JP6652193B2 - ピアサープラグの製造方法 - Google Patents
ピアサープラグの製造方法 Download PDFInfo
- Publication number
- JP6652193B2 JP6652193B2 JP2018533425A JP2018533425A JP6652193B2 JP 6652193 B2 JP6652193 B2 JP 6652193B2 JP 2018533425 A JP2018533425 A JP 2018533425A JP 2018533425 A JP2018533425 A JP 2018533425A JP 6652193 B2 JP6652193 B2 JP 6652193B2
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- JP
- Japan
- Prior art keywords
- plug
- piercer
- layer
- spray coating
- thermal spray
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000004519 manufacturing process Methods 0.000 title claims description 25
- 238000005507 spraying Methods 0.000 claims description 60
- 238000010438 heat treatment Methods 0.000 claims description 51
- 238000000034 method Methods 0.000 claims description 14
- 229910001080 W alloy Inorganic materials 0.000 claims description 11
- 229910001566 austenite Inorganic materials 0.000 claims description 11
- 230000009466 transformation Effects 0.000 claims description 8
- 239000010410 layer Substances 0.000 description 82
- 239000000463 material Substances 0.000 description 44
- 238000005253 cladding Methods 0.000 description 23
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 20
- 238000005096 rolling process Methods 0.000 description 20
- 239000011248 coating agent Substances 0.000 description 13
- 238000000576 coating method Methods 0.000 description 13
- 230000000694 effects Effects 0.000 description 12
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 11
- 229910052742 iron Inorganic materials 0.000 description 9
- 239000011572 manganese Substances 0.000 description 9
- 239000011651 chromium Substances 0.000 description 8
- 238000005553 drilling Methods 0.000 description 8
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 6
- 238000007751 thermal spraying Methods 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 4
- 229910052804 chromium Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 239000012535 impurity Substances 0.000 description 4
- 239000010955 niobium Substances 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000010936 titanium Substances 0.000 description 4
- 238000003466 welding Methods 0.000 description 4
- 230000004323 axial length Effects 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 239000011261 inert gas Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229910052758 niobium Inorganic materials 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229910052719 titanium Inorganic materials 0.000 description 3
- 229910052721 tungsten Inorganic materials 0.000 description 3
- 239000011575 calcium Substances 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 230000003628 erosive effect Effects 0.000 description 2
- 229910052748 manganese Inorganic materials 0.000 description 2
- 238000010791 quenching Methods 0.000 description 2
- 230000000171 quenching effect Effects 0.000 description 2
- 229910052761 rare earth metal Inorganic materials 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 2
- 239000010937 tungsten Substances 0.000 description 2
- 229910052720 vanadium Inorganic materials 0.000 description 2
- 229910000859 α-Fe Inorganic materials 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000009863 impact test Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B25/00—Mandrels for metal tube rolling mills, e.g. mandrels of the types used in the methods covered by group B21B17/00; Accessories or auxiliary means therefor ; Construction of, or alloys for, mandrels or plugs
-
- 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
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B19/00—Tube-rolling by rollers arranged outside the work and having their axes not perpendicular to the axis of the work
- B21B19/02—Tube-rolling by rollers arranged outside the work and having their axes not perpendicular to the axis of the work the axes of the rollers being arranged essentially diagonally to the axis of the work, e.g. "cross" tube-rolling ; Diescher mills, Stiefel disc piercers or Stiefel rotary piercers
- B21B19/04—Rolling basic material of solid, i.e. non-hollow, structure; Piercing, e.g. rotary piercing mills
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3033—Ni as the principal constituent
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
- C21D1/42—Induction heating
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D6/00—Heat treatment of ferrous alloys
- C21D6/004—Heat treatment of ferrous alloys containing Cr and Ni
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D6/00—Heat treatment of ferrous alloys
- C21D6/005—Heat treatment of ferrous alloys containing Mn
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- C—CHEMISTRY; METALLURGY
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
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- C—CHEMISTRY; METALLURGY
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D6/00—Heat treatment of ferrous alloys
- C21D6/008—Heat treatment of ferrous alloys containing Si
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/057—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%
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- C22C—ALLOYS
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- C22C27/04—Alloys based on tungsten or molybdenum
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- C22C—ALLOYS
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
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- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
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- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
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- C22C38/52—Ferrous alloys, e.g. steel alloys containing chromium with nickel with cobalt
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
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- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
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- C—CHEMISTRY; METALLURGY
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- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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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
- 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
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- C23C4/067—Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
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- 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
- 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
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- C—CHEMISTRY; METALLURGY
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- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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- C—CHEMISTRY; METALLURGY
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- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
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- C—CHEMISTRY; METALLURGY
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- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Crystallography & Structural Chemistry (AREA)
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Description
図1は、本実施形態に係る製造方法によって製造されるピアサープラグ10の縦断面図である。縦断面とは、ピアサープラグ10の中心軸Xを含む断面であり、横断面とは、中心軸Xに垂直な断面である。ピアサープラグ10の中心軸Xが延びる方向を長手方向又は軸方向という。
プラグ本体1は、先端部11と、筒部12とを備える。筒部12は、先端部の後方に配置されている。筒部12は、穴121を有する。
炭素(C)は高温強度向上に対する有効成分である。C含有量が0.08%以下では効果がない。C含有量が0.5%を超えると、硬度が高くなりすぎる。また、炭化物の析出状態の制御がしにくくなる。したがって、C含有量は0.08〜0.5%とする。C含有量は、好ましくは0.3%以下であり、さらに好ましくは0.2%以下である。C含有量は、好ましくは0.09%以上であり、さらに好ましくは0.1%以上である。
シリコン(Si)は脱酸素に有効な成分である。Si含有量が0.1%以下では効果が小さい。Si含有量が1.0%を超えると素材の靭性が劣化し始める。したがって、Si含有量は0.1〜1.0%とする。Si含有量は、好ましくは0.9%以下であり、さらに好ましくは0.8%以下である。Si含有量は、好ましくは0.2%以上であり、さらに好ましくは0.3%以上である。
マンガン(Mn)は高温におけるオーステナイトを安定化する。すなわち、δフェライトの生成を抑制して靭性低下を抑制する。その効果はMn含有量が0.2%以上で得られる。しかし、Mn含有量が1.5%を超えると硬度が高くなりすぎ、穿孔後に焼き割れが生じやすくなる。したがって、Mn含有量は0.2〜1.5%とする。Mn含有量は、好ましくは1.4%以下であり、さらに好ましくは1.3%以下である。Mn含有量は、好ましくは0.3%以上であり、さらに好ましくは0.4%以上である。
ニッケル(Ni)はプラグ表層部に形成される焼き入れ相の靭性を改善する効果がある。その効果はNi含有量が2.0%でほぼ飽和する。それ以上の添加はコスト増加要因となる。したがって、Ni含有量は0〜2.0%とする。Ni含有量は、好ましくは1.9%以下であり、さらに好ましくは1.8%以下である。Ni含有量は、好ましくは0.2%以上であり、さらに好ましくは0.3%以上である。
モリブデン(Mo)及びタングステン(W)は置換可能な元素である。これらの元素は高温強度の改善に有効であり、かつAc1点を上昇させて穿孔後に表面に焼きが入る部分を低減する効果がある。しかし、総和が8.0%を超えると、高温でもフェライトが残留し、強度及び靭性が低下する。したがって、総和は8.0%以下とする。Mo含有量は、好ましくは3.9%以下であり、さらに好ましくは3.8%以下である。Mo含有量は、好ましくは0.75%以上であり、さらに好ましくは0.8%以上である。W含有量は、好ましくは3.9%以下であり、さらに好ましくは3.8%以下である。W含有量は、好ましくは0.75%以上であり、さらに好ましくは0.8%以上である。
銅(Cu)はオーステナイト安定化元素であり、穿孔時に高温に保持されてオーステナイトとなったプラグ表層部の靱性を改善する効果がある。したがって、Cu含有量は0〜0.5%とする。
ボロン(B)が少しでも含有されれば、粒界の強度を増加させる効果がある。しかし、B含有量が0.2%を超えると、逆に脆化相が析出し靭性が劣化する。したがって、B含有量は0〜0.2%とする。ニオブ(Nb)、バナジウム(V)、クロム(Cr)及びチタン(Ti)は少しでも含有すれば、結晶粒を微細化する効果がある。したがって、Nb、V及びTiの元素の含有量の各々は0〜1.0%とし、Cr含有量は0〜10.0%とする。
肉盛層2は、プラグ本体1の先端部11の表面上に形成される。肉盛層2は、少なくとも先端部11の表面全体を覆う。肉盛層2は、図2に示すように、先端部11の後方まで延びていてもよい。肉盛層2は、プラグ本体1の軸方向中央部付近まで設けられていてもよい。肉盛層2の後端は、筒部12の前端よりも前方に位置する。
図1を再度参照して、溶射皮膜3は、肉盛層2が形成されたプラグ本体1の表面上に形成されている。図1の例では、溶射皮膜3は、肉盛層2の表面全体、及びプラグ本体1の側面のうち肉盛層2から露出する部分の全体を覆う。すなわち、溶射皮膜3は、プラグ本体1の後端面のみを露出させるように、肉盛層2及びプラグ本体1の表面上に形成されている。
上記のように構成されたピアサープラグ10は、穿孔圧延に利用される。図4は、ピアサープラグ10が組み込まれた穿孔機100の概略構成を示す図である。図4に示すように、穿孔圧延に際し、ピアサープラグ10の穴121(図1及び図2)にバー(芯金)20の先端部が挿入されることにより、ピアサープラグ10にバー20が取り付けられる。ピアサープラグ10は、一対の傾斜ロール30,30の間において、パスラインPL上に配置される。ピアサープラグ10は、ビレットBの中央部に押し込まれる。これにより、ビレットBが穿孔圧延されて中空素管が形成される。
以下、ピアサープラグ10の製造方法について説明する。本実施形態に係る製造方法は、プラグ本体1を準備する工程と、肉盛層2を形成する工程と、溶射皮膜3を形成する工程と、肉盛層2及び溶射皮膜3が形成されたプラグ本体1を加熱する工程と、加熱されたプラグ本体1を冷却する工程とを備える。
ピアサープラグ10の製造に際し、まず、プラグ本体1を準備する。プラグ本体1は、例えば鍛造などによって作製することができる。
次に、プラグ本体1の先端部11の表面上に肉盛層2を形成する。これにより、プラグ本体1のうち、少なくとも先端部11が肉盛層2によって覆われる。肉盛層2は、軸方向の長さL2が肉盛層2の形成後のプラグ本体1の長さLの15〜50%(0.15×L≦L2≦0.50×L)となるように形成される。
次に、肉盛層2が形成されたプラグ本体1の表面上に、溶射皮膜3を形成する。本実施形態では、溶射皮膜3は、肉盛層2が形成されたプラグ本体1の表面のうち、後端面を除く部分全体に形成される。ただし、逃げ部103には溶射皮膜3を形成しなくてもよい。溶射皮膜3は、少なくとも圧延部104及びリーリング部105の全体に形成されればよい。
次に、肉盛層2及び溶射皮膜3が形成されたプラグ本体1を加熱する。具体的には、先端部11の温度がオーステナイト変態温度(Ac3点)以上になるようにプラグ本体1を加熱する。プラグ本体1の加熱工程において、筒部12の温度はAc3点未満に維持される。
次に、加熱されたプラグ10aを冷却する。例えば、加熱装置4又は加熱装置5による加熱を停止してその扉を開放し、プラグ10aを400℃以下に冷却する。プラグ10aは、通常、室温まで冷却される。冷却速度は、焼きが入る速度であればよく、放冷程度かそれ以上であればよい。
本実施形態に係る製造方法では、プラグ本体1の先端部11に肉盛層2が形成される。肉盛層2は、優れた高温強度を有する。このため、ピアサープラグ10によって穿孔圧延を行う際、先端部11の変形を抑制することができる。
Claims (3)
- ピアサープラグの製造方法であって、
先端部と、バーを取り付けるための穴を含み、前記先端部の後方に配置される筒部と、を備えるプラグ本体を準備する工程と、
前記先端部の表面上に肉盛層を形成する工程と、
前記肉盛層が形成された前記先端部の温度がオーステナイト変態温度以上になり、かつ前記筒部の温度が前記オーステナイト変態温度未満になるように、前記プラグ本体を加熱する工程と、
を備える、製造方法。 - 請求項1に記載のピアサープラグの製造方法であって、さらに、
前記加熱する工程に先だって、前記肉盛層が形成された前記プラグ本体の表面上に溶射皮膜を形成する工程、
を備える、製造方法。 - 請求項1又は2に記載のピアサープラグの製造方法であって、
前記肉盛層は、Ni−W合金で構成される、製造方法。
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