TWI532547B - Surface treatment of die - cast metal molds - Google Patents
Surface treatment of die - cast metal molds Download PDFInfo
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- TWI532547B TWI532547B TW100116421A TW100116421A TWI532547B TW I532547 B TWI532547 B TW I532547B TW 100116421 A TW100116421 A TW 100116421A TW 100116421 A TW100116421 A TW 100116421A TW I532547 B TWI532547 B TW I532547B
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- C23C8/30—Carbo-nitriding
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- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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- C23C8/28—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases more than one element being applied in one step
- C23C8/30—Carbo-nitriding
- C23C8/32—Carbo-nitriding of ferrous surfaces
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- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/34—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases more than one element being applied in more than one step
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- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/36—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases using ionised gases, e.g. ionitriding
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- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/36—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases using ionised gases, e.g. ionitriding
- C23C8/38—Treatment of ferrous surfaces
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- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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Description
本發明係關於一種藉由珠擊處理而對金屬模具設計面施加壓縮殘餘應力而提供之壓鑄金屬模具之表面處理方法。
於反覆進行金屬熔融液之注入、凝固以及成型品脫模之成型週期之壓鑄成型時,會因為依成型週期而施加之熱歷程,而於金屬模具之設計面較易產生細微的熱裂(熱龜裂),亦較易產生因機械性接觸所引起之磨損。該熱裂會發展為裂痕而使金屬模具損傷,磨損會降低成型品之尺寸精度。因此,為提高耐熱裂性或耐磨損性而延長金屬模具之壽命,會實施提高金屬模具設計面之硬度之表面氮化處理或賦予壓縮殘餘應力之珠擊處理等。
主要就處理之容易度、成本方面而言,金屬模具之表面氮化處理多藉由氣體氮化來進行。該方法係使氨氣於高溫下分解,使所產生之氮自金屬模具設計面向金屬模具內部擴散,從而施予擴散硬化層。另一方面,金屬模具中之珠擊處理主要係藉由以下方法進行:利用投射裝置使直徑1mm以下之由陶瓷或硬質金屬所構成之小球加速並噴射至金屬模具設計面。可藉由因小球之碰撞引起之加工硬化,對金屬模具設計面施加壓縮殘餘應力。
例如,於專利文獻1中揭示有:對金屬模具設計面實施氮化處理而形成氮擴散硬化層後,進而進行珠擊處理,從而對其表面施加較高之壓縮殘餘應力。藉由將該氮化處理與珠擊處理組合實施,可大幅提高金屬模具之壽命。
然而,亦已知於氮化處理中,於氮擴散硬化層之表面會形成缺乏塑性變形能力之化合物層。由於該化合物層會導致因熱裂所引起之裂痕之成長或因剝離所引起之磨損,故提出有不形成該化合物層、或儘量較薄地形成之氮化處理之方法。
例如,於專利文獻2中揭示有一種2段處理:於450~530℃之相對低之溫度範圍內進行氨氣氮化,其後減少或停止氨之供給,並且於550~590℃之處理溫度進行使氮內部擴散之熱處理。於相對低之溫度範圍內之氨氣氮化時,化合物層較薄地形成。另一方面,氮擴散層之深度亦變淺。因此,藉由熱處理而使氮擴散層之氮擴散至金屬模具深處,成為較薄狀態之化合物層並獲得較厚之氮擴散層。
同樣於專利文獻3中揭示有一種2段處理:於未達570℃之溫度之減壓下進行氨氣氮化,其後減少或停止氨之供給,並且於570℃~650℃之處理溫度進行使氮內部擴散之熱處理。其中提到:於該減壓下之氣體氮化時,可於較薄且非多孔之狀態下獲得氮化合物層,又藉由熱處理,氮擴散層之深度亦變得更深。
[專利文獻1]日本特開2004-148362號公報
[專利文獻2]日本特開平10-306364號公報
[專利文獻3]日本特開平11-100655號公報
於欲使如專利文獻2及3中所揭示之氮化合物層較薄地形成之氨氣氮化時,供給至金屬模具之氮之絕對量較少,如欲藉由熱處理而使氮擴散層之氮擴散至更深處,則無法賦予氮擴散層充分之硬度。
本發明係鑒於該情況而成者,其目的在於提供一種表面處理方法,其實質上不施予導致熱裂或磨損之氮化合物層,另一方面,可大量導入氮至金屬模具內部,結果,可形成耐熱裂性及耐磨損性優異之壓鑄金屬模具。
本發明人發現藉由熱處理,於氣體軟氮化、氣體浸硫氮化、電漿氮化等各種氮化處理中所形成之最表層之氮化合物可相對容易地分解。並且,於實質上不施予氮化合物層之金屬模具之製造方法的研究過程中得知:藉由該分解而產生氮,並使其擴散至金屬模具之內部,從而可增加供給至金屬模具之氮量。
因此,本發明之壓鑄金屬模具之表面處理方法,係對金屬模具設計面施加壓縮殘餘應力而提供者,其特徵在於:包含以下步驟:氮化步驟:導入至少含有氨氣之氣體至加熱爐內,從而於上述金屬模具設計面形成至少含有由氮化合物構成之化合物層的氮化層;化合物分解步驟:自上述加熱爐內排出氨氣並且導入環境氣體,進行加熱處理,從而使上述氮化合物分解;及珠擊步驟:對上述金屬模具設計面進行珠擊處理;於上述氮化步驟中形成之上述氮化層所含之上述化合物層的厚度在2~7μm之範圍內。
根據該方法,可將藉由導入至少含有氨氣之氣體至加熱爐內進行之氮化處理而形成之氮化合物層控制為特定之厚度,從而使該氮化合物於化合物分解步驟中分解,結果,實質上不施予氮化合物層,並可由藉此所產生之氮而增加供給至金屬模具之氮量,施予具有較高之硬度之氮擴散層。而且,實質上消失之氮化合物層含有較多空隙,會吸收珠擊處理中之珠粒之碰撞能量並使其散失。然而,於氮化步驟中,藉由仍然將該氮化合物層控制為特定之厚度,可賦予來自珠擊處理之壓縮殘餘應力。即,藉由較高之硬度與較高之壓縮殘餘應力,可提供耐磨損性以及耐熱裂性優異之壓鑄金屬模具。
於上述方法中,較佳為於上述化合物分解步驟中,於至少低於上述氮化步驟之溫度進行上述加熱處理。此時,可賦予更高之硬度及較高之壓縮殘餘應力,從而提供耐磨損性及耐熱裂性更優異之壓鑄金屬模具。
關於本發明之壓鑄金屬模具之表面處理方法,藉由如圖1至圖8所示之驗證試驗之結果,對其進行詳細說明。驗證試驗係藉由如下方式而進行:準備與壓鑄金屬模具對應之圓筒狀之試驗片1(參照圖1),從而實施各種表面處理,並對其進行評價。
準備如圖1所示之外徑D1=15mm、內徑D2=3mm以及長度L=20mm之圓筒狀之試驗片1。試驗片1係自與日本工業標準(JIS)合金工具鋼鋼材SKD61相當之圓桿材料加工而成。再者,代替與SKD61相當之材料,實施例9中係自與SKD7相當之圓桿材料,實施例10中係自與JIS合金工具鋼鋼材SKH51相當之圓桿材料而加工成試驗片1。關於各實施例以及比較例之鋼種,匯總示於圖2。
繼而,一面於加熱爐內加熱試驗片1一面導入氨氣至爐內,對試驗片1之外周面進行氣體軟氮化處理(氮化步驟)。再者,代替氣體軟氮化處理,於實施例6中進行氣體浸硫氮化處理,於實施例7及比較例5中進行電漿氮化處理。關於各實施例以及比較例中之氮化處理之種類、氣體、溫度以及時間,匯總示於圖2。
繼而,自加熱爐內排出氨氣後,導入氮作為環境氣體,於相同之加熱爐內直接對試驗片1進行加熱處理並實施擴散處理,如下所述使氮化處理中所產生之化合物層2(參照圖4)之氮化合物完全分解(化合物分解步驟)。關於該擴散處理之溫度以及時間,亦匯總示於圖2。
繼而,對試驗片1之外周面,例如,藉由0.3MPa之投射壓投射直徑0.05mm~0.2mm之非晶質製之小球,進行珠擊處理(珠擊步驟)。
對已實施上述處理之試驗片1,測定其長邊方向中央部附近之外周面之殘餘應力。
又,藉由如圖3所示之試驗裝置20,對試驗片1反覆進行加熱、冷卻試驗,從而評價耐熱裂性。詳細而言,將試驗裝置20之支撐部22之細徑部22a插入至試驗片1之貫通孔1a中,利用托架23自上下將試驗片1夾住並固定。利用高頻線圈21,用4秒鐘將試驗片1之外周面自室溫加熱至700℃,自未圖示之放水口噴射冷卻水24,用3秒鐘冷卻至室溫,藉由鼓風而使其乾燥1秒鐘。合計反覆1000次該加熱、冷卻以及乾燥之循環,自試驗裝置20將試驗片1拆下。關於自試驗裝置20拆下之試驗片1,於相對於中心軸垂直之平面對其長邊方向之中央部附近進行切割,填入樹脂後,對切割面進行鏡面研磨。利用光學顯微鏡(倍率100倍)對切割面進行觀察,並對於產生於試驗片1之外周面之熱裂(HC)之數量進行測定。
再者,將上述氮化處理後之試驗片1之一部分自爐中取出,並對下述化合物層2(參照圖4)之厚度進行測定。於相對於中心軸垂直之平面,對自爐中取出之試驗片1,於其長邊方向中央部附近進行切割,對切割面進行鏡面研磨後,利用光學顯微鏡進行觀察,並測定化合物層2之厚度。
然而,於氮化處理中,如圖4(a)以及圖5(a)所示,氣相中之經活化之氮自試驗片1之外周面向其內部(基材)4擴散,從而於外周面附近形成氮化層5。氮化層5係由最表層之氮化合物層2及其內部側之氮擴散層3所構成。化合物層2係由Fe或Cr之複合氮化物所構成,係非常脆之層。再者,與氣體氮化相比,於電漿氮化時其成長速度非常緩慢。氮擴散層3係含有分散析出之氮化物之氮的固溶層。
於繼上述氮化處理之後的擴散處理中,如圖4(b)以及圖5(b)所示,氮化層5之深度擴大。詳細而言,自氣相中通過試驗片1之外周面而供給之氮之通量下降,氮擴散層3之氮主要向試驗片1之內部擴散。此處,若化合物層2之氮化合物分解,則藉此所產生之氮亦向試驗片1之內部擴散,但由於化合物中所含有之氮濃度(參照圖5(a)之參照符號3a)大幅高於氮擴散層3之類之氮固溶體中所含有之氮濃度(參照圖5(a)之參照符號3b),故可獲得氮量大幅較多之氮擴散層3(參照圖5(b)之參照符號31)。再者,關於僅對藉由氮化處理而獲得之氮擴散層3進行擴散處理之情形,示於圖5(b)之參照符號32。
另一方面,若化合物層2之氮化合物分解,則由於其體積收縮,故成為含有較多空隙之表面層2'。該表面層2'會吸收珠擊處理中之珠粒之碰撞能量並使其散失,從而阻礙由此而產生之壓縮殘餘應力之形成。詳細如下文所述。
以下對上述之測定結果進行敍述。首先,關於反覆加熱、冷卻試驗後之熱裂(HC)之數量與化合物層2之厚度的關係示於圖6。
可知若使化合物層2之厚度增加,則熱裂之數量減少,從而提高耐熱裂性。即,於使化合物層2之厚度較薄地形成為1.5μm及1.0μm之比較例1及5中,熱裂數量分別為597條以及441條。相對於此,於使化合物層2之厚度更厚地形成為2~7μm之實施例1至14中,熱裂數量大幅減少至13~257條。
尤其於低於氮化處理溫度之溫度進行擴散處理(加熱處理)之實施例11中,熱裂數量大幅減少。因此可知較佳為於至少低於氮化步驟之溫度,進行化合物分解步驟中之加熱處理。
如上所述,若使化合物層2之厚度增加,則藉由擴散處理而分解之氮化合物之量會增加,故提高氮擴散層3之氮量,提高擴散處理後之硬度,並提高耐磨損性,並且提高耐熱裂性。
另一方面,亦可知若使化合物層2之厚度增加至特定以上,則使熱裂之數量急劇增加,且使耐熱裂性大幅降低。即,於使化合物層2之厚度較厚地形成為8.0、9.0以及10.0μm之比較例2、3以及4中,熱裂數量分別為706、707以及840條,與實施例1至14相比,急劇增加。
關於上述之藉由珠擊處理,而對試驗片1施加之壓縮殘餘應力與化合物層2之厚度的關係,示於圖7。再者,於圖7中,壓縮應力係以負值表示。
可知若使化合物層2之厚度增加,則能使壓縮殘餘應力之絕對值增加。即,於使化合物層2之厚度較薄地形成為1.5μm以及1.0μm之比較例1以及5中,壓縮殘餘應力分別為-965MPa以及-993MPa。相對於此,於使化合物層2之厚度較厚地形成為2~7μm之實施例1至14中,壓縮殘餘應力為-1350MPa~-1755MPa,其絕對值大幅增加。
另一方面,亦可知若使化合物層2之厚度增加至特定以上,則能使壓縮殘餘應力之絕對值急劇降低。即,於使化合物層2之厚度較厚地形成為8.0、9.0以及10.0μm之比較例2、3以及4中,壓縮殘餘應力分別為-1298MPa、-1251MPa、以及-938MPa,與實施例1至14相比,其絕對值大幅下降。
如上所述,若使化合物層2之厚度增加至特定以上,則使壓縮殘餘應力之絕對值大幅降低,從而使耐熱裂性大幅降低。其原因在於,表面層2'較多地含有化合物層2之化合物分解而形成之空隙(參照圖4(b))。即,由於化合物層2變厚,藉由擴散處理而亦使表面層2'較厚地形成,從而急劇阻礙來自珠擊處理之壓縮殘餘應力之形成,結果,耐熱裂性大幅下降。
圖8(a)係實施例11中之氮化處理後之試驗片1之切割面的光學顯微鏡照片。又,圖8(b)係實施例11中繼氮化處理後施加擴散處理後之試驗片1之切割面的光學顯微鏡照片。於前者中,觀察到化合物層2以及氮擴散層3。另一方面,於後者中,觀察到氮擴散層3之厚度增加,並且化合物分解,尤其於接近氮擴散層3之側,觀察到黑色且含有空隙之表面層2'。
根據以上情況,藉由將化合物層2之厚度,即化合物分解後殘餘之含有空隙之表面層2'之厚度限制為固定,可良好地施加來自珠擊處理之壓縮殘餘應力,從而提供耐熱裂性優異之壓鑄金屬模具。尤其於如實施例之通常之珠擊處理之條件下,用以達成該目的之化合物層2(化合物分解後殘餘之表面層2')之厚度為2~7μm。
然而,關於如實施例6及7之氣體軟氮化與氣體浸硫氮化以及電漿氮化等氮化處理之差異、以及如實施例9及實施例10之相當於SKD61之材料與相當於SKD7之材料以及相當於SKH51之材料之鋼材的差異,於同一圖表上列有圖6及圖7之化合物層2之厚度與熱裂數量以及壓縮殘餘應力的關係。即暗示:與氮化處理之差異、以及通常之金屬模具材料之差異無關,均能應用本發明之方法。
以上之本實施例之壓鑄金屬模具之表面處理方法包含以下步驟:氮化步驟:藉由氣體軟氮化、氣體浸硫氮化、電漿氮化等氮化處理(該等處理係將至少含有氨氣之氣體導入加熱爐內),於金屬模具設計面形成至少含有由氮化合物所構成之化合物層的氮化層;化合物分解步驟:自加熱爐內排出氨氣並且導入環境氣體,進行加熱處理,從而使氮化合物分解;以及珠擊步驟:對金屬模具設計面進行珠擊處理。此處,於氮化步驟中所形成之氮化層所含之化合物層之厚度在2~7μm之範圍內。
將因為「導入至少含有氨氣之氣體至加熱爐內而進行之氮化處理」而形成之氮化合物層控制為特定之厚度,藉此使該氮化合物於化合物分解步驟中分解,結果,實質上不施予氮化合物層,並可由藉此所產生之氮而增加供給至金屬模具之氮量,從而施予具有較高之硬度之氮擴散層。而且,實質上消失之氮化合物層成為含有較多空隙之層而殘餘,吸收珠擊處理中之珠粒之碰撞能量並使其散失。然而,藉由於氮化步驟中仍然將該氮化合物層控制為特定之厚度,可對氮擴散層賦予來自珠擊處理之壓縮殘餘應力。即,藉由較高之硬度與較高之壓縮殘餘應力,可提供耐磨損性及耐熱裂性優異之壓鑄金屬模具。
至此對本發明之代表性實施例以及基於其之變形例進行了說明,但本發明未必限定於該等。即,只要為發明所屬技術領域中具有通常知識者,應可於不脫離隨附之申請專利範圍之前提下,發現各種代替實施例以及改變例。
例如於上述之說明中,雖表示了試驗片之具體形狀以及尺寸,但其目的僅為方便說明,而並非限定本發明。
1...試驗片
1a...貫通孔
2...化合物層
2'...表面層
3...氮擴散層
3a、3b...氮濃度參照符號
4...基材
5...氮化層
20...試驗裝置
21...高頻線圈
22...支撐部
22a...細徑部
23...托架
24...冷卻水
31、32...參照符號
D1...外徑
D2...內徑
L...長度
圖1係本發明之金屬模具表面處理方法之實施例中所使用之試驗片的斜視圖。
圖2係表示圖1之試驗片之鋼種以及表面處理條件的圖。
圖3係表示本發明之金屬模具表面處理方法之實施例中所使用的加熱、冷卻試驗裝置之一例的圖。
圖4係表示本發明之金屬模具表面處理方法中之氮化步驟後(圖4(a))以及化合物分解步驟後(圖4(b))的試驗片之表面附近之變化的放大剖面圖。
圖5之圖5(a)以及圖5(b)係表示圖4(a)以及圖4(b)之試驗片的表面附近之氮濃度之變化的圖。
圖6係表示已實施本發明之金屬模具表面處理方法之試驗片的化合物層厚度與熱裂(HC)數量之關係的圖表。
圖7係表示本發明之金屬模具表面處理方法中之珠擊步驟之試驗片的化合物層厚度與殘餘應力之關係的圖表。
圖8係本發明之金屬模具表面處理方法中之氮化步驟後的試驗片(實施例11)之剖面的照片。
Claims (2)
- 一種壓鑄金屬模具之表面處理方法,係於金屬模具設計面施加壓縮殘餘應力而提供,其包含以下步驟:氮化步驟:導入至少含有氨氣之氣體至加熱爐內,從而於該金屬模具設計面形成至少含有由氮化合物構成之化合物層的氮化層;化合物分解步驟:自該加熱爐內排出氨氣並導入環境氣體,進行加熱處理,從而使該氮化合物分解;及珠擊步驟:對該金屬模具設計面進行珠擊處理,於該氮化步驟中形成之該氮化層所含之該化合物層的厚度在2~7μm之範圍內。
- 如申請專利範圍第1項之壓鑄金屬模具之表面處理方法,其中,於該化合物分解步驟中,於至少低於該氮化步驟之溫度進行該加熱處理。
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WO2015137388A1 (ja) | 2014-03-11 | 2015-09-17 | 本田技研工業株式会社 | 鋼部品およびその製造方法 |
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