Classifications

• • 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
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
• • 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
  • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
  • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
• • 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
• • B22F1/0003—
• • B22F1/0059—
• • 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
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/10—Sintering only
• • 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
  • B22F9/00—Making metallic powder or suspensions thereof
  • B22F9/02—Making metallic powder or suspensions thereof using physical processes
  • B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
• • 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
  • B22F9/00—Making metallic powder or suspensions thereof
  • B22F9/02—Making metallic powder or suspensions thereof using physical processes
  • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
  • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
  • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/24—Ferrous alloys, e.g. steel alloys containing chromium with vanadium
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/26—Ferrous alloys, e.g. steel alloys containing chromium with niobium or tantalum
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/28—Ferrous alloys, e.g. steel alloys containing chromium with titanium or zirconium
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/38—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of manganese
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
  • C22C38/42—Ferrous alloys, e.g. steel alloys containing chromium with nickel with copper
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
  • C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
  • C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
  • C22C38/50—Ferrous alloys, e.g. steel alloys containing chromium with nickel with titanium or zirconium
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
  • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
  • C22C38/58—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
• • 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
  • B22F2301/00—Metallic composition of the powder or its coating
  • B22F2301/35—Iron
• • 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
  • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
  • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

• the present invention relates to a metal powder for powder metallurgy, a compound, a granulated powder, and a sintered body.
• a composition containing a metal powder and a binder is molded into a desired shape to obtain a molded body, and the obtained molded body is degreased and sintered, whereby a sintered body is produced.
• an atomic diffusion phenomenon occurs among particles of the metal powder, whereby the molded body is gradually densified, resulting in sintering.
• JP-A-2012-87416 proposes a metal powder for powder metallurgy which contains Zr and Si, with the remainder including at least one element selected from the group consisting of Fe, Co, and Ni, and inevitable elements.
• the sinterability is enhanced by the action of Zr, and a sintered body having a high density can be easily produced.
• JP-A-6-279913 discloses a composition for metal injection molding which contains 100 parts by weight of a stainless steel powder containing 0.03% by weight or less of C, 8 to 32% by weight of Ni, 12 to 32% by weight of Cr, and 1 to 7% by weight of Mo, with the remainder including Fe and inevitable impurities, and 0.1 to 5.5 parts by weight of at least one powder containing Ti or/and Nb and having an average particle diameter of 10 to 60 ⁇ m.
• a sintered body having a high sintered density and excellent corrosion resistance is obtained.
• JP-A-2007-177675 discloses a needle seal for a needle valve, which has a composition containing 0.95 to 1.4% by mass of C, 1.0% by mass or less of Si, 1.0% by mass or less of Mn, 16 to 18% by mass of Cr, and 0.02 to 3% by mass of Nb, with the remainder including Fe and inevitable impurities, has a density after sintering of 7.65 to 7.75 g/cm 3 , and is obtained by molding using a metal injection molding method. According to this, a needle seal having a high density is obtained.
• the thus obtained sintered body has become widely used recently for a variety of machine parts, structural parts, and the like.
• a sintered body is further subjected to an additional treatment such as a hot isostatic pressing treatment (HIP treatment) to increase the density, however, the workload is significantly increased, and also an increase in the cost is inevitable.
• HIP treatment hot isostatic pressing treatment
• An advantage of some aspects of the invention is to provide a metal powder for powder metallurgy, a compound, and a granulated powder, each of which is capable of producing a sintered body having a high density, and a sintered body having a high density produced by using the metal powder for powder metallurgy.
• a metal powder for powder metallurgy according to an aspect of the invention contains Fe as a principal component, Cr in a proportion of 10% by mass or more and 30% by mass or less, C in a proportion of 0.15% by mass or more and 1.5% by mass or less, Si in a proportion of 0.3% by mass or more and 1% by mass or less, and Mn and Ni in a total proportion of 0.05% by mass or more and 1.6% by mass or less, wherein when one element selected from the group consisting of Ti, V, Y, Zr, Nb, Hf, and Ta is defined as a first element, and one element selected from the group consisting of Ti, V, Y, Zr, Nb, Hf, and Ta, and having a larger group number in the periodic table than that of the first element or having the same group number in the periodic table as that of the first element and a larger period number in the periodic table than that of the first element is defined as a second element, the first element is contained in a proportion of 0.01% by mass or more and 0.5%
• the alloy composition is optimized so that the densification during sintering of the metal powder for powder metallurgy can be enhanced.
• a metal powder for powder metallurgy capable of producing a sintered body having a high density is obtained without performing an additional treatment.
• the metal powder for powder metallurgy it is preferred that the metal powder has a martensite crystal structure.
• the martensite crystal structure includes a body-centered cubic lattice in the form of a solid solution supersaturated with, for example, C.
• This body-centered cubic lattice is formed by transformation from a face-centered cubic lattice accompanying firing or a heat treatment after firing, and the volume thereof is expanded at that time. Therefore, a metal powder for powder metallurgy having a martensite crystal structure is capable of producing a sintered body having a high hardness.
• the ratio (X1/X2) of a value (X1) obtained by dividing the content (E1) of the first element by the mass number of the first element to a value (X2) obtained by dividing the content (E2) of the second element by the mass number of the second element is 0.3 or more and 3 or less.
• the sum of the content of the first element and the content of the second element is 0.02% by mass or more and 0.6% by mass or less.
• the metal powder for powder metallurgy it is preferred that the metal powder has an average particle diameter of 0.5 ⁇ m or more and 30 ⁇ m or less.
• pores remaining in a sintered body are extremely decreased, and therefore, a sintered body having a particularly high density and particularly excellent mechanical properties can be produced.
• a compound according to an aspect of the invention includes the metal powder for powder metallurgy according to the aspect of the invention and a binder which binds the particles of the metal powder for powder metallurgy to one another.
• a granulated powder according to an aspect of the invention is obtained by granulating the metal powder for powder metallurgy according to the aspect of the invention.
• a sintered body according to an aspect of the invention is produced by sintering a metal powder for powder metallurgy containing Fe as a principal component, Cr in a proportion of 10% by mass or more and 30% by mass or less, C in a proportion of 0.15% by mass or more and 1.5% by mass or less, Si in a proportion of 0.3% by mass or more and 1% by mass or less, and Mn and Ni in a total proportion of 0.05% by mass or more and 1.6% by mass or less, wherein when one element selected from the group consisting of Ti, V, Y, Zr, Nb, Hf, and Ta is defined as a first element, and one element selected from the group consisting of Ti, V, Y, Zr, Nb, Hf, and Ta, and having a larger group number in the periodic table than that of the first element or having the same group number in the periodic table as that of the first element and a larger period number in the periodic table than that of the first element is defined as a second element, the first element is contained in
• a sintered body having a high density is obtained without performing an additional treatment.
• a sintered body having a desired shape can be obtained by molding a composition containing a metal powder for powder metallurgy and a binder into a desired shape, followed by degreasing and sintering.
• a powder metallurgy technique an advantage that a sintered body with a complicated and fine shape can be produced in a near-net shape (a shape close to a final shape) as compared with the other metallurgy techniques is obtained.
• the obtained sintered body was further subjected to an additional treatment such as a hot isostatic pressing treatment (HIP treatment) to increase the density.
• an additional treatment such as a hot isostatic pressing treatment (HIP treatment) to increase the density.
• HIP treatment hot isostatic pressing treatment
• the present inventors have made extensive studies to find conditions for obtaining a sintered body having a high density without performing an additional treatment. As a result, they found that the density of a sintered body can be increased by optimizing the composition of an alloy which forms a metal powder, and thus completed the invention.
• the metal powder for powder metallurgy according to the invention is a metal powder which contains Cr in a proportion of 10% by mass or more and 30% by mass or less, C in a proportion of 0.15% by mass or more and 1.5% by mass or less, Si in a proportion of 0.3% by mass or more and 1% by mass or less, Mn and Ni in a total proportion of 0.05% by mass or more and 1.6% by mass or less, the below-mentioned first element in a proportion of 0.01% by mass or more and 0.5% by mass or less, and the below-mentioned second element in a proportion of 0.01% by mass or more and 0.5% by mass or less, with the remainder including Fe and other elements.
• the densification during sintering can be particularly enhanced.
• a sintered body having a high density can be produced without performing an additional treatment.
• a sintered body having excellent mechanical properties By increasing the density of a sintered body, a sintered body having excellent mechanical properties is obtained.
• Such a sintered body can be widely applied also to, for example, machine parts, structural parts, and the like, to which an external force (load) is applied.
• the first element is one element selected from the group consisting of the following seven elements: Ti, V, Y, Zr, Nb, Hf, and Ta
• the second element is one element selected from the group consisting of the above-mentioned seven elements and having a larger group number in the periodic table than that of the first element or one element selected from the group consisting of the above-mentioned seven elements and having the same group number in the periodic table as that of the first element and a larger period number in the periodic table than that of the first element.
• metal powder for powder metallurgy is sometimes simply referred to as “metal powder”.
• Cr chromium
• the content of Cr in the metal powder is set to 10% by mass or more and 30% by mass or less, but is preferably 10.5% by mass or more and 20% by mass or less, more preferably 11% by mass or more and 18% by mass or less. If the content of Cr is less than the above lower limit, the corrosion resistance of a sintered body to be produced is insufficient depending on the overall composition. On the other hand, if the content of Cr exceeds the above upper limit, the sinterability is deteriorated depending on the overall composition so that it becomes difficult to increase the density of the sintered body.
• C carbon
• the first element and the second element each form a carbide by binding to C.
• the dispersed deposit serves as an obstacle to inhibit the significant growth of crystal grains, and therefore, a variation in the size of crystal grains is suppressed. Accordingly, it becomes difficult to generate pores in a sintered body, and also the increase in the size of crystal grains is prevented, and thus, a sintered body having a high density and excellent mechanical properties is obtained.
• the content of C in the metal powder is set to 0.15% by mass or more and 1.5% by mass or less, but is preferably 0.35% by mass or more and 1.15% by mass or less, more preferably 0.4% by mass or more and 1.1% by mass or less. If the content of C is less than the above lower limit, crystal grains are liable to grow depending on the overall composition so that the mechanical properties of the sintered body are insufficient. On the other hand, if the content of C exceeds the above upper limit, the amount of C is too large depending on the overall composition so that the sinterability is deteriorated instead.
• Si silicon is an element which provides corrosion resistance and high mechanical properties to a sintered body to be produced, and by using the metal powder containing Si, a sintered body capable of maintaining high mechanical properties over a long period of time is obtained.
• the content of Si in the metal powder is set to 0.3% by mass or more and 1% by mass or less, but is preferably 0.35% by mass or more and 0.85% by mass or less, more preferably 0.5% by mass or more and 0.8% by mass or less. If the content of Si is less than the above lower limit, the effect of the addition of Si is weakened depending on the overall composition so that the corrosion resistance and the mechanical properties of a sintered body to be produced are deteriorated. On the other hand, if the content of Si exceeds the above upper limit, the amount of Si is too large depending on the overall composition so that the corrosion resistance and the mechanical properties are deteriorated instead.
• Mn is an element which provides corrosion resistance and high mechanical properties to a sintered body to be produced in the same manner as Si.
• the content of Mn in the metal powder is not particularly limited, but is preferably 0.01% by mass or more and 1.25% by mass or less, more preferably 0.03% by mass or more and 0.3% by mass or less, further more preferably 0.05% by mass or more and 0.2% by mass or less.
• the corrosion resistance and the mechanical properties of a sintered body to be produced may not be sufficiently enhanced depending on the overall composition.
• the content of Mn exceeds the above upper limit, the corrosion resistance and the mechanical properties may be deteriorated instead.
• Ni is an element which provides corrosion resistance and heat resistance to a sintered body to be produced.
• the content of Ni in the metal powder is not particularly limited, but is preferably 0.05% by mass or more and 0.6% by mass or less, more preferably 0.06% by mass or more and 0.4% by mass or less, further more preferably 0.07% by mass or more and 0.25% by mass or less.
• the corrosion resistance and the heat resistance of a sintered body to be produced may not be sufficiently enhanced depending on the overall composition.
• the content of Ni exceeds the above upper limit, the corrosion resistance and the heat resistance may be deteriorated instead.
• Mn and Ni are contained in a total proportion of 0.05% by mass or more and 1.6% by mass or less. According to this, the mechanical properties of the sintered body can be particularly enhanced.
• the sum of the content of Mn and the content of Ni is preferably 0.08% by mass or more and 1.3% by mass or less, more preferably 0.1% by mass or more and 1% by mass or less. Further, the sum of the contents of Mn and Ni is only required to be within the above-mentioned range, and the content of either Mn or Ni may be 0. That is, the metal powder for powder metallurgy according to the invention may contain at least one of Mn and Ni.
• the first element and the second element each deposit a carbide or an oxide (hereinafter also collectively referred to as “carbide or the like”). It is considered that this deposited carbide or the like inhibits the significant growth of crystal grains when the metal powder is sintered. As a result, as described above, it becomes difficult to generate pores in a sintered body, and also the increase in the size of crystal grains is prevented, and thus, a sintered body having a high density and excellent mechanical properties is obtained.
• the deposited carbide or the like promotes the accumulation of silicon oxide at a crystal grain boundary, and as a result, the sintering is promoted and the density is increased while preventing the increase in the size of crystal grains.
• the first element and the second element are two elements selected from the group consisting of the following seven elements: Ti, V, Y, Zr, Nb, Hf, and Ta, but preferably include an element belonging to group IIIA or group IVA in the long periodic table (Ti, Y, Zr, or Hf).
• group IIIA or group IVA in the long periodic table (Ti, Y, Zr, or Hf).
• the first element is only required to be one element selected from the group consisting of the following seven elements: Ti, V, Y, Zr, Nb, Hf, and Ta as described above, but is preferably an element belonging to group IIIA or group IVA in the long periodic table in the group consisting of the above-mentioned seven elements.
• An element belonging to group IIIA or group IVA removes oxygen contained as an oxide in the metal powder and therefore can particularly enhance the sinterability of the metal powder. According to this, the concentration of oxygen remaining in the crystal grains after sintering can be decreased. As a result, the content of oxygen in the sintered body can be decreased, and the density can be increased. Further, these elements are elements having high activity, and therefore are considered to cause rapid atomic diffusion.
• this atomic diffusion acts as a driving force, and thereby a distance between particles of the metal powder is efficiently decreased and a neck is formed between the particles, so that the densification of a molded body is promoted. As a result, the density of the sintered body can be further increased.
• the second element is only required to be one element selected from the group consisting of the following seven elements: Ti, V, Y, Zr, Nb, Hf, and Ta and different from the first element as described above, but is preferably an element belonging to group 5A in the long periodic table in the group consisting of the above-mentioned seven elements.
• An element belonging to group 5A particularly efficiently deposits the above-mentioned carbide or the like, and therefore, can efficiently inhibit the significant growth of crystal grains during sintering. As a result, the production of fine crystal grains is promoted, and thus, the density of the sintered body can be increased and also the mechanical properties of the sintered body can be enhanced.
• the metal powder containing such a first element and a second element enables the production of a sintered body having a particularly high density.
• Zr is a ferrite forming element, and therefore deposits a body-centered cubic lattice phase.
• This body-centered cubic lattice phase has more excellent sinterability than the other crystal lattice phases, and therefore contributes to the densification of a sintered body.
• the content of the first element in the metal powder is set to 0.01% by mass or more and 0.5% by mass or less, but is set to preferably 0.03% by mass or more and 0.3% by mass or less, more preferably 0.05% by mass or more and 0.2% by mass or less. If the content of the first element is less than the above lower limit, the effect of the addition of the first element is weakened depending on the overall composition so that the density of a sintered body to be produced is not sufficiently increased. On the other hand, if the content of the first element exceeds the above upper limit, the amount of the first element is too large depending on the overall composition so that the ratio of the above-mentioned carbide or the like is too high, and therefore, the densification is deteriorated instead.
• the content of the second element in the metal powder is set to 0.01% by mass or more and 0.5% by mass or less, but is set to preferably 0.03% by mass or more and 0.3% by mass or less, more preferably 0.05% by mass or more and 0.2% by mass or less. If the content of the second element is less than the above lower limit, the effect of the addition of the second element is weakened depending on the overall composition so that the density of a sintered body to be produced is not sufficiently increased. On the other hand, if the content of the second element exceeds the above upper limit, the amount of the second element is too large depending on the overall composition so that the ratio of the above-mentioned carbide or the like is too high, and therefore, the densification is deteriorated instead.
• each of the first element and the second element deposits a carbide or the like, however, in the case where an element belonging to group IIIA or group IVA is selected as the first element as described above and an element belonging to group VA is selected as the second element as described above, it is presumed that when the metal powder is sintered, the timing when a carbide or the like of the first element is deposited and the timing when a carbide or the like of the second element is deposited differ from each other. It is considered that due to the difference in timing when a carbide or the like is deposited in this manner, sintering gradually proceeds so that the generation of pores is prevented, and thus, a dense sintered body is obtained. That is, it is considered that by the existence of both of the carbide or the like of the first element and the carbide or the like of the second element, the increase in the size of crystal grains can be suppressed while increasing the density of the sintered body.
• the metal powder is only required to contain two elements selected from the group consisting of the above-mentioned seven elements, but may further contain an element which is selected from this group and is different from these two elements. That is, the metal powder may contain three or more elements selected from the group consisting of the above-mentioned seven elements. According to this, the above-mentioned effect can be further enhanced, which slightly varies depending on the combination of the elements to be contained.
• the ratio of the content of the first element to the content of the second element in consideration of the mass number of the element selected as the first element and the mass number of the element selected as the second element.
• the ratio X1/X2 of the index X1 to the index X2 is preferably 0.3 or more and 3 or less, more preferably 0.5 or more and 2 or less, further more preferably 0.75 or more and 1.3 or less.
• pores remaining in a molded body can be eliminated as if they were swept out sequentially from the inside, and therefore, pores generated in a sintered body can be minimized. Therefore, by setting the ratio X1/X2 within the above range, a metal powder capable of producing a sintered body having a high density and excellent mechanical properties can be obtained. Further, the balance between the number of atoms of the first element and the number of atoms of the second element is optimized, and therefore, an effect brought about by the first element and an effect brought about by the second element are synergistically exhibited, and thus, a sintered body having a particularly high density can be obtained.
• the ratio (E1/E2) of the content E1 (mass %) to the content E2 (mass %) is also calculated.
• E1/E2 is preferably 0.29 or more and 2.95 or less, more preferably 0.49 or more and 1.96 or less.
• E1/E2 is preferably 0.58 or more and 5.76 or less, more preferably 0.96 or more and 3.84 or less.
• E1/E2 is preferably 0.15 or more and 1.55 or less, more preferably 0.26 or more and 1.03 or less.
• E1/E2 is preferably 0.15 or more and 1.54 or less, more preferably 0.26 or more and 1.03 or less.
• E1/E2 is preferably 0.29 or more and 2.87 or less, more preferably 0.48 or more and 1.91 or less.
• E1/E2 is preferably 0.16 or more and 1.64 or less, more preferably 0.27 or more and 1.10 or less.
• E1/E2 is preferably 0.16 or more and 1.58 or less, more preferably 0.26 or more and 1.05 or less.
• E1/E2 is preferably 0.15 or more and 1.51 or less, more preferably 0.25 or more and 1.01 or less.
• E1/E2 is preferably 0.54 or more and 5.38 or less, more preferably 0.90 or more and 3.58 or less.
• E1/E2 can be calculated in the same manner as described above.
• the sum (E1+E2) of the content E1 of the first element and the content E2 of the second element is preferably 0.02% by mass or more and 0.6% by mass or less, more preferably 0.05% by mass or more and 0.5% by mass or less, further more preferably 0.1% by mass or more and 0.4% by mass or less.
• (E1+E2)/Si is preferably 0.1 or more and 0.7 or less, more preferably 0.15 or more and 0.6 or less, further more preferably 0.17 or more and 0.5 or less.
• the carbide or the like of the first element and the carbide or the like of the second element act as “nuclei”, and therefore, silicon oxide is accumulated at a crystal grain boundary in the sintered body.
• silicon oxide is accumulated at a crystal grain boundary in the sintered body.
• the deposited silicon oxide easily moves to the triple point of a crystal grain boundary during the accumulation, and therefore, the crystal growth is suppressed at this point (a flux pinning effect). As a result, the significant growth of crystal grains is suppressed, and thus, a sintered body having finer crystals is obtained. Such a sintered body has particularly high mechanical properties.
• the accumulated silicon oxide is easily located at the triple point of a crystal grain boundary as described above, and therefore tends to be shaped into a particle. Therefore, in the sintered body, a first region which is in the form of such a particle and has a relatively high silicon oxide content and a second region which has a relatively lower silicon oxide content than the first region are easily formed. By the existence of the first region, the concentration of oxides inside the crystal is decreased, and the significant growth of crystal grains is suppressed as described above.
• the first region contains (oxygen) as a principal element
• the second region contains Fe as a principal element.
• the first region mainly exists at a crystal grain boundary
• the second region mainly exists inside the crystal grain. Therefore, in the first region, when the content of Si and the content of Fe are compared, the content of Si is higher than the content of Fe. On the other hand, in the second region, the content of Si is much smaller than the content of Fe. Based on these analysis results, it is found that Si and O are accumulated in the first region.
• the content of Si is preferably 1.5 times or more and 10000 times or less the content of Fe in the first region.
• the content of Si in the first region is preferably 3 times or more and 10000 times or less the content of Si in the second region.
• the content of the first element and the content of the second element satisfies the relationship that the content in the first region is larger than the content in the second region, which may vary depending on the compositional ratio.
• the carbide or the like of the first element and the carbide or the like of the second element act as nuclei when silicon oxide is accumulated as described above.
• the content of the first element in the first region is preferably 3 times or more and 10000 times or less the content of the first element in the second region.
• the content of the second element in the first region is preferably 3 times or more and 10000 times or less the content of the second element in the second region.
• silicon oxide as described above is considered to be one of the causes for the densification of a sintered body. Therefore, it is considered that even in a sintered body having a density increased according to the invention, silicon oxide may not be accumulated depending on the compositional ratio in some cases. That is, the first region and the second region may not be included depending on the compositional ratio.
• the diameter of the first region in the form of a particle varies depending on the content of Si in the entire sintered body, but is set to about 0.5 ⁇ m or more and 15 ⁇ m or less, preferably about 1 ⁇ m or more and 10 ⁇ m or less. According to this, the densification of the sintered body can be sufficiently promoted while preventing the decrease in the mechanical properties of the sintered body accompanying the accumulation of silicon oxide.
• the diameter of the first region can be obtained as the average of the diameter of a circle having the same area (circle equivalent diameter) as that of the first region determined by the color shade in an electron micrograph of the cross section of the sintered body. When the average is obtained, the measured values of 10 or more regions are used.
• (E1+E2)/C is preferably 0.05 or more and 0.7 or less, more preferably 0.1 or more and 0.5 or less, further more preferably 0.13 or more and 0.35 or less.
• the metal powder for powder metallurgy according to the invention may contain, other than the above-mentioned elements, at least one element of Mo, Pb, S, and Al as needed. These elements may be inevitably contained in some cases.
• Mo is an element which enhances the corrosion resistance of a sintered body to be produced.
• the content of Mo in the metal powder is not particularly limited, but is preferably 0.2% by mass or more and 0.8% by mass or less, more preferably 0.3% by mass or more and 0.6% by mass or less.
• Pb is an element which enhances the machinability of a sintered body to be produced.
• the content of Pb in the metal powder is preferably 0.03% by mass or more and 0.5% by mass or less, more preferably 0.05% by mass or more and 0.3% by mass or less.
• S is an element which enhances the machinability of a sintered body to be produced.
• the content of S in the metal powder is not particularly limited, but is preferably 0.5% by mass or less, more preferably 0.01% by mass or more and 0.3% by mass or less.
• Al is an element which enhances the oxidation resistance of a sintered body to be produced.
• the content of Al in the metal powder is not particularly limited, but is preferably 0.5% by mass or less, more preferably 0.05% by mass or more and 0.3% by mass or less.
• B, Se, Te, Pd, W, Co, N, Cu, or the like may be added other than the above-mentioned elements.
• the contents of these elements are not particularly limited, but the content of each of these elements is preferably less than 0.1% by mass, and also the total content of these elements is preferably less than 0.2% by mass. These elements may be inevitably contained in some cases.
• the metal powder for powder metallurgy according to the invention may contain impurities.
• the impurities include all elements other than the above-mentioned elements, and specific examples thereof include Li, Be, Na, Mg, P, K, Ca, Sc, Zn, Ga, Ge, Ag, In, Sn, Sb, Os, Ir, Pt, Au, and Bi.
• the incorporation amount of these impurity elements is preferably set such that the content of each of the impurity elements is less than the content of each of Fe, Cr, Si, the first element, and the second element. Further, the incorporation amounts of these impurity elements are preferably set such that the content of each of the impurity elements is less than 0.03% by mass, more preferably less than 0.02% by mass.
• the total content of these impurity elements is set to preferably less than 0.3% by mass, more preferably less than 0.2% by mass. These elements do not inhibit the effect as described above as long as the content thereof is within the above range, and therefore may be intentionally added to the metal powder.
• O oxygen
• the amount thereof is preferably about 0.8% by mass or less, more preferably about 0.5% by mass or less.
• the lower limit thereof is not particularly set, but is preferably 0.03% by mass or more from the viewpoint of ease of mass production or the like.
• Fe is a component (principal component) whose content is the highest in the alloy constituting the metal powder for powder metallurgy according to the invention and has a great influence on the properties of the sintered body.
• the content of Fe is not particularly limited, but is preferably 50% by mass or more.
• the compositional ratio of the metal powder for powder metallurgy can be determined by, for example, Iron and steel—Atomic absorption spectrometric method specified in JIS G 1257 (2000), Iron and steel—ICP atomic emission spectrometric method specified in JIS G 1258 (2007), Iron and steel—Method for spark discharge atomic emission spectrometric analysis specified in JIS G 1253 (2002), Iron and steel—Method for X-ray fluorescence spectrometric analysis specified in JIS G 1256 (1997), gravimetric, titrimetric, and absorption spectrometric methods specified in JIS G 1211 to G 1237, or the like.
• an optical emission spectrometer for solids (spark optical emission spectrometer, model: SPECTROLAB, type: LAVMB08A) manufactured by SPECTRO Analytical Instruments GmbH or an ICP device (model: CIROS-120) manufactured by Rigaku Corporation can be used.
• JIS G 1211 to G 1237 are as follows.
• JIS G 1214 Iron and steel—Methods for determination of phosphorus content
• JIS G 1221 Iron and steel—Methods for determination of vanadium content
• JIS G 1223 (1997): Iron and steel—Methods for determination of titanium content
• C (carbon) and S (sulfur) are determined, particularly, an infrared absorption method after combustion in a current of oxygen (after combustion in a high-frequency induction heating furnace) specified in JIS G 1211 (2011) is also used.
• a carbon-sulfur analyzer, CS-200 manufactured by LECO Corporation can be used.
• N (nitrogen) and O (oxygen) are determined, particularly, a method for determination of nitrogen content in iron and steel specified in JIS G 1228 (2006) and a method for determination of oxygen content in metallic materials specified in JIS Z 2613 (2006) are also used.
• an oxygen-nitrogen analyzer TC-300/EF-300 manufactured by LECO Corporation can be used.
• the metal powder for powder metallurgy according to the invention preferably has a martensite crystal structure.
• the martensite crystal structure includes a body-centered cubic lattice in the form of a solid solution supersaturated with, for example, C. This body-centered cubic lattice is formed by transformation from a face-centered cubic lattice accompanying firing or a heat treatment after firing, and the volume thereof is expanded at that time. Therefore, a metal powder for powder metallurgy having a martensite crystal structure is capable of producing a sintered body having a high hardness.
• the metal powder for powder metallurgy has a martensite crystal structure by, for example, X-ray diffractometry.
• the average particle diameter of the metal powder for powder metallurgy according to the invention is preferably 0.5 ⁇ m or more and 30 ⁇ m or less, more preferably 1 ⁇ m or more and 20 ⁇ m or less, further more preferably 2 ⁇ m or more and 10 ⁇ m or less.
• the average particle diameter can be obtained as a particle diameter when the cumulative amount obtained by cumulating the percentages of the particles from the smaller diameter side reaches 50% in a cumulative particle size distribution on a mass basis obtained by laser diffractometry.
• the average particle diameter of the metal powder for powder metallurgy is less than the above lower limit, the moldability is deteriorated in the case where the shape which is difficult to mold is formed, and therefore, the sintered density may be decreased.
• the average particle diameter of the metal powder exceeds the above upper limit, spaces between the particles become larger during molding, and therefore, the sintered density may be decreased also in this case.
• the particle size distribution of the metal powder for powder metallurgy is preferably as narrow as possible. Specifically, when the average particle diameter of the metal powder for powder metallurgy is within the above range, the maximum particle diameter of the metal powder is preferably 200 ⁇ m or less, more preferably 150 ⁇ m or less. By controlling the maximum particle diameter of the metal powder for powder metallurgy within the above range, the particle size distribution of the metal powder for powder metallurgy can be made narrower, and thus, the density of the sintered body can be further increased.
• the “maximum particle diameter” refers to a particle diameter when the cumulative amount obtained by cumulating the percentages of the particles from the smaller diameter side reaches 99.9% in a cumulative particle size distribution on amass basis obtained by laser diffractometry.
• the average of the aspect ratio defined by S/L is preferably about 0.4 or more and 1 or less, more preferably about 0.7 or more and 1 or less.
• the metal powder for powder metallurgy having an aspect ratio within this range has a shape relatively close to a spherical shape, and therefore, the packing factor when the metal powder is molded is increased. As a result, the density of the sintered body can be further increased.
• the “major axis” is the maximum length in the projected image of the particle
• the “minor axis” is the maximum length in the direction perpendicular to the major axis.
• the average of the aspect ratio can be obtained as the average of the measured aspect ratios of 100 or more particles.
• the tap density of the metal powder for powder metallurgy according to the invention is preferably 3.5 g/cm 3 or more, more preferably 4 g/cm 3 or more. According to the metal powder for powder metallurgy having such a high tap density, when a molded body is obtained, the interparticle packing efficiency is particularly increased. Therefore, a particularly dense sintered body can be obtained in the end.
• the specific surface area of the metal powder for powder metallurgy according to the invention is not particularly limited, but is preferably 0.1 m 2 /g or more, more preferably 0.2 m 2 /g or more. According to the metal powder for powder metallurgy having such a large specific surface area, a surface activity (surface energy) is increased so that it is possible to easily sinter the metal powder even if less energy is applied. Therefore, when a molded body is sintered, a difference in sintering rate hardly occurs between the inner side and the outer side of the molded body, and thus, the decrease in the sintered density due to the pores remaining inside the molded body can be suppressed.
• the metal powder for powder metallurgy according to the invention preferably contains, for example, a martensite stainless steel chemical component specified in JIS G 4303 (2012) or the like. According to this, a sintered body to be produced has excellent weather resistance specific to stainless steel, and also has excellent mechanical properties.
• the above-mentioned “chemical component” refers to a chemical component included in the JIS standard in which martensite stainless steel is specified such as JIS G 4303 (2012), and specifically refers to, for example, a combination of elements contained according to the contents (unit: mass %) specified in Table 6 of JIS G 4303 (2012).
• the method for producing a sintered body includes (A) a composition preparation step in which a composition for producing a sintered body is prepared, (B) a molding step in which a molded body is produced, (C) a degreasing step in which a degreasing treatment is performed, and (D) a firing step in which firing is performed.
• A a composition preparation step in which a composition for producing a sintered body is prepared
• B a molding step in which a molded body is produced
• C a degreasing step in which a degreasing treatment is performed
• D a firing step in which firing is performed.
• the metal powder for powder metallurgy according to the invention and a binder are prepared, and these materials are kneaded using a kneader, whereby a kneaded material is obtained.
• the metal powder for powder metallurgy is uniformly dispersed.
• the metal powder for powder metallurgy according to the invention is produced by, for example, any of a variety of powdering methods such as an atomization method (such as a water atomization method, a gas atomization method, or a spinning water atomization method), a reducing method, a carbonyl method, and a pulverization method.
• an atomization method such as a water atomization method, a gas atomization method, or a spinning water atomization method
• a reducing method such as a carbonyl method, and a pulverization method.
• the metal powder for powder metallurgy according to the invention is preferably a metal powder produced by an atomization method, more preferably a metal powder produced by a water atomization method or a spinning water atomization method.
• the atomization method is a method in which a molten metal (metal melt) is caused to collide with a fluid (liquid or gas) sprayed at a high speed to atomize the metal melt into a fine powder and also to cool the fine powder, whereby a metal powder is produced.
• a molten metal metal melt
• a fluid liquid or gas
• the shape of the particle of the obtained powder is closer to a spherical shape by the action of surface tension. Due to this, when the metal powder is molded, a molded body having a high packing factor is obtained. That is, a powder capable of producing a sintered body having a high density can be obtained.
• the pressure of water (hereinafter referred to as “atomization water”) to be sprayed to the molten metal is not particularly limited, but is set to preferably about 75 MPa or more and 120 MPa or less (750 kgf/cm 2 or more and 1200 kgf/cm 2 or less), more preferably about 90 MPa or more and 120 MPa or less (900 kgf/cm 2 or more and 1200 kgf/cm 2 or less).
• the temperature of the atomization water is also not particularly limited, but is preferably set to about 1° C. or higher and 20° C. or lower.
• the atomization water is often sprayed in a cone shape such that it has a vertex on the falling path of the metal melt and the outer diameter gradually decreases downward.
• the vertex angle ⁇ of the cone formed by the atomization water is preferably about 10° or more and 40° or less, more preferably about 15° or more and 35° or less. According to this, a metal powder for powder metallurgy having a composition as described above can be reliably produced.
• the metal melt can be cooled particularly quickly. Due to this, a powder having high quality can be obtained in a wide alloy composition range.
• the cooling rate when cooling the metal melt in the atomization method is preferably 1 ⁇ 10 4 ° C./s or more, more preferably 1 ⁇ 10 5 ° C./s or more.
• the thus obtained metal powder for powder metallurgy may be classified as needed.
• classification method include dry classification such as sieving classification, inertial classification, and centrifugal classification, and wet classification such as sedimentation classification.
• binder examples include polyolefins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymers, acrylic resins such as polymethyl methacrylate and polybutyl methacrylate, styrenic resins such as polystyrene, polyesters such as polyvinyl chloride, polyvinylidene chloride, polyamide, polyethylene terephthalate, and polybutylene terephthalate, various resins such as polyether, polyvinyl alcohol, polyvinylpyrrolidone, and copolymers thereof, and various organic binders such as various waxes, paraffins, higher fatty acids (such as stearic acid), higher alcohols, higher fatty acid esters, and higher fatty acid amides. These can be used alone or by mixing two or more types thereof.
• polyolefins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymers
• acrylic resins such as polymethyl methacryl
• the content of the binder is preferably about 2% by mass or more and 20% by mass or less, more preferably about 5% by mass or more and 10% by mass or less with respect to the total amount of the kneaded material.
• a plasticizer may be added as needed.
• the plasticizer include phthalate esters (such as DOP, DEP, and DBP), adipate esters, trimellitate esters, and sebacate esters. These can be used alone or by mixing two or more types thereof.
• any of a variety of additives such as a lubricant, an antioxidant, a degreasing accelerator, and a surfactant can be added as needed.
• the kneading conditions vary depending on the respective conditions such as the metal composition or the particle diameter of the metal powder for powder metallurgy to be used, the composition of the binder, and the blending amount thereof.
• the kneading temperature can be set to about 50° C. or higher and 200° C. or lower, and the kneading time can be set to about 15 minutes or more and 210 minutes or less.
• the kneaded material is formed into a pellet (small particle) as needed.
• the particle diameter of the pellet is set to, for example, about 1 mm or more and 15 mm or less.
• a granulated powder may be produced.
• the kneaded material, the granulated powder, and the like are examples of the composition to be subjected to the molding step described below.
• the embodiment of the granulated powder according to the invention is directed to a granulated powder obtained by binding a plurality of metal particles to one another with a binder by subjecting the metal powder for powder metallurgy according to the invention to a granulation treatment.
• binder to be used for producing the granulated powder examples include polyolefins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymers, acrylic resins such as polymethyl methacrylate and polybutyl methacrylate, styrenic resins such as polystyrene, polyesters such as polyvinyl chloride, polyvinylidene chloride, polyamide, polyethylene terephthalate, and polybutylene terephthalate, various resins such as polyether, polyvinyl alcohol, polyvinylpyrrolidone, and copolymers thereof, and various organic binders such as various waxes, paraffins, higher fatty acids (such as stearic acid), higher alcohols, higher fatty acid esters, and higher fatty acid amides. These can be used alone or by mixing two or more types thereof.
• a binder containing a polyvinyl alcohol or polyvinylpyrrolidone is preferred.
• These binder components have a high binding ability, and therefore can efficiently form the granulated powder even in a relatively small amount. Further, the thermal decomposability thereof is also high, and therefore, the binder can be reliably decomposed and removed in a short time during degreasing and firing.
• the content of the binder is preferably about 0.2% by mass or more and 10% by mass or less, more preferably about 0.3% by mass or more and 5% by mass or less, further more preferably about 0.3% by mass or more and 2% by mass or less with respect to the total amount of the granulated powder.
• a difference in size between the molded body and the degreased body, that is, so-called a shrinkage ratio is optimized, whereby a decrease in the dimensional accuracy of the finally obtained sintered body can be prevented.
• any of a variety of additives such as a plasticizer, a lubricant, an antioxidant, a degreasing accelerator, and a surfactant may be added as needed.
• Examples of the granulation treatment include a spray drying method, a tumbling granulation method, a fluidized bed granulation method, and a tumbling fluidized bed granulation method.
• a solvent which dissolves the binder is used as needed.
• the solvent include inorganic solvents such as water and carbon tetrachloride, and organic solvents such as ketone-based solvents, alcohol-based solvents, ether-based solvents, cellosolve-based solvents, aliphatic hydrocarbon-based solvents, aromatic hydrocarbon-based solvents, aromatic heterocyclic compound-based solvents, amide-based solvents, halogen compound-based solvents, ester-based solvents, amine-based solvents, nitrile-based solvents, nitro-based solvents, and aldehyde-based solvents, and one type or a mixture of two or more types selected from these solvents is used.
• the average particle diameter of the granulated powder is not particularly limited, and is preferably about 10 ⁇ m or more and 200 ⁇ m or less, more preferably about 20 ⁇ m or more and 100 ⁇ m or less, further more preferably about 25 ⁇ m or more and 60 ⁇ m or less.
• the granulated powder having such a particle diameter has favorable fluidity, and can more faithfully reflect the shape of a molding die.
• the average particle diameter can be obtained as a particle diameter when the cumulative amount obtained by cumulating the percentages of the particles from the smaller diameter side reaches 50% in a cumulative particle size distribution on amass basis obtained by laser diffractometry.
• the kneaded material or the granulated powder is molded, whereby a molded body having the same shape as that of a desired sintered body is produced.
• the method for producing a molded body is not particularly limited, and for example, any of a variety of molding methods such as a powder compacting (compression molding) method, a metal powder injection molding (MIM: Metal Injection Molding) method, and an extrusion molding method can be used.
• molding methods such as a powder compacting (compression molding) method, a metal powder injection molding (MIM: Metal Injection Molding) method, and an extrusion molding method can be used.
• the molding conditions in the case of a powder compacting method among these methods are preferably such that the molding pressure is about 200 MPa or more and 1000 MPa or less (2 t/cm 2 or more and 10 t/cm 2 or less), which vary depending on the respective conditions such as the composition and the particle diameter of the metal powder for powder metallurgy to be used, the composition of the binder, and the blending amount thereof.
• the molding conditions in the case of a metal powder injection molding method are preferably such that the material temperature is about 80° C. or higher and 210° C. or lower, and the injection pressure is about 50 MPa or more and 500 MPa or less (0.5 t/cm 2 or more and 5 t/cm 2 or less), which vary depending on the respective conditions.
• the molding conditions in the case of an extrusion molding method are preferably such that the material temperature is about 80° C. or higher and 210° C. or lower, and the extrusion pressure is about 50 MPa or more and 500 MPa or less (0.5 t/cm 2 or more and 5 t/cm 2 or less), which vary depending on the respective conditions.
• the thus obtained molded body is in a state where the binder is uniformly distributed in spaces between the particles of the metal powder.
• the shape and size of the molded body to be produced are determined in anticipation of shrinkage of the molded body in the subsequent degreasing step and firing step.
• the thus obtained molded body is subjected to a degreasing treatment (binder removal treatment), whereby a degreased body is obtained.
• the binder is decomposed by heating the molded body, whereby the binder is removed from the molded body. In this manner, the degreasing treatment is performed.
• Examples of the degreasing treatment include a method of heating the molded body and a method of exposing the molded body to a gas capable of decomposing the binder.
• the conditions for heating the molded body are preferably such that the temperature is about 100° C. or higher and 750° C. or lower and the time is about 0.1 hours or more and 20 hours or less, and more preferably such that the temperature is about 150° C. or higher and 600° C. or lower and the time is about 0.5 hours or more and 15 hours or less, which slightly vary depending on the composition and the blending amount of the binder.
• the degreasing of the molded body can be necessarily and sufficiently performed without sintering the molded body. As a result, it is possible to reliably prevent the binder component from remaining inside the degreased body in a large amount.
• the atmosphere when the molded body is heated is not particularly limited, and an atmosphere of a reducing gas such as hydrogen, an atmosphere of an inert gas such as nitrogen or argon, an atmosphere of an oxidative gas such as air, a reduced pressure atmosphere obtained by reducing the pressure of such an atmosphere, or the like can be used.
• a reducing gas such as hydrogen
• an atmosphere of an inert gas such as nitrogen or argon
• an atmosphere of an oxidative gas such as air
• a reduced pressure atmosphere obtained by reducing the pressure of such an atmosphere, or the like can be used.
• Examples of the gas capable of decomposing the binder include ozone gas.
• this degreasing step into a plurality of steps in which the degreasing conditions are different, and performing the plurality of steps, the binder in the molded body can be more rapidly decomposed and removed so that the binder does not remain in the molded body.
• the degreased body may be subjected to a machining process such as grinding, polishing, or cutting.
• the degreased body has a relatively low hardness and relatively high plasticity, and therefore, the machining process can be easily performed while preventing the degreased body from losing its shape. According to such a machining process, a sintered body having high dimensional accuracy can be easily obtained in the end.
• the degreased body obtained in the above step (C) is fired in a firing furnace, whereby a sintered body is obtained.
• the firing temperature varies depending on the composition, the particle diameter, and the like of the metal powder for powder metallurgy used in the production of the molded body and the degreased body, but is set to, for example, about 980° C. or higher and 1330° C. or lower, and preferably set to about 1050° C. or higher and 1260° C. or lower.
• the firing time is set to 0.2 hours or more and 7 hours or less, but is preferably set to about 1 hour or more and 6 hours or less.
• the firing temperature or the below-described firing atmosphere may be changed in the middle of the step.
• the firing temperature is a relatively low temperature, it is easy to control the heating temperature in the firing furnace to be constant, and therefore, it is also easy to maintain the temperature of the degreased body constant. As a result, a more homogeneous sintered body can be produced.
• the firing temperature as described above is a temperature which can be sufficiently realized using a common firing furnace, and therefore, an inexpensive firing furnace can be used, and also the running cost can be kept low. In other words, in the case where the temperature exceeds the above-mentioned firing temperature, it is necessary to employ an expensive firing furnace using a special heat resistant material, and also the running cost may be increased.
• the atmosphere when performing firing is not particularly limited, however, in consideration of prevention of significant oxidation of the metal powder, an atmosphere of a reducing gas such as hydrogen, an atmosphere of an inert gas such as argon, a reduced pressure atmosphere obtained by reducing the pressure of such an atmosphere, or the like is preferably used.
• the thus obtained sintered body has a high density and excellent mechanical properties. That is, a sintered body produced by molding a composition containing the metal powder for powder metallurgy according to the invention and a binder, followed by degreasing and sintering has a higher relative density than a sintered body obtained by sintering a metal powder in the related art. Therefore, according to the invention, a sintered body having a high density which could not be obtained unless an additional treatment such as an HIP treatment is performed can be realized without performing an additional treatment.
• the relative density can be expected to be increased by 2% or more as compared with the related art, which slightly varies depending on the composition of the metal powder for powder metallurgy.
• the relative density of the obtained sintered body can be expected to be, for example, 97% or more (preferably 98% or more, more preferably 98.5% or more).
• the sintered body having a relative density within such a range has excellent mechanical properties comparable to those of ingot materials although it has a shape as close as possible to a desired shape by using a powder metallurgy technique, and therefore, the sintered body can be applied to a variety of machine parts, structural parts, and the like with virtually no post-processing.
• the tensile strength and the 0.2% proof stress of a sintered body produced by molding a composition containing the metal powder for powder metallurgy according to the invention and a binder, followed by degreasing and sintering are higher than those of a sintered body obtained by performing sintering in the same manner using a metal powder in the related art. This is considered to be because by optimizing the alloy composition, the sinterability of the metal powder is enhanced, and thus, the mechanical properties of a sintered body to be produced using the metal powder are enhanced.
• the sintered body produced as described above has a high surface hardness.
• the Vickers hardness of the surface of the sintered body is expected to be 570 or more and 1200 or less, which slightly varies depending on the composition of the metal powder for powder metallurgy, and further is expected to be preferably 600 or more and 1000 or less.
• the sintered body having such a hardness has particularly high durability.
• the sintered body has a sufficiently high density and mechanical properties even without performing an additional treatment, however, in order to further increase the density and enhance the mechanical properties, a variety of additional treatments may be performed.
• an additional treatment of increasing the density such as the HIP treatment described above may be performed, and also a variety of quenching treatments, a variety of sub-zero treatments, a variety of tempering treatments, and the like may be performed. These additional treatments may be performed alone or two or more treatments thereof may be performed in combination.
• this treatment is preferably used, for example, when a sintered body containing a martensite crystal structure is produced.
• the sub-zero treatment is a treatment in which an austenite crystal structure which is not transformed into a martensite crystal structure by the quenching treatment and is retained is transformed into martensite by cooling.
• the retained austenite crystal structure is often transformed into martensite over time, however, at this time, the volume of the sintered body changes. Therefore, a problem occurs that the size of the sintered body changes over time. Therefore, by performing the sub-zero treatment after the quenching treatment, the retained austenite crystal structure can be transformed into martensite partly forcibly, and thus, the occurrence of the problem that the size changes over time can be prevented.
• the temperature is about 0° C. or lower and the time is about 0.2 hours or more and 3 hours or less.
• the tempering treatment is a treatment in which the sintered body having undergone the quenching treatment is heated again at a lower temperature than in the quenching treatment.
• the temperature is about 100° C. or higher and 200° C. or lower and the time is about 0.3 hours or more and 5 hours or less.
• the content of C in the final sintered body may change within the range of 5% or more and 100% or less (preferably within the range of 30% or more and 100% or less) of the content of C in the metal powder for powder metallurgy, which varies depending on the conditions for the step or the conditions for the treatment.
• the content of 0 in the final sintered body may change within the range of 1% or more and 50% or less (preferably within the range of 3% or more and 50% or less) of the content of 0 in the metal powder for powder metallurgy, which varies depending on the conditions for the step or the conditions for the treatment.
• the produced sintered body may be subjected to an HIP treatment as part of the additional treatments to be performed as needed, however, even if the HIP treatment is performed, a sufficient effect is not exhibited in many cases.
• the density of the sintered body can be further increased, however, the density of the sintered body obtained according to the invention has already been sufficiently increased at the end of the firing step in the first place. Therefore, even if the HIP treatment is further performed, densification hardly proceeds any further.
• the material to be treated may be contaminated, the composition or the physical properties of the material to be treated may unintentionally change accompanying the contamination, or the color of the material to be treated may change accompanying the contamination.
• residual stress is generated or increased in the material to be treated, and a problem such as a change in the shape or a decrease in the dimensional accuracy may occur as the residual stress is released over time.
• a sintered body having a sufficiently high density can be produced without performing such an HIP treatment, and therefore, a sintered body having an increased density and also an increased strength can be obtained in the same manner as in the case of performing an HIP treatment.
• Such a sintered body is less contaminated and discolored, and also an unintended change in the composition or physical properties, or the like occurs less, and also a problem such as a change in the shape or a decrease in the dimensional accuracy occurs less. Therefore, according to the invention, a sintered body having high mechanical strength and dimensional accuracy, and excellent durability can be efficiently produced.
• the sintered body produced according to the invention requires almost no additional treatments for enhancing the mechanical properties, and therefore, the composition and the crystal structure tend to become uniform in the entire sintered body. Due to this, the sintered body has high structural anisotropy and therefore has excellent durability against a load from every direction regardless of its shape.
• the porosity near the surface thereof is often relatively smaller than inside the sintered body.
• the reason therefor is not clear, however, one of the reasons is that by the addition of the first element and the second element, the sintering reaction more easily proceeds near the surface of the molded body than inside the molded body.
• A2 ⁇ A1 is preferably 0.1% or more and 3% or less, more preferably 0.2% or more and 2% or less.
• the sintered body showing the value of A2 ⁇ A1 within the above range not only has necessary and sufficient mechanical strength, but also can easily flatten the surface. That is, by polishing the surface of such a sintered body, a surface having high specularity can be obtained.
• Such a sintered body having high specularity not only has high mechanical strength, but also has excellent aesthetic properties. Therefore, such a sintered body is favorably used also for application requiring excellent aesthetic appearance.
• the porosity A1 near the surface of the sintered body refers to a porosity in a 25- ⁇ m radius region centered on the position at a depth of 50 ⁇ m from the surface of the cross section of the sintered body.
• the porosity A2 inside the sintered body refers to a porosity in a 25- ⁇ m radius region centered on the position at a depth of 300 ⁇ m from the surface of the cross section of the sintered body.
• the metal powder for powder metallurgy, the compound, the granulated powder, and the sintered body according to the invention have been described with reference to preferred embodiments, however, the invention is not limited thereto.
• the sintered body according to the invention is used for, for example, parts for transport machinery such as parts for automobiles, parts for bicycles, parts for railcars, parts for ships, parts for airplanes, and parts for space transport machinery (such as rockets); parts for electronic devices such as parts for personal computers and parts for mobile phone terminals; parts for electrical devices such as refrigerators, washing machines, and cooling and heating machines; parts for machines such as machine tools and semiconductor production devices; parts for plants such as atomic power plants, thermal power plants, hydroelectric power plants, oil refinery plants, and chemical complexes; parts for timepieces, metallic tableware, jewels, ornaments such as frames for glasses, and all other sorts of structural parts.
• parts for transport machinery such as parts for automobiles, parts for bicycles, parts for railcars, parts for ships, parts for airplanes, and parts for space transport machinery (such as rockets); parts for electronic devices such as parts for personal computers and parts for mobile phone terminals; parts for electrical devices such as refrigerators, washing machines, and cooling and heating machines; parts for machines such as machine tools and
• the composition of the powder shown in Table 1 was identified and determined by an inductively coupled high-frequency plasma optical emission spectrometry (ICP analysis method).
• ICP analysis method an ICP device (model: CIROS-120) manufactured by Rigaku Corporation was used. Further, in the identification and determination of C, a carbon-sulfur analyzer (CS-200) manufactured by LECO Corporation was used. Further, in the identification and determination of O, an oxygen-nitrogen analyzer (TC-300/EF-300) manufactured by LECO Corporation was used.
• this mixed starting material was kneaded using a kneader, whereby a compound was obtained.
• this compound was molded using an injection molding device under the following molding conditions, whereby a molded body was produced.
• the obtained degreased body was fired under the following firing conditions, whereby a sintered body was obtained.
• the shape of the sintered body was determined to be a cylinder with a diameter of 10 mm and a thickness of 5 mm.
• the obtained sintered body was subjected to a quenching treatment under the following conditions.
• the sintered body having undergone the quenching treatment was subjected to a sub-zero treatment under the following conditions.
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 1 or 2, respectively.
• the sintered bodies of sample Nos. 36 and 67 were obtained by performing an HIP treatment under the following conditions after firing. Further, the sintered bodies of sample Nos. 28 to 30 and 57 to 59 were obtained by using the metal powder produced by a gas atomization method, respectively, and indicated by “gas” in the column of Remarks in Tables 1 and 2.
• Example 12.94 1.02 0.79 0.05 0.01 0.09 0.06 ⁇ 0.01 0.31 remainder 5.00 0.06 0.08 0.06 0.15 No. 24
• Example 12.11 0.51 0.53 0.20 0.17 0.11 0.08 ⁇ 0.01 0.27 remainder 1.18 0.37 0.70 0.73 0.19 No.
• Example No. 32 Compar- 12.95 0.76 0.78 0.04 0.00 0.08 0.10 ⁇ 0.01 0.31 remainder — 0.04 0.05 0.05 0.18 ative Example No.
• Example 16.50 1.12 0.32 0.08 0.09 0.18 0.15 ⁇ 0.01 0.25 remainder 0.89 0.17 0.53 0.15 0.33 No. 45
• Example 16.26 1.05 0.62 0.08 0.06 0.05 0.07 ⁇ 0.01 0.29 remainder 1.33 0.14 0.23 0.13 0.12 No. 46
• Example 16.69 0.98 0.44 0.08 0.08 0.07 0.09 ⁇ 0.01 0.57 remainder 1.00 0.16 0.36 0.16 0.16 No. 48
• Each sintered body contained very small amounts of impurities, but the description thereof in Tables 1 and 2 is omitted.
• the metal powder was granulated by a spray drying method.
• the binder used at this time was polyvinyl alcohol, which was used in an amount of 1 part by mass with respect to 100 parts by mass of the metal powder. Further, a solvent (ion exchanged water) was used in an amount of 50 parts by mass with respect to 1 part by mass of polyvinyl alcohol. In this manner, a granulated powder having an average particle diameter of 50 ⁇ m was obtained.
• this granulated powder was compact-molded under the following molding conditions.
• a press molding machine was used.
• the shape of the molded body to be produced was determined to be a cube with a side length of 20 mm.
• the sintered body having undergone the quenching treatment was subjected to a sub-zero treatment under the following conditions.
• the sintered body having undergone the sub-zero treatment was subjected to a tempering treatment under the following conditions.
• Sintered bodies were obtained in the same manner as in the case of sample No. 68 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 3, respectively.
• the sintered body of sample No. 84 was obtained by performing an HIP treatment under the following conditions after firing.
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 3 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the following evaluation criteria.
• the Vickers hardness is 495 or more.
• the Vickers hardness is less than 495.
• the tensile strength of the sintered body is very high (1800 MPa or more).
• the tensile strength of the sintered body is high (1600 MPa or more and less than 1800 MPa).
• the tensile strength of the sintered body is slightly high (1400 MPa or more and less than 1600 MPa).
• the tensile strength of the sintered body is slightly low (1200 MPa or more and less than 1400 MPa).
• the tensile strength of the sintered body is low (1000 MPa or more and less than 1200 MPa).
• the tensile strength of the sintered body is very low (800 MPa or more and less than 1000 MPa).
• the tensile strength of the sintered body is particularly low (less than 800 MPa).
• A The 0.2% proof stress of the sintered body is very high (1200 MPa or more).
• the 0.2% proof stress of the sintered body is high (1100 MPa or more and less than 1200 MPa).
• the 0.2% proof stress of the sintered body is slightly high (1000 MPa or more and less than 1100 MPa).
• the 0.2% proof stress of the sintered body is slightly low (900 MPa or more and less than 1000 MPa).
• the 0.2% proof stress of the sintered body is low (800 MPa or more and less than 900 MPa).
• the 0.2% proof stress of the sintered body is very low (700 MPa or more and less than 800 MPa).
• the 0.2% proof stress of the sintered body is particularly low (less than 700 MPa).
• A The elongation of the sintered body is very large (7% or more).
• the elongation of the sintered body is slightly large (5% or more and less than 6%).
• the elongation of the sintered body is slightly small (4% or more and less than 5%).
• the elongation of the sintered body is small (3% or more and less than 4%).
• the elongation of the sintered body is very small (2% or more and less than 3%).
• the elongation of the sintered body is particularly small (less than 2%).
• the fatigue strength was measured in accordance with the test method specified in JIS Z 2273 (1978).
• the waveform of an applied load corresponding to a repeated stress was set to an alternating sine wave, and the minimum/maximum stress ratio (minimum stress/maximum stress) was set to 0.1. Further, the repeated frequency was set to 30 Hz, and the repeat count was set to 1 ⁇ 10 7 .
• the measured fatigue strength was evaluated according to the following evaluation criteria.
• the fatigue strength of the sintered body is 575 MPa or more.
• the fatigue strength of the sintered body is 555 MPa or more and less than 575 MPa.
• the fatigue strength of the sintered body is 535 MPa or more and less than 555 MPa.
• the fatigue strength of the sintered body is 515 MPa or more and less than 535 MPa.
• the fatigue strength of the sintered body is 495 MPa or more and less than 515 MPa.
• the fatigue strength of the sintered body is less than 495 MPa.
• Example 4.05 98.5 A B B B B No. 11 Example 3.97 98.9 A A A B B No. 12
• Example 3.92 98.6 A B B B B No. 13 Example 3.74 97.5 A B B C C No. 14
• Example 3.81 97.2 A B B B B No. 15 Example 3.86 97.4 A B B B B No. 16
• Example 3.88 97.1 A B B B B No. 17 Example 3.76 97.2 A B B B B No. 18
• Example 3.84 97.0 A C C B B No. 19 Example 3.84 97.2 A B B C C No. 20
• Example 3.86 96.8 A C C C No. 21 Example 3.76 97.3 A B B B No. 22
• Example 3.77 95.8 A D D B B No. 23 Example 3.94 96.2 A D C B B No.
• Example 3.05 95.7 A D D D D No. 25 Example 3.12 95.6 A D D D D No. 26
• Example 2.85 95.1 A D D D D No. 28 Example 7.84 99.1 A A A A A No. 29
• Example 8.04 99.2 A A A A A No. 30 Example 7.23 98.3 A B B B B No. 31 Comparative 3.67 93.8 F F F C C C Example No. 32 Comparative 3.48 94.5 F E C C C C Example No. 33 Comparative 2.97 94.8 F E E D D Example No. 34 Comparative 3.05 93.2 F F F D D Example No. 35 Comparative 2.16 93.1 F F F F F Example No. 36 Comparative 3.04 99.2 A A A B B Example
• Example 4.58 98.4 A B B B B No. 47 Example 6.35 98.9 A B B C C No. 48
• Example 10.8 98.9 A C C C No. 50 Example 4.78 95.9 A D D B B No. 51
• Example 4.69 96.4 A D C B B No. 52 Example 4.36 95.7 A D D D D No. 53
• Example 15.4 95.4 A D D D D No. 55 Example 4.23 99.1 A B B B B No. 56
• Example 3.87 99.3 A A A A A No. 57 Example 8.31 99.3 A A A A A No. 58
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example (excluding the sintered bodies having undergone the HIP treatment). Further, it was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example (excluding the sintered bodies having undergone the HIP treatment).
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 7, respectively.
• the sintered body of sample No. 105 was obtained by performing an HIP treatment under the following conditions after firing.
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 7 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example (excluding the sintered body having undergone the HIP treatment). Further, it was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example (excluding the sintered body having undergone the HIP treatment).
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 9, respectively.
• a metal powder, a Ti powder having an average particle diameter of 40 ⁇ m, and a Nb powder having an average particle diameter of 25 ⁇ m were mixed, whereby a mixed powder was prepared.
• each of the mixing amounts of the metal powder, the Ti powder, and the Nb powder was adjusted so that the composition of the mixed powder was as shown in Table 9.
• Example No. Comparative 12.95 0.74 0.78 0.07 0.00 0.11 0.15 ⁇ 0.01 0.34 remainder Example No. Comparative 13.26 0.45 0.42 0.73 0.07 0.12 0.06 ⁇ 0.01 0.28 remainder 116
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 9 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example. It was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example.
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 11, respectively.
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 11 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example. It was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example.
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 13, respectively.
• Example 11.36 1.15 0.87 0.07 0.15 0.09 0.12 ⁇ 0.01 0.31 remainder 0.47 0.22 0.25 0.19 0.21 135 No.
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 13 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example. It was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example.
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 15, respectively.
• Example 11.38 1.09 0.85 0.07 0.15 0.11 0.08 ⁇ 0.01 0.26 remainder 0.47 0.22 0.26 0.20 0.19 148 No.
• Example 13.09 1.03 0.81 0.03 0.03 0.58 0.17 ⁇ 0.01 0.28 remainder 1.00 0.06 0.07 0.06 0.75 151
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 15 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example. It was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example.
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 17, respectively.
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 17 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example. It was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example.
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 19, respectively.
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 19 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example. It was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example.
• Sintered bodies were obtained in the same manner as the method for producing the sintered body of sample No. 1 except that the composition and the like of the metal powder for powder metallurgy were changed as shown in Table 21, respectively.
• Each sintered body contained very small amounts of impurities, but the description thereof in Table 21 is omitted.
• the sintered density was measured in accordance with the method for measuring the density of sintered metal materials specified in JIS Z 2501 (2000), and also the relative density of each sintered body was calculated with reference to the true density of the metal powder for powder metallurgy used for producing each sintered body.
• the Vickers hardness was measured in accordance with the Vickers hardness test method specified in JIS Z 2244 (2009).
• the measured hardness was evaluated according to the evaluation criteria described in 2.2.
• the measured fatigue strength was evaluated according to the evaluation criteria described in 2.4.
• the sintered bodies corresponding to Example each have a higher relative density than the sintered bodies corresponding to Comparative Example. It was also confirmed that there is a significant difference in properties such as tensile strength, 0.2% proof stress, elongation, and fatigue strength between the sintered bodies corresponding to Example and the sintered bodies corresponding to Comparative Example.
• each of the sintered bodies of the respective sample Nos. shown in Table 23 was cut and the cross section was polished.
• each of the sintered bodies of the respective sample Nos. shown in Table 23 was subjected to a barrel polishing treatment.
• the specular gloss of the sintered body was measured in accordance with the method for measuring the specular gloss specified in JIS Z 8741 (1997).
• the incident angle of light with respect to the surface of the sintered body was set to 60°, and as a reference plane for calculating the specular gloss, a glass having a specular gloss of 90 and a refractive index of 1.500 was used.
• the measured specular gloss was evaluated according to the following evaluation criteria.
• A The specularity of the surface is very high (the specular gloss is 200 or more).
• the specularity of the surface is high (the specular gloss is 150 or more and less than 200).
• the specularity of the surface is slightly high (the specular gloss is 100 or more and less than 150).
• the specularity of the surface is slightly low (the specular gloss is 60 or more and less than 100).
• the specularity of the surface is low (the specular gloss is 30 or more and less than 60).
• the specularity of the surface is very low (the specular gloss is less than 30).
• the sintered bodies corresponding to Example each have a higher specular gloss than the sintered bodies corresponding to Comparative Example. This is considered to be because the porosity near the surface of the sintered body is small, and therefore, light scattering is suppressed, however, the ratio of regular reflection is increased.

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