.8质量％以下的铬、0.1质量％以上且0.4质量％以下的钼、和0.05质量％以上且0.3质量％以下的钒构成的组中的一种以上的元素。
进行派敦处理(patenting)作为步骤(S20)。在该步骤(S20)中，对在步骤(S10)中准备的原料钢丝进行派敦处理。
具体而言，进行如下的热处理：将原料钢丝加热至奥氏体化温度(A1点)以上的温度范围，然后迅速冷却至高于马氏体转变起始温度(Ms点)的温度范围，并保持在该温度范围内。由此，原料钢丝的金属结构形成为具有小的层间距的微细珠光体结构。在此，在派敦处理中，从抑制发生脱碳的观点考虑，将原料钢丝加热至A1点以上的温度范围的处理在非活性气体气氛下实施。
接着，进行第一拉伸步骤作为步骤(S30)。在该步骤(S30)中，对在步骤(S20)中经过派敦处理的原料钢丝进行拉丝(拉伸处理)。如图5所示，得到具有珠光体结构和垂直于纵向的圆形横截面的芯线10。
进行镀敷步骤作为步骤(S40)。如图5和图6所示，在该步骤(S40)中，形成覆盖在步骤(S30)中得到的芯线10的外周表面11的多个镀层。首先，形成由铜或铜合金构成的铜镀层20。在步骤(S40)中形成的铜镀层20的厚度例如为30μm以上且90μm以下。然后在铜镀层20上形成硬质层30。具体而言，进行镀镍或镀铬以形成用作硬质层30的镍镀层或铬镀层。接下来，在硬质层30上形成表面层40。具体而言，在硬质层30上形成作为表面层40的金镀层、银镀层、锡镀层。由此，如图6所示，在芯线10上形成铜镀层20、硬质层30和表面层40。
进行第二拉伸步骤作为步骤(S50)。如图6和图1所示，在该步骤(S50)中，对在步骤(S40)中已在其上形成铜镀层20、硬质层30和表面层40的芯线10进行拉伸处理。由此，得到具有适合用于期望的斜圈弹簧2的线径的斜圈弹簧用线材1。通过上述步骤，完成了本实施方式中的斜圈弹簧用线材1的制造。以下将对通过使用斜圈弹簧用线材1制造斜圈弹簧2的方法进行说明。
进行卷绕步骤作为步骤(S60)。如图1和图2所示，在该步骤(S60)中，将在步骤(S50)中得到的斜圈弹簧用线材1加工成为斜圈弹簧2的形状。具体而言，将斜圈弹簧用线材1加工成螺旋形状并被成形为斜圈弹簧2的形状。
进行应变消除步骤作为步骤(S70)。在该步骤(S70)中，对已经在步骤(S60)中成形为斜圈弹簧2的形状的斜圈弹簧用线材1进行热处理，以将线材1加热至例如250℃至400℃的温度范围。这减少在步骤(S60)中引入到斜圈弹簧用线材1的应变。因此，能够得到宽的非线性区域。通过上述步骤，完成了根据本实施方式的斜圈弹簧2的制造。
实施例
准备根据本发明的斜圈弹簧用线材。进行测量拉伸强度和电导率以及确认疲劳强度和电导率稳定性的实验。实验步骤如下所述。
进行步骤(S10)至(S50)以制造斜圈弹簧用线材。各个芯线10的直径为0.42mm或0.32mm。使用含有0.63质量％以上且0.68质量％以下的碳、1.80质量％以上且2.20质量％以下的硅、0.70质量％以上且0.90质量％以下的锰、0.50质量％以上且0.80质量％以下的铬、和0.05质量％以上且0.15质量％以下的钒且剩余部分为铁和不可避免的杂质的钢作为构成芯线10的钢。作为杂质含有的磷和硫各自的含量为0.025质量％以下。使用由铜合金构成的层作为铜镀层20。使用镍(Ni)层或铬(Cr)层作为硬质层30。省略表面层40的形成(样品A至E)。提供省略硬质层30的类似线材作为本发明的范围以外的线材(样品F和G)以用于比较。提供直径为0.42mm并且由铍铜构成的线材作为本发明的范围以外的线材(样品H)以用于比较。测量各个样品的拉伸强度和电导率。拉伸强度由岛津公司提供的SD-500-C拉伸试验机测量。电导率由Hioki E.E.公司提供的3522LCR HiTESTER测量。表1显示了样品和测试结果的详情。
表1
如表1所示，作为根据本发明的斜圈弹簧用线材的样品A至C、D和E的拉伸强度和电导率等于或高于具有相同芯线直径和相同铜镀层厚度的样品G和F的拉伸强度和电导率。作为根据本发明的斜圈弹簧用线材的样品A至E具有相当于或高于作为由铍铜构成的线材的样品H的拉伸强度和电导率。结果表明，在根据本发明的斜圈弹簧用线材中，没有发现由于硬质层的形成而导致的明显缺点，并且确保了相当于或高于由铍铜构成的线材的拉伸强度和电导率。
进行实验来确认这些线材的疲劳强度和电导率的稳定性。利用亨特疲劳试验机进行转动弯曲疲劳实验，以确认施加的应力与直至断裂的应力循环次数之间的关系。疲劳强度定义为施加107次应力循环后未发生断裂的应力。此外，利用亨特疲劳试验机在300MPa的施加应力下进行转动弯曲疲劳实验，以确认在预定的施加应力循环之后的电导率。电导率的稳定性通过施加107次应力循环后的电导率来评价。当施加107次应力循环后的电导率(实验后的电导率)为15％IACS以上时，可以评价为电导率的稳定性足以用于实际应用。
图7和8示出了疲劳强度实验的结果。在图7和图8的每个图中，横轴表示应力循环次数，纵轴表示应力振幅。图7示出当芯线10具有0.42mm的直径时的实验结果。图8示出当芯线10具有0.32mm的直径时的实验结果
图7和8以及表1表明，在直径为0.42mm和0.32mm的芯线10的任意情况下，作为根据本发明的斜圈弹簧用线材的样品A至E具有等于或高于具有超出本发明范围的疲劳强度的线材F和G的疲劳强度。另外，作为根据本发明的斜圈弹簧用线材的样品A至C具有等于或高于作为由铍铜构成的线材的样品H的疲劳强度。
图9和10显示确认电导率稳定性的实验结果。在图9和10的每个图中，横轴表示应力循环次数，纵轴表示电导率。图9示出了当芯线10具有0.42mm的直径时的实验结果。图10示出了当芯线10具有0.32mm的直径时的实验结果
图9和10以及表1表明，在直径为0.42mm和0.32mm的芯线10的任意情况下，作为根据本发明的斜圈弹簧用线材的样品A至E维持等于或高于具有本发明的范围以外的电导率的线材F和G的电导率值。另外，作为根据本发明的斜圈弹簧用线材的样品A至E即使在施加107次应力循环后也具有15％IACS以上的电导率。因此，可以评价为样品具有足以用于实际应用的电导率稳定性。
上述实验结果表明，根据本发明的斜圈弹簧用线材可以实现足够的强度和稳定的导电性。
[附录]
如上所述，在根据本发明的斜圈弹簧用线材中，可以提供一种由铍铜的替代材料构成、具有宽的非线性区域、并且能够实现稳定的导电性的斜圈弹簧用线材。这种线材并不是只能用于斜圈弹簧，而是可以用于普通弹簧。根据包含由具有珠光体结构和适当的成分组成的钢构成的高强度芯线、铜镀层和硬质层的线材，可以制造能够维持高排斥力同时确保稳定的导电性的弹簧。因此，所述线材适合作为用于弹簧(螺旋弹簧)如开关用弹簧(导电弹簧)的制造的弹簧用线材。另外，由所述线材形成的弹簧适合作为弹簧(螺旋弹簧)如开关用弹簧(导电弹簧)。
本公开的实施方式和实施例只是为了进行说明并且在任何方面都不是限制性的。本发明的范围由权利要求的各项限定，而不限定于上述说明，并且旨在包含在与所述权利要求的各项等同的意义和范围内的任何修改。
标号说明
1：斜圈弹簧用线材
2：斜圈弹簧
10：芯线
11：外周表面
20：铜镀层
21：外周表面
30：硬质层
31：外周表面
40：表面层
50：合金区域

Claims (13)

1.一种斜圈弹簧用线材，所述线材包含：
芯线，所述芯线由具有珠光体结构的钢构成；
铜镀层，所述铜镀层覆盖所述芯线的外周表面并由铜或铜合金构成；和
硬质层，所述硬质层邻近所述铜镀层的外周设置并且具有高于所述铜镀层的硬度，
所述钢含有0.5质量％以上且1.0质量％以下的碳、0.1质量％以上且2.5质量％以下的硅、和0.3质量％以上且0.9质量％以下的锰，剩余部分为铁和不可避免的杂质。
2.根据权利要求1所述的斜圈弹簧用线材，其中所述钢还含有选自由0.1质量％以上且0.4质量％以下的镍、0.1质量％以上且1.8质量％以下的铬、0.1质量％以上且0.4质量％以下的钼、和0.05质量％以上且0.3质量％以下的钒构成的组中的一种以上的元素。
3.根据权利要求1或2所述的斜圈弹簧用线材，其中所述硬质层具有300HV以上的硬度。
4.根据权利要求1至3中任一项所述的斜圈弹簧用线材，其中所述硬质层的硬度比所述铜镀层的硬度高50HV以上。
5.根据权利要求1至4中任一项所述的斜圈弹簧用线材，其中所述硬质层的厚度对所述铜镀层的厚度之比为1/10以上且小于1。
6.根据权利要求1至5中任一项所述的斜圈弹簧用线材，其中所述硬质层为镀层。
7.根据权利要求1至6中任一项所述的斜圈弹簧用线材，其中所述硬质层为镍层或铬层。
8.根据权利要求1至7中任一项所述的斜圈弹簧用线材，其中所述线材具有900MPa以上且3000MPa以下的拉伸强度。
9.根据权利要求1至8中任一项所述的斜圈弹簧用线材，其中所述线材具有15％IACS以上且50％IACS以下的电导率。
10.根据权利要求1至9中任一项所述的斜圈弹簧用线材，其中在所述铜镀层和所述硬质层之间设置有含有构成所述铜镀层的金属元素和构成所述硬质层的金属元素的合金区域。
11.根据权利要求10所述的斜圈弹簧用线材，其中所述硬质层为镍层，并且所述合金区域含有铜和镍。
12.根据权利要求1至11中任一项所述的斜圈弹簧用线材，其中在所述硬质层上以包含所述斜圈弹簧用线材的外周表面的方式设置有金层、银层或锡层。
13.一种斜圈弹簧，所述斜圈弹簧包含根据权利要求1至12中任一项所述的斜圈弹簧用线材。
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