US20150017043A1 - Powder metal with solid lubricant and powder metal scroll compressor made therefrom - Google Patents
Powder metal with solid lubricant and powder metal scroll compressor made therefrom Download PDFInfo
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- US20150017043A1 US20150017043A1 US14/377,218 US201314377218A US2015017043A1 US 20150017043 A1 US20150017043 A1 US 20150017043A1 US 201314377218 A US201314377218 A US 201314377218A US 2015017043 A1 US2015017043 A1 US 2015017043A1
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- Prior art keywords
- powder
- powder metal
- scroll compressor
- solid lubricant
- graphite
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- 239000000843 powder Substances 0.000 title claims abstract description 180
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 149
- 239000002184 metal Substances 0.000 title claims abstract description 149
- 239000000314 lubricant Substances 0.000 title claims abstract description 86
- 239000007787 solid Substances 0.000 title claims abstract description 81
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 86
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical group [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 72
- 239000010439 graphite Substances 0.000 claims description 36
- 229910002804 graphite Inorganic materials 0.000 claims description 36
- 229910052759 nickel Inorganic materials 0.000 claims description 36
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 33
- 229910052799 carbon Inorganic materials 0.000 claims description 26
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 20
- 238000005245 sintering Methods 0.000 claims description 19
- 229910052623 talc Inorganic materials 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 17
- 239000002245 particle Substances 0.000 claims description 17
- 239000007769 metal material Substances 0.000 claims description 15
- 239000000470 constituent Substances 0.000 claims description 14
- 239000000454 talc Substances 0.000 claims description 13
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 11
- 238000005056 compaction Methods 0.000 claims description 11
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 229910052582 BN Inorganic materials 0.000 claims description 6
- 229910017112 Fe—C Inorganic materials 0.000 claims description 5
- 238000012545 processing Methods 0.000 claims description 5
- 230000000717 retained effect Effects 0.000 claims description 2
- 239000000203 mixture Substances 0.000 abstract description 16
- 238000009472 formulation Methods 0.000 abstract description 14
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 239000010949 copper Substances 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000003507 refrigerant Substances 0.000 description 3
- 238000007792 addition Methods 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000007858 starting material Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 239000001993 wax Substances 0.000 description 2
- 238000005275 alloying Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- -1 for example Substances 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 235000013350 formula milk Nutrition 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- HGPXWXLYXNVULB-UHFFFAOYSA-M lithium stearate Chemical compound [Li+].CCCCCCCCCCCCCCCCCC([O-])=O HGPXWXLYXNVULB-UHFFFAOYSA-M 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000002923 metal particle Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 150000002815 nickel Chemical class 0.000 description 1
- 239000004482 other powder Substances 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 235000020610 powder formula Nutrition 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0264—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5%
-
- B22F1/007—
-
- B22F1/0003—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/09—Mixtures of metallic powders
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
- F04C18/02—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents
- F04C18/0207—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
- F04C18/02—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents
- F04C18/0207—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form
- F04C18/0215—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form where only one member is moving
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
- F04C18/02—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents
- F04C18/0207—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form
- F04C18/0246—Details concerning the involute wraps or their base, e.g. geometry
- F04C18/0253—Details concerning the base
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C29/00—Component parts, details or accessories of pumps or pumping installations, not provided for in groups F04C18/00 - F04C28/00
- F04C29/02—Lubrication; Lubricant separation
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01C—ROTARY-PISTON OR OSCILLATING-PISTON MACHINES OR ENGINES
- F01C17/00—Arrangements for drive of co-operating members, e.g. for rotary piston and casing
- F01C17/06—Arrangements for drive of co-operating members, e.g. for rotary piston and casing using cranks, universal joints or similar elements
- F01C17/066—Arrangements for drive of co-operating members, e.g. for rotary piston and casing using cranks, universal joints or similar elements with an intermediate piece sliding along perpendicular axes, e.g. Oldham coupling
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2230/00—Manufacture
- F04C2230/20—Manufacture essentially without removing material
- F04C2230/22—Manufacture essentially without removing material by sintering
Definitions
- This disclosure relates to powder metal formulations including solid lubricants and further relates to powder metal parts, such as scroll compressors, made using these powder metal formulations.
- Scroll compressors are typically used for compressing gases or a refrigerant.
- two parts are situated so as to have interleaving and complimentary scroll portions.
- These scroll portions may be shaped as involutes, spirals, or other such curves.
- one of the scroll portions is gyrated relative to the other scroll portion. This movement of the scroll portions relative to one another causes the points of contact between the two scroll portions to vary. These changing points of contact between the scrolls, when made over a continuous length, can result in the forced movement and the compression of gases and/or refrigerants between the two parts.
- the parts for a scroll compressor can have relatively complex geometries (i.e., may have an involute or a spiral shape) and can present fabrication challenges. Because powder metallurgy is well adapted to handle certain complex geometries and high part volumes, powder metal processes have been explored as one means to make the scroll portion of a scroll compressor or, more ambitiously, all of a scroll compressor.
- Powder metal parts may be fabricated in the following manner.
- a powder metal starting material is compacted under pressure using a die and tool set to form the loose powder metal into a powder metal compact.
- This powder metal compact has a shape that is relatively close to, but slightly larger than, the shape of the final desired part.
- This powder metal compact is then sintered to cause the adjacent powder metal particles to diffuse into one another and to neck together thereby bonding the particles together.
- This sintering is typically done at just below the melting temperature of the powder metal material but, in some instances, a liquid phase may also be developed during sintering.
- the sintered powder metal forms a much stronger sintered part that might be subjected to any of a number of finishing processes (e.g., machining, grinding, deburring, and so forth), reworking (e.g., forging or coining), or simply used as-sintered.
- finishing processes e.g., machining, grinding, deburring, and so forth
- reworking e.g., forging or coining
- a powder metal formulation is disclosed which is particularly useful in the production of powder metal scroll compressors.
- This powder metal formulation includes a solid lubricant such as, for example, talc or boron nitride which is carried through the powder metal formation process such that the solid lubricant is part of the final powder metal scroll compressor.
- the solid lubricant is a nickel-coated graphite powder.
- the solid lubricant is admixed with the other constituents of the powder metal material.
- a scroll compressor can be made that includes a solid lubricant.
- this solid lubricant helps promote smooth contact between the scrolls with reduced amounts of friction.
- the solid lubricant is also inert such that it does not present any concerns when it is used to compress, for example, a refrigerant.
- a powder metal scroll compressor includes a hub and a scroll adjoined to one another in which a powder metal forms at least a portion of the powder metal scroll compressor including the scroll.
- the powder metal includes iron powder, carbon in an amount of less than 0.9% by weight of the powder metal, and a solid lubricant in the powder metal.
- the iron powder and solid lubricant may be admixed with one another prior to compaction and sintering of the powder metal scroll compressor.
- the solid lubricant may be 0.25% to 3.0% by weight of the powder metal and the powder metal may include only iron powder, carbon, the solid lubricant and be substantially free of other constituents.
- the powder metal may contain other constituents.
- the powder metal may further include copper powder (which may be elemental copper powder) in an amount of less than 3.0% by weight of the powder metal.
- the iron powder, the copper powder, and the solid lubricant may be admixed with one another prior to compaction and sintering of the powder metal scroll compressor and the powder metal may include only iron powder, carbon, copper powder, and the solid lubricant and be substantially free of other constituents.
- solid lubricants may be suitable for use in the powder metal.
- the solid lubricant should be capable of surviving the compaction and sintering process (for example, not burn off at sintering temperatures).
- the solid lubricants being referred to are not typical lubricants, waxes, or binders that are conventionally used to help the compacted powder metal parts retain their shape or be ejected from the compaction tooling, as those conventional lubricants, waxes, or binders are consumed and lost during any initial burn off and/or sintering operations.
- many of the solid lubricants described herein remain inert and stable in an Fe—C or an Fe—Cu—C system through processing of temperatures up to 1080 degrees Centigrade, for example.
- talc Mg 3 Si 4 O 10 (OH) 2
- the talc may have a nominal 15 to 25 micron mean particle size (d50).
- hexagonal boron nitride BN
- the hexagonal boron nitride may have a nominal 5 to 30 micron mean particle size (d50).
- the solid lubricant may be provided in the form of a nickel-coated graphite powder.
- the carbon may be present in an amount of less than 0.9% by weight of the powder metal material, exclusive of the graphite of the nickel-coated graphite powder (as this graphite powder does not significantly contribute to the carbon content in the iron).
- a nickel coating of the nickel-coated graphite powder may substantially surround the graphite to protect the graphite during sintering of the powder metal scroll compressor and to prevent the graphite from combining with the iron powder.
- a nickel content of the nickel-coated graphite powder may be in a range of 55 to 80 wt % with the remainder being graphite.
- a total amount of graphite in the powder metal scroll compressor may be in the range of 0.5 to 5.0 wt %, or more narrowly 1.0 to 3.0 wt %, exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material.
- the nickel-coated graphite powder may have an average particle size of approximately 100 microns.
- a powder metal such as a powder metal that may be used for a powder metal scroll compressor of the type described above.
- the powder metal includes iron powder, carbon in an amount of less than 0.9% by weight of the powder metal material, and a solid lubricant.
- the iron powder and solid lubricant are admixed with one another.
- the powder metal may include iron powder, carbon, the solid lubricant and be substantially free of other constituents.
- the powder metal may further include a copper powder (such as an elemental copper powder) in an amount of less than 3.0% by weight of the powder metal.
- the iron powder, the copper powder, and the solid lubricant may be admixed with one another, and the powder metal may include iron powder, carbon, copper powder, and the solid lubricant and be substantially free of other constituents.
- the solid lubricant may be 0.25% to 3.0% by weight of the powder metal.
- the solid lubricant may remain inert and stable in an Fe—C or an Fe—Cu—C system through processing of temperatures up to 1080 degrees Centigrade.
- the solid lubricant may be talc (Mg 3 Si 4 O 10 (OH) 2 ).
- the talc may have a nominal 15 to 25 micron mean particle size (d50).
- the solid lubricant may be hexagonal boron nitride (BN).
- BN hexagonal boron nitride
- the hexagonal boron nitride may have a nominal 5 to 30 micron mean particle size (d50).
- the solid lubricant may be a nickel-coated graphite powder and in which the carbon in an amount of less than 0.9% by weight of the powder metal material is exclusive of the graphite of the nickel-coated graphite powder.
- a nickel coating of the nickel-coated graphite powder may substantially surround the graphite to protect the graphite during sintering of the powder metal scroll compressor and to prevent the graphite from combining with the iron powder.
- a nickel content of the nickel-coated graphite powder may be in a range of 55 to 80 wt % with the remainder being graphite.
- a total amount of graphite in the powder metal scroll compressor may be in the range of 0.5 to 5.0 wt %, or more narrowly 1.0 to 3.0 wt %, exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material.
- the nickel-coated graphite powder may be an average particle size of approximately 100 microns.
- a part may be made using any of the powder metal formulations described herein by compacting and sintering the powder metal to form the part.
- the solid lubricant is retained throughout the process and is dispersed throughout the part including the surface of the part. It may be particularly advantageous when this surface of the part is a bearing surface such that the solid lubricant can serve as a lubricant on this surface.
- FIG. 1 is a top perspective view of a one-piece scroll compressor showing the hub side.
- FIG. 2 is a bottom perspective view of the scroll compressor of FIG. 1 showing the scroll side.
- FIG. 3 is a top plan view of the scroll compressor of FIG. 1 .
- FIG. 4 is a cross-sectional side view of the scroll compressor taken along line 4 - 4 of FIG. 3 .
- the powder metal scroll compressor 100 can be produced from a single powder metal compact using the powder metal processes according to the method described in PCT International Publication No. WO 2010/135232 later filed as a U.S. national phase application having Ser. No. 13/320,867 and published as US 2012/0118104, which is incorporated by reference as if set forth in its entirety herein.
- the powder metal formulation could be used to separately make one or more portions of the part or the entirety of the part using, for example, the methods described in PCT International Publication No. WO 2010/135232 and U.S. Patent Application Publication No. US 2012/0118104.
- the details of the structure and the processes used to fabricate the scroll compressor should not be so limited to only the structures and methods explicitly listed. Accordingly, the below described scroll compressor is intended to be illustrative, but not limiting.
- the scroll compressor 100 is a powder metal part which is formed by compression along an axis of compaction A-A.
- the scroll compressor 100 includes a flange 102 , a hub 104 , and a scroll 106 .
- the flange 102 has a top face 108 and a bottom face 110 which extend in a direction perpendicular to the axis A-A and which are essentially planar and parallel to one another.
- Two mounting slots 112 are formed around an outer periphery of the flange 102 for mounting the scroll compressor 100 to another item in a refrigeration assembly or the like.
- the hub 104 axially extends from the top face 108 of the flange 102 .
- the hub 104 is generally cylindrically-shaped and has a radially outward facing surface 114 , a radially inward facing surface 116 , and a top axial face 118 . Both the radially outward facing surface 114 and the radially inward facing surface 116 may have a slight taper as they extend away from the top face 108 of the flange 102 towards the top axial face 118 . By having a taper, the scroll compressor 100 can be more easily separated from the tool members during the ejection process.
- the scroll 106 extends axially from the bottom face 110 of the flange 102 .
- the scroll 106 is a spiraling wall that spirals relative to the axis A-A.
- the scroll 106 includes an inner wall end 120 and an outer wall end 122 with a generally radially outward facing surface 124 and a generally radially inward facing surface 126 extending between the ends 120 and 122 .
- These surfaces 124 and 126 run generally parallel to one another as they spiral away from the axis A-A, creating a spiraling wall of uniform thickness.
- a bottom axial face 128 of the scroll 106 is also spiral-shaped.
- the generally radially outward facing surface 124 and the generally radially inward facing surface 126 may have a taper to ease the ejection process from the tool and die set during compaction of the powder metal.
- the spiral is similar to an Archimedean spiral, meaning that if a radial line is drawn relative to the axis A-A, a channel 130 formed between the generally radially outward and inward facing surfaces 124 and 126 is also of substantially constant width regardless of the distance from the axis A-A.
- other involute geometries might be used and nothing should limit the scroll compressor geometry to that which is illustrated in FIGS. 1 through 4 .
- top features such as the hub 104 are formed by transferring powder metal within the die cavity by a powder transfer motion of the lower tool members. As the powder is transferred, the powder fill to final part ratio along the vertical columns of the part must be approximately 2:1 to provide a part that is relatively uniformly dense after the compaction process.
- the powder metal used to make this powder metal scroll compressor includes iron powder (either elemental or prealloyed iron), carbon in an amount less than 0.9 wt % of the powder metal, and solid lubricant in an amount between 0.25 wt % and 3.0 wt % of the powder metal.
- iron powder either elemental or prealloyed iron
- carbon in an amount less than 0.9 wt % of the powder metal
- solid lubricant in an amount between 0.25 wt % and 3.0 wt % of the powder metal.
- Other elemental additions could also be included such as, for example, copper (Cu) and nickel (Ni).
- the powder metal formulation is relatively simplistic in that it does not require more than these listed constituents, but may include trace amounts of other elements that do not substantially affect the properties of the powder metal.
- the various constituent powders may be admixed together along with pressing lubricants (e.g., lithium stearate, Licowax, etc.) in addition to the solid lubricant.
- pressing lubricants e.g., lithium stearate, Licowax, etc.
- the solid lubricant for this powder metal formulation may be talc, which is also known as hydrated magnesium silicate and has the chemical formula of Mg 3 Si 4 O 10 (OH) 2 .
- talc When used as a solid lubricant, some amount of quartz impurity may exist within the talc.
- the talc When talc is used as the solid lubricant, the talc may be preferably provided in a powder form having a nominal 15 to 25 micron mean particle size (d50).
- the solid lubricant for this powder formulation may be a hexagonal boron nitride (BN).
- BN hexagonal boron nitride
- the boron nitride may be preferably provided in a powder form having a nominal 5 to 30 micron mean particle size (d50).
- nickel-coated graphite powder As the solid lubricant.
- the nickel coating protects the graphite during sintering and prevents the graphite from combining with the iron powder. In the finished product, the coating protects and preserves the graphite until rupture of the nickel coating during use of the component (e.g., rupture due to wear on surfaces), to release the graphite lubricant.
- the nickel-coated graphite has nickel content ranging from 55 to 80 wt % with the remainder being graphite.
- the nickel-coated graphite powder may have an average particle size of approximately 100 microns.
- Graphite size may be coarse (Tyler mesh size ⁇ 120/+230 at 88-98% or a range of 115 to 65 microns) to fine (Tyler mesh size ⁇ 120/+270 at >85% and ⁇ 270/+325 ⁇ 15% or a range of 115 to 43 microns) with both having a small amount of more coarse and finer particle sizes ( ⁇ 5 wt %).
- the solid lubricant is added to the mix to provide a graphite level of 0.5 wt % to 5 wt %, although a graphite range of 1 wt % to 3 wt % is believed to be typical for most applications. This graphite is exclusive of the carbon content in the powder metal which is used to alter the metallurgical properties of the iron powder.
- this powder metal formulation incorporates the powder for the solid lubricant as an admixed constituent in the powder metal.
- the admixed solid lubricant is inert in Fe—C, Fe—Cu—C and other powder metal mixtures processed at temperatures around 1180 degrees Centigrade. This means that even after the powder metal has been compacted and sintered into a final part, all or a substantial portion of the solid lubricant remains present.
- the solid lubricant assists in reducing frictional heat and spalling/galling in a system with reciprocal motion under a mechanical load such as that in which a scroll compressor is used (and, in particular, in the scroll section of the scroll compressor).
- the solid lubricant is resistant to adhesion and does not create significant resistance to motion of the scroll compressor.
- the inclusion of the solid lubricant may be best implemented in powder metal parts that have ferritic/pearlitic microstructures and its inclusion can also be used for improving machinability.
- the powder metal formulation can be formulated to have less than 0.9 wt % carbon, less than 3.0% copper, and between 0.25 to 3.0 wt % of solid lubricant with the remainder of the powder being elemental iron with no other substantial additions. Again, this is a relatively simple powder formula that does not contain a large number of alloying elements.
- Powder metal formulations such as those described above can be prepared and then processed into a sintered powder metal part by compacting the powder into a powder metal compact and then sintering the powder. It is contemplated that such parts might be compacted as unitary bodies or might be formed from separately compacted components that are subsequently joined together to form a single final part. However, it is contemplated that any section of a part made from various joined sections may have the powder metal containing the solid lubricant in those sections in which the solid lubricant will be most desirable.
- the scroll section of a scroll compressor may be made using the powder described above, while the other section to which the scroll section is joined may be made of a powder metal material that does not include the solid lubricant. Of course, nothing excludes both sections of a multi-portion component from being made of a powder containing the solid lubricant even if they are joined.
- this process allows for conventional compaction processes in rigid dies and eliminates the subsequent infiltration of a solid lubricant into the porous sintered body after sintering.
Abstract
A powder metal formulation includes a solid lubricant and is particularly useful for the production of powder metal scroll compressors.
Description
- This claims the benefit of U.S. Provisional Patent Application No. 61/599,042 filed Feb. 15, 2012 and U.S. Provisional Patent Application No. 61/720,226 filed Oct. 30, 2012. The contents of both of these applications are incorporated by reference as if set forth in their entirety herein for all purposes.
- This disclosure relates to powder metal formulations including solid lubricants and further relates to powder metal parts, such as scroll compressors, made using these powder metal formulations.
- Scroll compressors are typically used for compressing gases or a refrigerant. In such a scroll compressor, two parts are situated so as to have interleaving and complimentary scroll portions. These scroll portions may be shaped as involutes, spirals, or other such curves.
- During operation of the scroll compressor, one of the scroll portions is gyrated relative to the other scroll portion. This movement of the scroll portions relative to one another causes the points of contact between the two scroll portions to vary. These changing points of contact between the scrolls, when made over a continuous length, can result in the forced movement and the compression of gases and/or refrigerants between the two parts.
- As noted above, the parts for a scroll compressor can have relatively complex geometries (i.e., may have an involute or a spiral shape) and can present fabrication challenges. Because powder metallurgy is well adapted to handle certain complex geometries and high part volumes, powder metal processes have been explored as one means to make the scroll portion of a scroll compressor or, more ambitiously, all of a scroll compressor.
- Powder metal parts may be fabricated in the following manner. A powder metal starting material is compacted under pressure using a die and tool set to form the loose powder metal into a powder metal compact. This powder metal compact has a shape that is relatively close to, but slightly larger than, the shape of the final desired part. This powder metal compact is then sintered to cause the adjacent powder metal particles to diffuse into one another and to neck together thereby bonding the particles together. This sintering is typically done at just below the melting temperature of the powder metal material but, in some instances, a liquid phase may also be developed during sintering. In comparison to the initial powder metal compact, the sintered powder metal forms a much stronger sintered part that might be subjected to any of a number of finishing processes (e.g., machining, grinding, deburring, and so forth), reworking (e.g., forging or coining), or simply used as-sintered.
- A powder metal formulation is disclosed which is particularly useful in the production of powder metal scroll compressors. This powder metal formulation includes a solid lubricant such as, for example, talc or boron nitride which is carried through the powder metal formation process such that the solid lubricant is part of the final powder metal scroll compressor. In another example, the solid lubricant is a nickel-coated graphite powder. In some forms, the solid lubricant is admixed with the other constituents of the powder metal material. These solid lubricants remain stable at the elevated processing temperatures employed during the sintering of the powder metal and so this solid lubricant remains in and, at least to some degree, available at the surface of the powder metal part after sintering.
- Using this powder metal as a starting material, a scroll compressor can be made that includes a solid lubricant. Among other things, this solid lubricant helps promote smooth contact between the scrolls with reduced amounts of friction. The solid lubricant is also inert such that it does not present any concerns when it is used to compress, for example, a refrigerant.
- According to one aspect, a powder metal scroll compressor is provided. The powder metal scroll compressor includes a hub and a scroll adjoined to one another in which a powder metal forms at least a portion of the powder metal scroll compressor including the scroll. The powder metal includes iron powder, carbon in an amount of less than 0.9% by weight of the powder metal, and a solid lubricant in the powder metal.
- The iron powder and solid lubricant may be admixed with one another prior to compaction and sintering of the powder metal scroll compressor.
- In one form, the solid lubricant may be 0.25% to 3.0% by weight of the powder metal and the powder metal may include only iron powder, carbon, the solid lubricant and be substantially free of other constituents.
- However, in other forms, the powder metal may contain other constituents. For example, the powder metal may further include copper powder (which may be elemental copper powder) in an amount of less than 3.0% by weight of the powder metal. In this form, the iron powder, the copper powder, and the solid lubricant may be admixed with one another prior to compaction and sintering of the powder metal scroll compressor and the powder metal may include only iron powder, carbon, copper powder, and the solid lubricant and be substantially free of other constituents.
- Various types of solid lubricants may be suitable for use in the powder metal. In order to provide the lubricating function in the final component, the solid lubricant should be capable of surviving the compaction and sintering process (for example, not burn off at sintering temperatures). Thus, one having ordinary skill in the art will appreciate that the solid lubricants being referred to are not typical lubricants, waxes, or binders that are conventionally used to help the compacted powder metal parts retain their shape or be ejected from the compaction tooling, as those conventional lubricants, waxes, or binders are consumed and lost during any initial burn off and/or sintering operations. Accordingly, many of the solid lubricants described herein remain inert and stable in an Fe—C or an Fe—Cu—C system through processing of temperatures up to 1080 degrees Centigrade, for example.
- One solid lubricant that may be used is talc (Mg3Si4O10(OH)2). The talc may have a nominal 15 to 25 micron mean particle size (d50).
- Another solid lubricant that may be used is hexagonal boron nitride (BN). The hexagonal boron nitride may have a nominal 5 to 30 micron mean particle size (d50).
- The solid lubricant may be provided in the form of a nickel-coated graphite powder. In this instance, the carbon may be present in an amount of less than 0.9% by weight of the powder metal material, exclusive of the graphite of the nickel-coated graphite powder (as this graphite powder does not significantly contribute to the carbon content in the iron). A nickel coating of the nickel-coated graphite powder may substantially surround the graphite to protect the graphite during sintering of the powder metal scroll compressor and to prevent the graphite from combining with the iron powder. A nickel content of the nickel-coated graphite powder may be in a range of 55 to 80 wt % with the remainder being graphite. A total amount of graphite in the powder metal scroll compressor may be in the range of 0.5 to 5.0 wt %, or more narrowly 1.0 to 3.0 wt %, exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material. The nickel-coated graphite powder may have an average particle size of approximately 100 microns.
- According to another aspect, a powder metal is provided, such as a powder metal that may be used for a powder metal scroll compressor of the type described above. The powder metal includes iron powder, carbon in an amount of less than 0.9% by weight of the powder metal material, and a solid lubricant. The iron powder and solid lubricant are admixed with one another.
- In one form of the powder metal, the powder metal may include iron powder, carbon, the solid lubricant and be substantially free of other constituents.
- In another form, the powder metal may further include a copper powder (such as an elemental copper powder) in an amount of less than 3.0% by weight of the powder metal. The iron powder, the copper powder, and the solid lubricant may be admixed with one another, and the powder metal may include iron powder, carbon, copper powder, and the solid lubricant and be substantially free of other constituents.
- The solid lubricant may be 0.25% to 3.0% by weight of the powder metal. For the reasons identified above relating to the retention of the solid lubricant in the final part, the solid lubricant may remain inert and stable in an Fe—C or an Fe—Cu—C system through processing of temperatures up to 1080 degrees Centigrade.
- In one form of the powder metal, the solid lubricant may be talc (Mg3Si4O10(OH)2). The talc may have a nominal 15 to 25 micron mean particle size (d50).
- In another form, the solid lubricant may be hexagonal boron nitride (BN). The hexagonal boron nitride may have a nominal 5 to 30 micron mean particle size (d50).
- In still another form, the solid lubricant may be a nickel-coated graphite powder and in which the carbon in an amount of less than 0.9% by weight of the powder metal material is exclusive of the graphite of the nickel-coated graphite powder.
- A nickel coating of the nickel-coated graphite powder may substantially surround the graphite to protect the graphite during sintering of the powder metal scroll compressor and to prevent the graphite from combining with the iron powder. A nickel content of the nickel-coated graphite powder may be in a range of 55 to 80 wt % with the remainder being graphite. A total amount of graphite in the powder metal scroll compressor may be in the range of 0.5 to 5.0 wt %, or more narrowly 1.0 to 3.0 wt %, exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material. The nickel-coated graphite powder may be an average particle size of approximately 100 microns.
- A part may be made using any of the powder metal formulations described herein by compacting and sintering the powder metal to form the part. The solid lubricant is retained throughout the process and is dispersed throughout the part including the surface of the part. It may be particularly advantageous when this surface of the part is a bearing surface such that the solid lubricant can serve as a lubricant on this surface.
- These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of some preferred embodiments of the present invention. To assess the full scope of the invention, the claims should be looked to as these preferred embodiments are not intended to be the only embodiments within the scope of the claims.
-
FIG. 1 is a top perspective view of a one-piece scroll compressor showing the hub side. -
FIG. 2 is a bottom perspective view of the scroll compressor ofFIG. 1 showing the scroll side. -
FIG. 3 is a top plan view of the scroll compressor ofFIG. 1 . -
FIG. 4 is a cross-sectional side view of the scroll compressor taken along line 4-4 ofFIG. 3 . - Referring first to
FIGS. 1 through 4 , a one-piece scroll compressor 100 is shown. The powdermetal scroll compressor 100 can be produced from a single powder metal compact using the powder metal processes according to the method described in PCT International Publication No. WO 2010/135232 later filed as a U.S. national phase application having Ser. No. 13/320,867 and published as US 2012/0118104, which is incorporated by reference as if set forth in its entirety herein. - To be clear, in the instant disclosure, the powder metal formulation could be used to separately make one or more portions of the part or the entirety of the part using, for example, the methods described in PCT International Publication No. WO 2010/135232 and U.S. Patent Application Publication No. US 2012/0118104. However, the details of the structure and the processes used to fabricate the scroll compressor should not be so limited to only the structures and methods explicitly listed. Accordingly, the below described scroll compressor is intended to be illustrative, but not limiting.
- The
scroll compressor 100 is a powder metal part which is formed by compression along an axis of compaction A-A. Thescroll compressor 100 includes aflange 102, ahub 104, and ascroll 106. Theflange 102 has atop face 108 and abottom face 110 which extend in a direction perpendicular to the axis A-A and which are essentially planar and parallel to one another. Two mountingslots 112 are formed around an outer periphery of theflange 102 for mounting thescroll compressor 100 to another item in a refrigeration assembly or the like. - The
hub 104 axially extends from thetop face 108 of theflange 102. Thehub 104 is generally cylindrically-shaped and has a radially outward facingsurface 114, a radially inward facingsurface 116, and a topaxial face 118. Both the radially outward facingsurface 114 and the radially inward facingsurface 116 may have a slight taper as they extend away from thetop face 108 of theflange 102 towards the topaxial face 118. By having a taper, thescroll compressor 100 can be more easily separated from the tool members during the ejection process. - The
scroll 106 extends axially from thebottom face 110 of theflange 102. Thescroll 106 is a spiraling wall that spirals relative to the axis A-A. As such, thescroll 106 includes aninner wall end 120 and anouter wall end 122 with a generally radially outward facingsurface 124 and a generally radially inward facingsurface 126 extending between theends surfaces axial face 128 of thescroll 106 is also spiral-shaped. Again, the generally radially outward facingsurface 124 and the generally radially inward facingsurface 126 may have a taper to ease the ejection process from the tool and die set during compaction of the powder metal. - In the form shown, the spiral is similar to an Archimedean spiral, meaning that if a radial line is drawn relative to the axis A-A, a
channel 130 formed between the generally radially outward and inward facing surfaces 124 and 126 is also of substantially constant width regardless of the distance from the axis A-A. However, other involute geometries might be used and nothing should limit the scroll compressor geometry to that which is illustrated inFIGS. 1 through 4 . - A part having this geometry could not be easily formed as a unitary powder metal compact by a conventional powder metal compaction process. Typically, top features, such as the
hub 104 are formed by transferring powder metal within the die cavity by a powder transfer motion of the lower tool members. As the powder is transferred, the powder fill to final part ratio along the vertical columns of the part must be approximately 2:1 to provide a part that is relatively uniformly dense after the compaction process. - A comparison of a horizontal cross section through the
hub 104 and a horizontal cross section through thescroll 106 would reveal that there are areas of powder metal in thehub 104 which are not found in thescroll 106 and areas of powder metal in thescroll 106 that are not found in thehub 104. Thus, conventional tool and die sets are incapable of performing a powder transfer motion that provides an acceptable powder fill to final part ratio over a component having this final geometry. Instead, the hub and scroll sections are conventionally separately compacted and then joined afterwards. However, PCT International Publication No. WO 2010/135232 and U.S. Patent Application Publication No. US 2012/0118104 describe ways of fabricating a unitary part. Parts made using both the conventional and improved methods are contemplated as being within the scope of this invention. - Turning now to the powder metal formulation, the powder metal used to make this powder metal scroll compressor includes iron powder (either elemental or prealloyed iron), carbon in an amount less than 0.9 wt % of the powder metal, and solid lubricant in an amount between 0.25 wt % and 3.0 wt % of the powder metal. Other elemental additions could also be included such as, for example, copper (Cu) and nickel (Ni). However, the powder metal formulation is relatively simplistic in that it does not require more than these listed constituents, but may include trace amounts of other elements that do not substantially affect the properties of the powder metal.
- Mixing of the various constituent powders may be performed using conventional means such as v-blenders or double cone mixers. The various constituent powders can be admixed together along with pressing lubricants (e.g., lithium stearate, Licowax, etc.) in addition to the solid lubricant.
- In one form, the solid lubricant for this powder metal formulation may be talc, which is also known as hydrated magnesium silicate and has the chemical formula of Mg3Si4O10(OH)2. When used as a solid lubricant, some amount of quartz impurity may exist within the talc. When talc is used as the solid lubricant, the talc may be preferably provided in a powder form having a nominal 15 to 25 micron mean particle size (d50).
- In another form, the solid lubricant for this powder formulation may be a hexagonal boron nitride (BN). When used as a solid lubricant, the boron nitride may be preferably provided in a powder form having a nominal 5 to 30 micron mean particle size (d50).
- Another approach to provide an in-place solid lubricant in a powder metal component is to use nickel-coated graphite powder as the solid lubricant. The nickel coating protects the graphite during sintering and prevents the graphite from combining with the iron powder. In the finished product, the coating protects and preserves the graphite until rupture of the nickel coating during use of the component (e.g., rupture due to wear on surfaces), to release the graphite lubricant. The nickel-coated graphite has nickel content ranging from 55 to 80 wt % with the remainder being graphite. The nickel-coated graphite powder may have an average particle size of approximately 100 microns. Graphite size may be coarse (Tyler mesh size −120/+230 at 88-98% or a range of 115 to 65 microns) to fine (Tyler mesh size −120/+270 at >85% and −270/+325<15% or a range of 115 to 43 microns) with both having a small amount of more coarse and finer particle sizes (<5 wt %). The solid lubricant is added to the mix to provide a graphite level of 0.5 wt % to 5 wt %, although a graphite range of 1 wt % to 3 wt % is believed to be typical for most applications. This graphite is exclusive of the carbon content in the powder metal which is used to alter the metallurgical properties of the iron powder.
- Notably, this powder metal formulation incorporates the powder for the solid lubricant as an admixed constituent in the powder metal. The admixed solid lubricant is inert in Fe—C, Fe—Cu—C and other powder metal mixtures processed at temperatures around 1180 degrees Centigrade. This means that even after the powder metal has been compacted and sintered into a final part, all or a substantial portion of the solid lubricant remains present.
- The solid lubricant assists in reducing frictional heat and spalling/galling in a system with reciprocal motion under a mechanical load such as that in which a scroll compressor is used (and, in particular, in the scroll section of the scroll compressor). The solid lubricant is resistant to adhesion and does not create significant resistance to motion of the scroll compressor. The inclusion of the solid lubricant may be best implemented in powder metal parts that have ferritic/pearlitic microstructures and its inclusion can also be used for improving machinability.
- In one specific embodiment that is particularly advantageous for powder metal scroll compressors, the powder metal formulation can be formulated to have less than 0.9 wt % carbon, less than 3.0% copper, and between 0.25 to 3.0 wt % of solid lubricant with the remainder of the powder being elemental iron with no other substantial additions. Again, this is a relatively simple powder formula that does not contain a large number of alloying elements.
- Powder metal formulations such as those described above can be prepared and then processed into a sintered powder metal part by compacting the powder into a powder metal compact and then sintering the powder. It is contemplated that such parts might be compacted as unitary bodies or might be formed from separately compacted components that are subsequently joined together to form a single final part. However, it is contemplated that any section of a part made from various joined sections may have the powder metal containing the solid lubricant in those sections in which the solid lubricant will be most desirable. For example, the scroll section of a scroll compressor may be made using the powder described above, while the other section to which the scroll section is joined may be made of a powder metal material that does not include the solid lubricant. Of course, nothing excludes both sections of a multi-portion component from being made of a powder containing the solid lubricant even if they are joined.
- Overall, this process allows for conventional compaction processes in rigid dies and eliminates the subsequent infiltration of a solid lubricant into the porous sintered body after sintering.
- It should be appreciated that various other modifications and variations to the preferred embodiments can be made within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced.
Claims (35)
1. A powder metal scroll compressor comprising:
a hub and a scroll adjoined to one another;
a powder metal forming at least a portion of the powder metal scroll compressor including the scroll, the powder metal including iron powder, carbon in an amount of less than 0.9% by weight of the powder metal, and a solid lubricant in the powder metal.
2. The powder metal scroll compressor of claim 1 , wherein the iron powder and solid lubricant are admixed with one another prior to compaction and sintering of the powder metal scroll compressor.
3. The powder metal scroll compressor of claim 1 , wherein the solid lubricant is 0.25% to 3.0% by weight of the powder metal and the powder metal includes iron powder, carbon, the solid lubricant and is substantially free of other constituents.
4. The powder metal scroll compressor of claim 1 , wherein the powder metal further includes copper powder in an amount of less than 3.0% by weight of the powder metal.
5. The powder metal scroll compressor of claim 4 , wherein the iron powder, the copper powder, and the solid lubricant are admixed with one another prior to compaction and sintering of the powder metal scroll compressor and the powder metal includes iron powder, carbon, copper powder, and the solid lubricant and is substantially free of other constituents.
6. The powder metal scroll compressor of claim 4 , wherein the copper powder is elemental copper powder.
7. The powder metal scroll compressor of claim 1 , wherein the solid lubricant is talc (Mg3Si4O10(OH)2).
8. The powder metal scroll compressor of claim 7 , wherein the talc has a nominal 15 to 25 micron mean particle size (d50).
9. The powder metal scroll compressor of claim 1 , wherein the solid lubricant is hexagonal boron nitride (BN).
10. The powder metal scroll compressor of claim 9 , wherein the hexagonal boron nitride has a nominal 5 to 30 micron mean particle size (d50).
11. The powder metal scroll compressor of claim 1 , wherein the solid lubricant remains inert and stable in an Fe—C or an Fe—Cu—C system through processing of temperatures up to 1080 degrees Centigrade.
12. The powder metal scroll compressor of claim 1 , wherein the solid lubricant is a nickel-coated graphite powder and in which the carbon in an amount of less than 0.9% by weight of the powder metal material is exclusive of the graphite of the nickel-coated graphite powder.
13. The powder metal scroll compressor of claim 12 , wherein a nickel coating of the nickel-coated graphite powder substantially surrounds the graphite to protect the graphite during sintering of the powder metal scroll compressor and to prevent the graphite from combining with the iron powder.
14. The powder metal scroll compressor of claim 12 , wherein a nickel content of the nickel-coated graphite powder is in a range of 55 to 80 wt % with the remainder being graphite.
15. The powder metal scroll compressor of claim 12 , wherein a total amount of graphite in the powder metal scroll compressor is in the range of 0.5 to 5.0 wt % exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material.
16. The powder metal scroll compressor of claim 12 , wherein a total amount of graphite in the powder metal scroll compressor is in the range of 1.0 to 3.0 wt % exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material.
17. The powder metal scroll compressor of claim 12 , wherein the nickel-coated graphite powder has an average particle size of approximately 100 microns.
18. A powder metal comprising:
iron powder;
carbon in an amount of less than 0.9% by weight of the powder metal material; and
a solid lubricant;
in which the iron powder and solid lubricant are admixed with one another.
19. The powder metal of claim 18 , wherein the solid lubricant is 0.25% to 3.0% by weight of the powder metal.
20. The powder metal of claim 18 , wherein the powder metal further includes copper powder in an amount of less than 3.0% by weight of the powder metal.
21. The powder metal of claim 20 , wherein the iron powder, the copper powder, and the solid lubricant are admixed with one another and the powder metal includes iron powder, carbon, copper powder, and the solid lubricant and is substantially free of other constituents.
22. The powder metal of claim 20 , wherein the copper powder is elemental copper powder.
23. The powder metal of claim 20 , wherein the solid lubricant is talc (Mg3Si4O10(OH)2).
24. The powder metal of claim 23 , wherein the talc has a nominal 15 to 25 micron mean particle size (d50).
25. The powder metal of claim 18 , wherein the solid lubricant is hexagonal boron nitride (BN).
26. The powder metal of claim 25 , wherein the hexagonal boron nitride has a nominal 5 to 30 micron mean particle size (d50).
27. The powder metal of claim 18 , wherein the solid lubricant remains inert and stable in an Fe—C or an Fe—Cu—C system through processing of temperatures up to 1080 degrees Centigrade.
28. The powder metal of claim 18 , wherein the powder metal includes iron powder, carbon, the solid lubricant and is substantially free of other constituents.
29. The powder metal of claim 18 , wherein the solid lubricant is a nickel-coated graphite powder and in which the carbon in an amount of less than 0.9% by weight of the powder metal material is exclusive of the graphite of the nickel-coated graphite powder.
30. The powder metal of claim 29 , wherein a nickel coating of the nickel-coated graphite powder substantially surrounds the graphite to protect the graphite during sintering of the powder metal scroll compressor and to prevent the graphite from combining with the iron powder.
31. The powder metal of claim 29 , wherein a nickel content of the nickel-coated graphite powder is in a range of 55 to 80 wt % with the remainder being graphite.
32. The powder metal of claim 29 , wherein a total amount of graphite in the powder metal scroll compressor is in the range of 0.5 to 5.0 wt % exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material.
33. The powder metal of claim 29 , wherein a total amount of graphite in the powder metal scroll compressor is in the range of 1.0 to 3.0 wt % exclusive of the carbon in an amount of less than 0.9% by weight of the powder metal material.
34. The powder metal of claim 29 , wherein the nickel-coated graphite powder has an average particle size of approximately 100 microns.
35. A part made using the powder metal of claim 18 , wherein the powder metal is compacted and sintered to form the part and the solid lubricant is retained throughout the process and is dispersed throughout the part including the surface of the part.
Priority Applications (1)
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US14/377,218 US20150017043A1 (en) | 2012-02-15 | 2013-02-11 | Powder metal with solid lubricant and powder metal scroll compressor made therefrom |
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US201261599042P | 2012-02-15 | 2012-02-15 | |
US201261720226P | 2012-10-30 | 2012-10-30 | |
US14/377,218 US20150017043A1 (en) | 2012-02-15 | 2013-02-11 | Powder metal with solid lubricant and powder metal scroll compressor made therefrom |
PCT/US2013/025576 WO2013122873A1 (en) | 2012-02-15 | 2013-02-11 | Powder metal with solid lubricant and powder metal scroll compressor made therefrom |
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US (1) | US20150017043A1 (en) |
JP (1) | JP2015528850A (en) |
CN (1) | CN104114306A (en) |
BR (1) | BR112014017956A8 (en) |
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Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US3708282A (en) * | 1969-09-03 | 1973-01-02 | Int Nickel Co | Production of sintered metal products |
US5534220A (en) * | 1992-04-01 | 1996-07-09 | Brico Engineering Limited | Method of sintering machinable ferrous-based materials |
US6015775A (en) * | 1995-08-08 | 2000-01-18 | Komatsu Ltd. | Self-lubricating sintered sliding material and method for manufacturing the same |
US6705848B2 (en) * | 2002-01-24 | 2004-03-16 | Copeland Corporation | Powder metal scrolls |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS58133347A (en) * | 1982-01-30 | 1983-08-09 | Oiles Ind Co Ltd | High temperature sintered slide member and preparation thereof |
JPH06192710A (en) * | 1992-12-25 | 1994-07-12 | Toshiba Corp | Sliding member for compressor and its production |
US6139598A (en) * | 1998-11-19 | 2000-10-31 | Eaton Corporation | Powdered metal valve seat insert |
SE0203134D0 (en) * | 2002-10-22 | 2002-10-22 | Hoeganaes Ab | Method of preparing iron-based components |
TWI412416B (en) * | 2006-02-15 | 2013-10-21 | Jfe Steel Corp | Iron-based powder mixture and method of manufacturing iron-based compacted body and iron-based sintered body |
US8955220B2 (en) * | 2009-03-11 | 2015-02-17 | Emerson Climate Technologies, Inc. | Powder metal scrolls and sinter-brazing methods for making the same |
US9180518B2 (en) | 2009-05-18 | 2015-11-10 | Gkn Sinter Metals, Llc | Powder metal die filling |
-
2013
- 2013-02-11 US US14/377,218 patent/US20150017043A1/en not_active Abandoned
- 2013-02-11 DE DE112013000990.0T patent/DE112013000990T5/en not_active Withdrawn
- 2013-02-11 CN CN201380009465.7A patent/CN104114306A/en active Pending
- 2013-02-11 WO PCT/US2013/025576 patent/WO2013122873A1/en active Application Filing
- 2013-02-11 JP JP2014557709A patent/JP2015528850A/en active Pending
- 2013-02-11 BR BR112014017956A patent/BR112014017956A8/en not_active Application Discontinuation
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3708282A (en) * | 1969-09-03 | 1973-01-02 | Int Nickel Co | Production of sintered metal products |
US5534220A (en) * | 1992-04-01 | 1996-07-09 | Brico Engineering Limited | Method of sintering machinable ferrous-based materials |
US6015775A (en) * | 1995-08-08 | 2000-01-18 | Komatsu Ltd. | Self-lubricating sintered sliding material and method for manufacturing the same |
US6705848B2 (en) * | 2002-01-24 | 2004-03-16 | Copeland Corporation | Powder metal scrolls |
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BR112014017956A8 (en) | 2017-07-11 |
CN104114306A (en) | 2014-10-22 |
BR112014017956A2 (en) | 2017-06-20 |
WO2013122873A1 (en) | 2013-08-22 |
JP2015528850A (en) | 2015-10-01 |
DE112013000990T5 (en) | 2015-04-09 |
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