CN1272165A - 斜盘式压缩机的斜盘 - Google Patents

斜盘式压缩机的斜盘 Download PDF

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CN1272165A
CN1272165A CN99800784A CN99800784A CN1272165A CN 1272165 A CN1272165 A CN 1272165A CN 99800784 A CN99800784 A CN 99800784A CN 99800784 A CN99800784 A CN 99800784A CN 1272165 A CN1272165 A CN 1272165A
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swash plate
matrix
alloy
weight
type compressor
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CN100333897C (zh
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村松省吾
秋月政宪
粥川浩明
水谷秀树
杉浦学
仲井间裕之
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Toyota Industries Corp
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B27/00—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders
    • F04B27/08—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders having cylinders coaxial with, or parallel or inclined to, main shaft axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B27/00—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders
    • F04B27/08—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders having cylinders coaxial with, or parallel or inclined to, main shaft axis
    • F04B27/10—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders having cylinders coaxial with, or parallel or inclined to, main shaft axis having stationary cylinders
    • F04B27/1036—Component parts, details, e.g. sealings, lubrication
    • F04B27/1054—Actuating elements
    • 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
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • 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
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B27/00—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders
    • F04B27/08—Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders having cylinders coaxial with, or parallel or inclined to, main shaft axis
    • F04B27/0873—Component parts, e.g. sealings; Manufacturing or assembly thereof
    • F04B27/0895—Component parts, e.g. sealings; Manufacturing or assembly thereof driving means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
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    • F05C2201/00—Metals
    • F05C2201/02—Light metals
    • F05C2201/021—Aluminium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2203/00—Non-metallic inorganic materials
    • F05C2203/06—Silicon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2253/00—Other material characteristics; Treatment of material
    • F05C2253/12—Coating
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    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/937—Sprayed metal
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    • Y10T428/12014—All metal or with adjacent metals having metal particles
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Abstract

含有12—60%的Si和当需要时还含有0.1—30%的Sn的铝合金,火焰喷涂在斜盘式压缩机的铁或铝基的基体上,形成抗咬合和抗磨损的表面层,其中分散有粒状的Si颗粒。

Description

斜盘式压缩机的斜盘
发明领域
本发明涉及斜盘式压缩机的斜盘。更具体而言，本发明涉及一种表面处理技术，该技术能显著提高由铁基或铝基材料组成的斜盘的滑动性能。
背景技术
在斜盘式压缩机中，斜盘2以刚性方式倾斜地固定到图1所示的转轴1上。采用另一种方案，斜盘是以可改变倾角的方式倾斜地固定到转轴上。借助于斜盘的旋转进行压缩和膨胀，斜盘能增加或减少压缩机内分隔空间的体积，视转轴的旋转而定。这种斜盘在称作滑瓦3的保护件上滑动。斜盘与滑瓦之间的气密性密封能使冷却介质在所述的空间中压缩和膨胀。4是个球状物。
在斜盘的滑动条件中，值得注意的一点是，在压缩机开始运行期间，冷却介质在润滑油到达斜盘和滑瓦之间的滑动部分之前到达滑动部分，因此冷却介质对仍留在滑动部分上的润滑油有冲洗作用，其结果是，滑动条件是无润滑油的干条件。所以对斜盘的滑动条件要求是非常严格的。
对在上述条件下使用的斜盘而言，所要求的滑动性能是抗咬合和耐磨等。因此有人建议向铝材料中加入硬成分，以提高耐磨性能，改进斜盘材料，和对铁基斜盘进行热处理，以提高硬度并从而提高耐磨性能。此外，还推荐下面的表面处理方法。
本申请人之一在日本未审定的专利公报Sho 51-36611中推荐，在使用铁基斜盘的情况下，将烧结的Cu材料粘结到滑瓦上。也就是说，铁基斜盘现已受到硬化处理。然而在相对件即滑瓦的材料是铁基材料时，在同一种类的材料之间发生滑动，因而容易出现咬合问题，为了避免上述问题，对与铁基斜盘相对的相应部件(滑瓦)，采用烧结的铜合金。
此外，为了避免在同一种类的材料之间滑动，并从而提高抗咬合性能，还建议在铁基斜盘上镀锡。由于在铁基斜盘上施加的镀锡层软，出现的问题是耐磨性能不够。
由铸造或锻造生产的共晶或过共晶Al-Si基铝合金具有极好的耐磨性能。然而在Si含量超过15％时，其生产是很困难的。因此，这种合金的耐磨性能受Si含量的限制。
最近有人建议采用熔体淬冷粉末的粉末冶金品(例如日本专利公报2535789)。
由于Si含量非常高，竟达14-30％之多，所以大大提高了耐磨性能。然而，所得的合金必须首先进行热压，然后进行热挤出之类的加工。因此，为了生产尺寸较大的部件例如斜盘，必须投资安装大功率的设备，例如锻压机和挤压机。所以降低了在费用上的竞争能力。
发明公开
因此，本发明的目的是对铁或铝基斜盘的表面提供具有提高耐咬合和耐磨性能的表面层，从而提高斜盘式压缩机的运行性能和可靠性。
因此本发明人进行了研究，结果能利用一种简单的方法制备一种在共晶区或过共晶区的Al-Si铝合金基滑动材料作为斜盘表面上的滑动层；并且证明其改进的性能明显地超过各种常规滑动层的性能。
本发明人大力进行试验并且发现，在共晶区或过共晶区内火焰喷涂Al-Si基铝合金提高了对基体的附着性能，而且使Si颗粒变细。于是完成了本发明。
即本发明的第一项发明是斜盘式压缩机的斜盘，其特征在于附着在基体上的火焰喷涂层包含20-60％(重量)的Si，其余基本上是Al，在其基质中分散有粒状的Si颗粒。本发明的第二项发明是斜盘式压缩机的斜盘，其特征在于附着在基体上的火焰喷涂层包含20-60％(重量)的Si，0.1-30％(重量)的Sn，其余基本上是Al，在其基质中分散有粒状的Si颗粒和Sn相。
火焰喷涂(喷涂)是基于日本工业标准工业术语汇编词典(GlossaryDictionary of JIS Industrial Terms)第4版1946页的定义，该定义表述为：“利用热源使材料转变成熔融或半熔融状态，将其喷到基体上形成膜”。更确切地说，“材料”是铝合金或其原料，例如Al和Si的粉末。半熔融状态系指象在高Si的Al-Si合金中，即在一种高熔点的材料中所获得的那种固-液共存状态。半熔融状态系指有一部分粉末尚未熔化。这一点在下文中进行阐述。
在下文中详细地阐述了本发明。除非另有说明，百分数均为重量％。
发明实施方案。
根据本发明第一项发明的Al-Si基合金，大量颗粒状的Si细分散在铝基质中。因此，Si提高了合金的硬度，从而提高了合金的耐磨性能。此外，大量粒状的Si颗粒分散得很细，消除了铝基质与滑瓦之间的粘附作用，从而排除了由于这种粘附作用而引起的咬合现象。
由本发明人提交的欧洲专利0713972 Al以Cu-Pb合金为实例对火焰喷涂的铜合金做了详细的阐述。熔融颗粒的迅速冷却和固化在Al合金的实例中是常见的。火焰喷涂Al-Si合金的一个特点是添加元素(Si)的熔点比基质元素(Al)的熔点高。结果，大量粒状的Si细分散在铝基质中。因此，获得的效果是Si提高了合金的硬度，从而提高了合金的耐磨性能。
在本发明中，粒状Si颗粒的形状与常规熔融合金原有的Si或轧制合金的Si颗粒不同。它们沿纵向具有单向性。更确切地说，本发明粒状Si颗粒的形状是球形的、结核状的、多边形的或不属于前三种形状的不规则形的，它们在任何方向上都具有几乎相同的尺寸。而且，在本发明的情况下，在常规熔融合金中所见的原有Si和共晶Si之间的明显区别消失了。
在根据本发明的铝合金由Si含量低于12％时，耐磨和防咬合效果略有提高。另一方面，在Si含量超过60％时，强度急剧下降，以致损害耐磨性能。优选的Si含量为15-50％。在Si颗粒的粒度超过50μm时，Si颗粒容易发生剥离。优选的粒度为1-40μm。
其次，本发明第二项发明的Al-Si-Sn基合金提高了耐磨和抗咬合性能。Si的形状和含量与对第一项发明所述的相同。Sn是提供润滑性能和兼容性能的成分。Sn优先附着到滑瓦上，避免同一种类材料即附着Al对轴承Al的滑动，结果提高了耐咬合性能。在Sn含量低于0.1％时，不能提高润滑等性能。另一方面，在Sn含量超过30％时，合金的强度下降。优选的Sn含量为5-25％。在该层中Sn相的形状是长片形的。从润滑性能来看，这种形状似乎是优选的。
根据本发明第一项和第二项发明的铝合金，可包含下列任选的元素。
Cu：Cu是以过饱和状态均匀地溶解在铝基质中，因而提高了铝合金的强度。因此Cu排除了铝的粘附磨损和由于Si颗粒剥落引起的磨损。此外，一部分Cu与Sn生成一种Sn-Cu金属互化物，因而提高了耐磨性能。然而，在Cu含量超过7.0％时，合金的硬度增加太大，不能制成适宜的滑动材料，优选的Cu含量为0.5-5％。
Mg：Mg与一部分Si结合，生成Mg-Si金属互化物。因此，Mg提高了耐磨性能。然而，在Mg含量超过5.0％时，生成的相大Mg相有损滑动性能。
Mn：Mn是以过饱和状态均匀地溶解在铝基质中，因而提高了铝合金的强度。由Mn获得的效果与由Cu获得的效果相同。然而，在Mn含量超过1.5％时，合金的硬度增加太大，不能制成适宜的滑动材料。优选的Mn含量为0.1-1％。
Fe：Fe是以过饱和状态均匀地溶解在铝基质中，因而提高了铝合金的强度。由Fe获得的效果与由Cu获得的效果相同。然而，在Fe含量超过1.5％时，合金的硬度增加太大，不能制成适宜的滑动材料。优选的Fe含量为0.1-1％。
Ni：Ni是以过饱和状态均匀地溶解在铝基质中，因而提高了铝合金的强度。由Ni获得的效果与由Cu获得的效果相同。然而，在Ni含量超过8％时，合金的硬度增加太大，不能制成适宜的滑动材料。优选的Ni含量为0.1-5％。
接着说明由火焰喷涂形成的滑动层，在本发明的第一和第二项发明中都有该层。
在本发明中，可以采用列于摩擦磨损润滑学家(Tribologist)第20页图2中的各种火焰喷涂方法，摩擦磨损润滑学家的出处同前。可优选采用其中的高挥发性含氧燃料火焰喷涂方法(HVOF，高挥发性含氧燃料)。看来利用这种方法可以获得特征性的Si形状和Sn相，因为它具有摩擦磨损润滑学家第20页右栏4-13行所述的特性，摩擦磨损润滑学家的出处同前。火焰喷涂的Al能如此迅速地冷却和固化，以使大量的Si被均匀地溶解，增加了Al的硬度。因此它具有在高强度下保持Si颗粒的特性。所以可排除Si颗粒的剥落和由这种剥落而引起的磨损。
可以采用合金例如Al-Si合金、Al-Si-Sn合金等粉化的粉末作为火焰喷涂的粉末。这些粉化的粉末可被完全熔化在基体上然后固化。采用另一种方案，可将部分未熔的粉化粉末施加到基体上，以便仍然保持未熔的粉末结构。
火焰喷涂条件优选为：氧压力0.45-0.76MPa；燃料压力0.45-0.76MPa；和火焰喷涂距离50-250mm。优选的火焰喷涂层厚度为10-500μm，特别优选10-300μm。
火焰喷涂合金的硬度为Hv(维氏硬度)100-600。由于含Si12％的常规合金的硬度为Hv 70-150，所以可以说根据本发明的火焰喷涂层是非常硬的。
可以采用例如铁、铜、铝等各种金属基体作为在其上形成火焰喷涂合金的基体。在借助于喷射处理等方法使基体的表面粗糙时，优选表面的粗糙度达到Rz 10-60μm，这样可提高膜的附着强度。更确切地说，采用剪切断裂测试方法测定膜的附着强度表明：火焰喷涂的Ni膜对喷射处理的钢基体的附着强度为30-50MPa；而根据本发明的膜的附着强度为40-60MPa。这些迄今一直被认为具有优良附着性能的火焰喷涂Ni膜的附着强度还高。
可对火焰喷涂的合金进行热处理来调节其硬度。
火焰喷涂层与基体的附着强度是通过铝(即火焰喷涂层的基质)与基体金属的熔合和互相扩散在它们之间形成合金产生的。在另一方面，分散相例如Si似乎缺乏这种功能，因而不能提高附着强度。由于Sn和Si往往能降低上述的附着性能，所以可利用这些元素的浓度从基体侧到表面的方向上连续或不连续地增加所形成的浓度梯度来提高附着强度。结果与基体接触的火焰喷涂层是一种纯粹的Al合金，其中形成第二相的元素，例如Si，浓度很低。这样的浓度梯度可通过改变火焰喷涂粉末混合料的组成来形成。
在采用无覆层施涂的火焰喷涂合金的情况下，优选将火焰喷涂过的表面抛光到Rz 3.2μm或更小。在采用覆层的情况下，可以采用具有极好兼容性的各种软覆层，例如Sn、Pb-Sn、MoS2和MoS2-石墨基覆层，以便提高抗咬合性能。
滑瓦本身已为人们所知。例如在本申请人提交的日本未审定的专利公报51-36611中就表示出滑瓦。可采用主要成分为铁的任一种材料作为铁基材料，然而轴承钢是优选的。此外滑瓦的生产方法根本不受限制。可任选地采用象轧制、锻造、粉末冶金、表面硬化之类的技术。
现在通过实施例来说明本发明。
附图简述
图1是表示斜盘、转轴和斜盘式压缩机滑瓦的附图。
图2是表示根据实施例1的火焰喷涂铝合金的微观结构照片。
实现发明的最佳方式
实施例1
制备一种金属粉末的混合物，以提供Al-40％ Si的组合物。同时采用钢粒(粒度0.7mm)喷射处理在市场上购买的纯铝轧制板，使其表面粗糙到Rz 45μm。
采用HVOF型的火焰喷涂机(DJ，Sulzer Meteco有限公司产品)在下列条件下进行火焰喷涂。
氧压力：150psi
燃料压力：100psi
火焰喷涂距离：180mm
火焰喷涂层的厚度：200μm
所得火焰喷涂层的硬度为Hv＝180-250，粒状Si颗粒的平均粒度为3μm。火焰喷涂层的表面抛光到Rz 1.2μm。然后在下列条件下进行磨损测试。
对比实施例1
在与实施例1相同的条件下制备纯铝的火焰喷涂层。进行同样的磨损测试。
对比实施例2
用砂模铸造含17％ Si的Al-Si合金，以便制备测试试样。
测试机器：三-柱/盘(three-pin/disc)摩擦磨损测试机
载荷：40 kg/cm2
转数：700 rpm
润滑：冷冻机润滑油+冷却介质气体
      (R 134a)
测试时间：120 min
测试的结果一并列于下面的表1中。
              表1
    磨损量(μm)
    实施例1     3
    对比实施例1     50
    对比实施例2     4
工业实用性
如上文所述，可以很容易地制成作为斜盘滑动层的过共晶Al-Si合金。此外，由于本发明合金的性能优于常规熔融Al-Si合金的性能，所以本发明会对提高斜盘式压缩机的性能做出巨大贡献。

Claims (7)

1.斜盘式压缩机的一种斜盘，其特征在于附着在基体上的火焰喷涂层包含12-60％(重量)的Si，其余基本上是Al，在该层的基质中分散有粒状的Si颗粒。
2.斜盘式压缩机的一种斜盘，其特征在于附着在基体上的火焰喷涂层包含12-60％(重量)的Si，0.1-30％(重量)的Sn，其余基本上是Al，在该层的基质中分散有粒状的Si颗粒和Sn相。
3.根据权利要求1或2的斜盘式压缩机的斜盘，其中所述的合金包含至少一种下列元素：至多7.0％(重量)的Cu；至多5.0％(重量)的Mg；至多1.5％(重量)的Mn；至多1.5％(重量)的Fe；和至多8.0％(重量)的Ni。
4.根据权利要求1-3任一项的斜盘式压缩机的斜盘，其中所述的基体是金属基体，其表面被处理粗糙。
5.根据权利要求1-4任一项的斜盘式压缩机的斜盘，其中所述粒状Si颗粒的平均粒径至多为50μm。
6.根据权利要求1-5任一项的斜盘式压缩机的斜盘，其中改变所述火焰喷涂层中所述Si和Sn的浓度，使它们的浓度沿从基体到火焰喷涂层表面的方向增加。
7.根据权利要求1-6任一项的斜盘式压缩机的斜盘，其中将软性膜施加到所述火焰喷涂的铝合金上。
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