JP5593610B2 - Method for producing film forming member - Google Patents

Description

 The present invention relates to a method for manufacturing a film forming member.

 When manufacturing a film-forming member, generally, as shown in Patent Document 1, in order to form a coating only on a necessary part, a part other than the necessary part is masked with a masking material and sprayed on the necessary part. Has been done. If such a method using a masking material is used, several types of thermal spray materials can be divided and sprayed for each part, and a film forming member having a plurality of different films can be manufactured.

By the way, recently, in order to improve the wear resistance, the support surface that receives the sliding of the sliding member not only forms a coating such as a thermal spray coating but also has a relationship with the sliding of the sliding member. Therefore, it may be required to partially vary the hardness of the coating on the same plane. As a means for realizing it, as described above, if a masking material and thermal spraying are used, it is possible to form a coating having different hardness for each part.
JP-A-5-111666

However, when a masking material and thermal spraying are used to form a coating with different hardness for each part, not only must the masking material be prepared, but the original work of setting and removing the masking material is required. . Moreover, accuracy (setting position accuracy) is required in the masking material setting operation, and in the masking material removal operation, the formed film should not be damaged along with the removal operation (so that the film is not peeled off). Etc.) are required.
In addition, when using a masking material and looking at the work process of forming two types of coatings with different hardnesses as a plurality of types, when forming a coating in one coating formation planned area, the other coating formation planned area is masked. When masking using a material and forming a film in the other film formation planned area, it is necessary to mask the film on one film formation planned area using a masking material. Therefore, (i) masking material setting process, (ii) thermal spraying process, (iii) masking material removal process, (iv) masking material setting process, (v) thermal spraying process, (vi) masking material removal process (Vi) Work must be performed in the order of the grinding process, and the same kind of work process is repeated with time, which is not preferable in terms of work efficiency.
Furthermore, in general, when a masking material is used, the formed film is not peeled off when the masking material is removed. Therefore, when a film having different hardness is formed for each part using a masking material and thermal spraying. , It tends to be difficult to accurately partition the coatings having different hardnesses for each part.

 This invention is made | formed in view of such a situation, The technical subject is to provide the manufacturing method of the film formation member which can form the film from which hardness differs for every site | part rapidly and reliably.

In order to achieve the technical problem, in the present invention (the invention according to claim 1),
On the surface of the base material, a recess is formed at a location where the coating hardness is desired to be different from the other area,
Next, on the base material surface including the recess, the coating is sprayed to make the thickness of the coating constant, and the hardness of the coating changes in either direction of increase or decrease, Sequentially, in the form of a laminate, forming a film laminate,
Next, the coating layer is ground so that the entire outer surface of the coating layer is flush. The preferred embodiment of claim 1 is as described in claim 2 and the following.

According to the first aspect of the present invention, the coating film having a different hardness for each part can be obtained without preparing any special member such as a masking material through the recess forming process, the coating layer forming process, and the grinding process. Accordingly, it is possible to simplify the manufacturing process (at least the step of removing the masking material is omitted) without the need for setting and removing the masking material.
Moreover, each process is performed only once in order of a recess formation process, a film lamination formation process, and a grinding | polishing process, and the same kind of process is not repeated over time. For this reason, work efficiency can be improved and the manufacturing time can be shortened.
Furthermore, the recess used for partitioning the coating with different hardness does not exist through the grinding process, and there is no possibility that the coating may be peeled off as in the case of the removal work of the masking material. . In addition, it is possible to partition a film with different hardness without considering the peeling of the film, and it is possible to clearly and accurately partition a film (parting line) with a different hardness.
Therefore, the manufacturing method of the film formation member which can form the film from which hardness differs for every site | part rapidly and reliably can be provided.
Of course, since each coating film is formed by thermal spraying, the above-mentioned effects can be obtained easily and reliably.

  According to the second aspect of the present invention, the hardness of each coating in the coating lamination is increased as the coating is closer to the substrate surface, so that the coating between the coating lamination and the substrate surface, and further in the lamination direction. Adhesion stability between them can be improved.

  According to the invention of claim 3, since the film stack is formed of three or more films, and the hardness of each film is gradually increased toward the substrate surface, the film stack having three or more films It is more preferable in improving the adhesion stability between the coatings adjacent in the stacking direction.

According to the invention of claim 4 , when changing the hardness of each coating in the coating lamination relative to the hardness of the coating adjacent in the laminating direction, the distance between the substrate surface and the thermal spray gun that performs thermal spraying is changed. Therefore, the hardness of each coating can be changed very easily.

According to the fifth aspect of the present invention, since the base material constitutes a support surface that supports the sliding of the sliding member, the coating material is applied to each part in response to the conflicting requirements of wear resistance and familiarity. It can respond precisely by the method of varying the hardness.

According to the invention which concerns on Claim 6 , since the thing of the shape where an inner wall stands upright from a flat recess bottom face is formed as a recess, in a grinding process, two types of film surfaces from which hardness differs are exposed. As a result, the coating regions having different hardnesses can be sharply defined.

According to the seventh aspect of the present invention, since the recesses are formed such that the inner walls facing each other are separated from the bottom surface of the recess toward the opening side, a plurality of coatings having different hardnesses in the grinding step A surface will be exposed and the coating area | region from which hardness differs can be changed gradually.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The manufacturing method according to the present embodiment is performed according to the process diagram shown in FIG.
First, as shown in FIGS. 1 to 3, a recess 2 is formed by performing machining on the substrate surface 1 a of the substrate 1 (machining process). The continuity of the thermal spray coating formed in the subsequent thermal spraying process (first, second and third thermal spray coating forming processes) is interrupted by the recess 2, and the thermal spray coating on the recess bottom surface 2 a is recessed 2. It is for making it lower than the sprayed coating on the non-processed surface 3 other than. In the present embodiment, the recess 2 has a shape in which the inner wall stands vertically from the flat bottom surface 2a of the recess, and the depth D of the recess 2 is, for example, about 60 μm.
Here, the base material 1 is basically a member that supports sliding of the sliding member, and wear resistance in a partial region according to the sliding characteristics of the sliding member. Members that require individuality and familiarity are targeted. The material is made of aluminum, cast iron or the like. In the present embodiment, the recess 2 is formed in a region where the familiarity of the base material surface 1a is required, and high wear resistance is required on the non-processed surface 3 of the base material surface 1a. .

When the recess 2 is formed on the substrate surface 1a, as shown in FIG. 1, spraying is performed on the entire portion where the coating is to be formed including the recess 2 (spraying process). This is because a thermal spray coating is formed on the entire portion where the coating is to be formed on the substrate surface 1a to basically ensure the wear resistance of the substrate surface 1a.
In this embodiment, as shown in FIG. 4, the thermal spraying forms the first, second, and third thermal sprayed coatings C1, C2, and C3 on the substrate surface 1a in a laminated state to form a coating laminate C. The thickness m1 (m2, m3) of each sprayed coating C1 (C2, C3) of the coating stack C is constant for each sprayed coating C1 (C2, C3). Specifically, the first, second, and third sprayed coatings C1, C2, and C3 are formed outward from the substrate surface 1a, and the thicknesses m1, m2, and m3 are about 40 μm, respectively. ing. Therefore, the continuity of the first, second, and third sprayed coatings C1, C2, and C3 on the substrate surface 1a is interrupted at the recess 2, and the first, second, and third sprays are also formed within the recess 2. Although the coatings C1, C2, and C3 are formed in a laminated state, they are positioned at positions lower than the first, second, and third sprayed coatings C1, C2, and C3 on the non-processed surface 3. For example, Cr3C2-25% NiCr (particle size 10 to 38 [mu] m) is used as the thermal spraying powder used for this thermal spraying.

 In the above thermal spraying, the distance (W / D) from the position of the thermal spray gun to the substrate surface 1a is made different every time the first, second and third thermal spray coatings C1, C2 and C3 are formed. This is because the hardness of the first, second, and third sprayed coatings C1, C2, and C3 is different. In other words, the distance (W / D) from the position of the spray gun to the base material surface 1a has an optimum value for high hardness, and the longer the optimum value is, the lower the hardness is. I am trying to adjust the hardness.

 This will be specifically described. In FIG. 3, the alternate long and short dash lines indicated by reference numerals L1, L2, and L3 indicate the positions of the spray guns when the first, second, and third sprayed coatings C1, C2, and C3 are formed, and S1, S2, S3 (S1 ( (Optimum value) <S2 <S3) indicates the distance between the position of the spray gun and the non-processed surface 3 when forming the first, second and third sprayed coatings C1, C2 and C3 (work distance W). / D), H1, H2, and H3 (H1 <H2 <H3) are the distances between the spray gun position and the recess bottom surface 2a when forming the first, second, and third sprayed coatings C1, C2, and C3. Each is shown. For this reason, the distance from the spray gun position L1 (L2, L3) to the base material surface 1a becomes longer as the third sprayed coating C1 to the third sprayed coating C3 are formed, and the first sprayed coating C1. The closer to the third sprayed coating C3, the lower the hardness. In this case, when forming each of the first, second, and third sprayed coatings C1, C2, and C3, the distances S1, S2, and S3 from the spray gun position to the base material surface 1a are the bottom surfaces of the recesses from the spray gun position. Although the depth D of the recess 2 is shorter than the distances H1, H2, and H3 up to 2a, this difference D (for example, about 60 μm) does not significantly affect the hardness change, and each sprayed coating C1, C2, C3. Regarding the hardness for each, the one on the non-processed surface 3 and the one on the recess bottom surface 2a are substantially in the same state. However, even if the depth D of the recess 2 affects the hardness, it will work advantageously in the present embodiment (when the recess 2 exists in the low hardness specification).

 In the present embodiment, the distance (W / D) from the position of the spray gun to the substrate surface 1a can be changed in the range of 180 mm to 250 mm as the first spray coating C1 to the third spray coating C3 are formed. become. Further, in this case, the thermal spraying is performed with the number of passes: 6 times over the entire portion where the coating film is to be formed on the substrate surface 1a. In the first and second passes, the first thermal spray coating C1 is formed by thermal spraying under a high hardness condition (most approached state), and in the next third through fourth passes, the second thermal spraying is performed by spraying under a medium hardness condition. The coating C2 is formed, and in the next 5th to 6th passes, the third sprayed coating C3 is formed by thermal spraying under a low hardness condition (most distant state). Here, the pass refers to the number of times of spraying the entire portion where the coating is to be formed on the substrate surface 1a.

Next, as shown in FIGS. 2, 5, and 6, the entire coating layer stack C on the substrate surface 1 a is ground (grinding step). The outermost surface of the film stack C is flush (coplanar) to form a support surface 5 that allows the sliding member to slide, and the surface hardness of the film stack C is set in the upper region of the recess bottom surface 2a. This is to make the difference between what exists and what exists in the upper region of the non-processed surface 3.
That is, in order to make the entire film stack C flush with each other, the portion of the film stack C existing in the upper region of the non-processed surface 3 is ground deeper than the portion of the film stack C existing in the upper region of the recess bottom surface 2a. Utilizing this, the surface hardness of the coating layer C portion existing in the upper region of the non-processed surface 3 is increased (the first sprayed coating C1 is exposed), and the upper region of the recess bottom surface 2a In other words, the surface layer C of the coating layer C has a low surface hardness (the third sprayed coating C3 is exposed). In this embodiment, the said relationship is acquired by grinding about 0.08-0.10 mm from the uppermost surface of the sprayed coating on the base-material surface 1a. In addition, this grinding process is performed using the process performed conventionally. In FIG. 5, a two-dot chain line indicated by a symbol K indicates a surface after grinding.

As a result, the support surface 5 of the substrate 1 exhibits familiarity in the coating layer C portion existing in the upper region of the recess bottom surface 2a, and in the coating layer C portion existing in the upper region of the non-processed surface 3. Thus, high wear resistance will be exhibited, and different functions for each part of the support surface 5 can be exhibited. In this case, since the shape of the recess 2 is a shape in which the inner wall stands upright from the flat bottom surface 2a of the recess, the hardness of the support surface 5 is sharply switched using the inner wall of the recess 2 as a parting line. Become.

Such a film forming member manufacturing method is used, for example, for the support surface 9 (contact surface with the rotor 10) of the side housing 8 in the rotary engine 6.
In the rotary engine 1, as the rotor 10 rotates in the rotor housing 11, the side seal 12 and the oil seal O attached to the side surface of the rotor 10 slide with respect to the side housing 8 (support surface 9). In this case, the sliding area OS of the oil seal O on the side housing 8 (support surface 9) becomes an annular portion (shown by hatching) with the center point of the side housing 8 as a reference, and the side housing 8 of the side seal 12 The sliding region SS on the (support surface 9) is an outer portion (shown with a hatch) of the central region (lemon-shaped portion) of the side housing 8, but the sliding of the side seal 12 is shown in FIG. As is apparent from the sliding locus of the side seal 12, the sliding is concentrated on the short shaft side portion of the side housing 8 (the portion where the sliding of the side seal 12 is concentrated is indicated by reference numeral 14 (in FIG. 9). , Enclosed part)). For this reason, the support surface 9 of the side seal 12 is basically required to have high wear resistance. However, in the portion 14 where the sliding of the side seal 12 is concentrated, higher wear resistance is required. Is done.
As countermeasures against this, it is conceivable to increase the hardness of the thermal spray coating on the entire side housing 8 (support surface 9) in accordance with the portion 14 where the sliding of the side seal 12 is concentrated, thereby improving the wear resistance. However, when the wear resistance is improved as described above, the familiarity between the oil seal 13 and the thermal spray coating is delayed in the sliding region OS of the oil seal 13, and the sealing performance during that time is lowered. Conversely, if the hardness of the thermal spray coating on the entire side housing 8 (support surface 9) is lowered in accordance with the sliding area OS of the oil seal 13, stepped wear may occur at the sliding concentrated portion 14 of the side seal 12. There is.
For this reason, on the support surface 9 of the side housing 8, the hardness of the sliding concentrated portion 14 of the side seal 12 is further increased by using the above-described manufacturing method, and the portions other than the sliding concentrated portion 14 of the side seal 12 are provided. Is made lower than the hardness of the sliding concentrated portion 14 of the side seal 12.

11 to 14 show a second embodiment. In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.

In this 2nd Embodiment, as shown in FIG. 11, the thing of the shape from which the inner wall which opposes leaves | separates as the recessed part 2 formed in the base material 1 leaves | separates from the center of the bottom face to the opening side is used. And the 1st-4th thermal spray coating C1-C4 with a fixed film thickness is formed in order by the method similar to the said 1st Embodiment on the base-material surface 1a containing this recess 2, The 1st The hardness of the fourth thermal spray coating C1 to C4 is also lowered toward the fourth thermal spray coating C4. The coating layer C is ground, and the support surface 5 is provided with a third spray coating C3, a second spray coating C2, and a first spray coating C1 from the center of the recess 2 toward the outside of the recess 2. Exposed. For this reason, in the present embodiment, the hardness of the support surface 5 gradually increases from the center of the recess 2 toward the outside of the recess 2.

Although the embodiments have been described above, the present invention includes the following aspects.
(1) The method for producing a film forming member according to the present invention is appropriately applied to other than the side housing of the rotary engine.
(2) In the embodiment, in order to sequentially change the hardness of each thermal spray coating, the thermal spray gun is separated from the substrate surface 1a, but conversely, as each thermal spray coating is sequentially formed, thermal spraying is performed. Bring the gun close to the optimum value (high hardness) on the substrate surface 1a. In this case, after the grinding process, the outermost surface hardness of the coating layer C portion existing in the upper region of the recess bottom surface 2a is increased, and the outermost surface hardness of the coating layer C portion existing in the upper region of the non-processed surface 3 is increased. The outer surface hardness is relatively low.

Process drawing which shows a series of manufacturing processes which concern on 1st Embodiment. Explanatory drawing which shows the base-material surface before the recess process which concerns on 1st Embodiment. Explanatory drawing explaining the manufacturing process following FIG. Explanatory drawing explaining the manufacturing process following FIG. Explanatory drawing explaining the manufacturing process following FIG. Explanatory drawing explaining the manufacturing process following FIG. Explanatory drawing explaining a rotary engine. The figure which shows the sliding area | region of an oil seal. The figure which shows the sliding area | region of a 3rd seal. Explanatory drawing explaining the sliding locus | trajectory of a side seal. Explanatory drawing explaining the recess which concerns on 2nd Embodiment. Explanatory drawing explaining the manufacturing process following FIG. Explanatory drawing explaining the manufacturing process following FIG. Explanatory drawing explaining the manufacturing process following FIG.

1 Base material (side housing)
DESCRIPTION OF SYMBOLS 1a Substrate surface 2 Recess 2a Recess bottom 3 Non-processed surface 5 Support surface 8 Side housing 9 Support surface C Coating lamination C1 1st thermal spray coating C2 2nd thermal spray coating C3 3rd thermal spray coating C4 4th thermal spray coating

Claims (7)

On the surface of the base material, a recess is formed at a location where the coating hardness is desired to be different from the other area,
Next, on the base material surface including the recess, the coating is sprayed to make the thickness of the coating constant, and the hardness of the coating changes in either direction of increase or decrease, Sequentially, in the form of a laminate, forming a film laminate,
Next, the coating layer is ground so that the entire outer surface of the coating layer is flush,
A method for producing a film-forming member. In claim 1,
Increasing the hardness of each coating in the coating lamination as it is closer to the substrate surface,
A method for producing a film-forming member. In claim 2,
The film stack is formed by three or more films,
Gradually increasing the hardness of each coating toward the substrate surface,
A method for producing a film-forming member. In any one of Claims 1-3 ,
When changing the hardness of each coating in the coating lamination with respect to the hardness of the coating adjacent to the lamination direction, the distance between the substrate surface and the thermal spray gun that performs thermal spraying is changed.
A method for producing a film-forming member. In any one of Claims 1-4 ,
The base material constitutes a support surface that supports sliding of the sliding member;
A method for producing a film-forming member. In any one of Claims 1-5 ,
As the recess, forming a shape in which the inner wall stands vertically from the bottom of the flat recess,
A method for producing a film-forming member. In any one of Claims 1-5 ,
As the recess, a shape in which opposing inner walls are separated from the bottom surface of the recess toward the opening side thereof is formed.
A method for producing a film-forming member.

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