US20170197245A1 - Mixed powder for powder metallurgy - Google Patents
Mixed powder for powder metallurgy Download PDFInfo
- Publication number
- US20170197245A1 US20170197245A1 US15/380,060 US201615380060A US2017197245A1 US 20170197245 A1 US20170197245 A1 US 20170197245A1 US 201615380060 A US201615380060 A US 201615380060A US 2017197245 A1 US2017197245 A1 US 2017197245A1
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- US
- United States
- Prior art keywords
- powder
- mass
- lubricant
- parts
- mixed powder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000011812 mixed powder Substances 0.000 title claims abstract description 71
- 238000004663 powder metallurgy Methods 0.000 title claims abstract description 42
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 77
- 229910052751 metal Inorganic materials 0.000 claims abstract description 75
- 239000002184 metal Substances 0.000 claims abstract description 75
- 239000000843 powder Substances 0.000 claims abstract description 67
- 239000010687 lubricating oil Substances 0.000 claims abstract description 52
- 239000000314 lubricant Substances 0.000 claims abstract description 38
- 229910052742 iron Inorganic materials 0.000 claims abstract description 36
- 239000002994 raw material Substances 0.000 claims abstract description 32
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 22
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims description 22
- 239000011733 molybdenum Substances 0.000 claims description 22
- 229910052750 molybdenum Inorganic materials 0.000 claims description 22
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 14
- 229910052725 zinc Inorganic materials 0.000 claims description 14
- 239000011701 zinc Substances 0.000 claims description 14
- 150000001342 alkaline earth metals Chemical class 0.000 claims description 12
- 150000003558 thiocarbamic acid derivatives Chemical class 0.000 claims description 6
- 229910052783 alkali metal Inorganic materials 0.000 claims description 5
- 150000001340 alkali metals Chemical class 0.000 claims description 5
- 150000003873 salicylate salts Chemical class 0.000 claims description 5
- 150000003871 sulfonates Chemical class 0.000 claims description 5
- 239000000428 dust Substances 0.000 abstract description 9
- 238000011156 evaluation Methods 0.000 description 34
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 33
- 229910002804 graphite Inorganic materials 0.000 description 26
- 239000010439 graphite Substances 0.000 description 26
- 238000002156 mixing Methods 0.000 description 20
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 17
- -1 alkaline earth metal salicylate Chemical class 0.000 description 17
- 239000011575 calcium Substances 0.000 description 17
- 229910052791 calcium Inorganic materials 0.000 description 17
- 239000002245 particle Substances 0.000 description 16
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 15
- AVVIDTZRJBSXML-UHFFFAOYSA-L calcium;2-carboxyphenolate;dihydrate Chemical compound O.O.[Ca+2].OC1=CC=CC=C1C([O-])=O.OC1=CC=CC=C1C([O-])=O AVVIDTZRJBSXML-UHFFFAOYSA-L 0.000 description 14
- 229910052717 sulfur Inorganic materials 0.000 description 14
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 13
- 239000011593 sulfur Substances 0.000 description 13
- 230000000052 comparative effect Effects 0.000 description 12
- 238000000034 method Methods 0.000 description 11
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 10
- 229910052788 barium Inorganic materials 0.000 description 10
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 10
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 8
- 239000007787 solid Substances 0.000 description 8
- WMYJOZQKDZZHAC-UHFFFAOYSA-H trizinc;dioxido-sulfanylidene-sulfido-$l^{5}-phosphane Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S WMYJOZQKDZZHAC-UHFFFAOYSA-H 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000000047 product Substances 0.000 description 7
- 229960001860 salicylate Drugs 0.000 description 7
- 229910052802 copper Inorganic materials 0.000 description 5
- 239000010949 copper Substances 0.000 description 5
- 150000002148 esters Chemical class 0.000 description 5
- 239000007789 gas Substances 0.000 description 5
- 229910052759 nickel Inorganic materials 0.000 description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 4
- 229910000640 Fe alloy Inorganic materials 0.000 description 4
- GNVMUORYQLCPJZ-UHFFFAOYSA-M Thiocarbamate Chemical compound NC([S-])=O GNVMUORYQLCPJZ-UHFFFAOYSA-M 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 229910052804 chromium Inorganic materials 0.000 description 4
- 239000011651 chromium Substances 0.000 description 4
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- OWXJWNXGYIVLBV-UHFFFAOYSA-J molybdenum(4+) tetracarbamothioate Chemical compound C(N)([O-])=S.[Mo+4].C(N)([O-])=S.C(N)([O-])=S.C(N)([O-])=S OWXJWNXGYIVLBV-UHFFFAOYSA-J 0.000 description 3
- WGOROJDSDNILMB-UHFFFAOYSA-N octatriacontanediamide Chemical compound NC(=O)CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC(N)=O WGOROJDSDNILMB-UHFFFAOYSA-N 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 229920005862 polyol Polymers 0.000 description 3
- YGSDEFSMJLZEOE-UHFFFAOYSA-M salicylate Chemical compound OC1=CC=CC=C1C([O-])=O YGSDEFSMJLZEOE-UHFFFAOYSA-M 0.000 description 3
- 238000005245 sintering Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 3
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 2
- 125000003342 alkenyl group Chemical group 0.000 description 2
- 150000004996 alkyl benzenes Chemical class 0.000 description 2
- 125000000217 alkyl group Chemical group 0.000 description 2
- 229910052787 antimony Inorganic materials 0.000 description 2
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 2
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 2
- 229910001634 calcium fluoride Inorganic materials 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- PQCZQSHMMXNPSM-UHFFFAOYSA-L copper;dicarbamothioate Chemical compound [Cu+2].NC([O-])=S.NC([O-])=S PQCZQSHMMXNPSM-UHFFFAOYSA-L 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000002708 enhancing effect Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- CADICXFYUNYKGD-UHFFFAOYSA-N sulfanylidenemanganese Chemical compound [Mn]=S CADICXFYUNYKGD-UHFFFAOYSA-N 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- 229910052714 tellurium Inorganic materials 0.000 description 2
- PORWMNRCUJJQNO-UHFFFAOYSA-N tellurium atom Chemical compound [Te] PORWMNRCUJJQNO-UHFFFAOYSA-N 0.000 description 2
- 238000013519 translation Methods 0.000 description 2
- SQOXTAJBVHQIOO-UHFFFAOYSA-L zinc;dicarbamothioate Chemical compound [Zn+2].NC([O-])=S.NC([O-])=S SQOXTAJBVHQIOO-UHFFFAOYSA-L 0.000 description 2
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 1
- 239000005642 Oleic acid Substances 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- XYRMLECORMNZEY-UHFFFAOYSA-B [Mo+4].[Mo+4].[Mo+4].[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S Chemical compound [Mo+4].[Mo+4].[Mo+4].[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S XYRMLECORMNZEY-UHFFFAOYSA-B 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- BHPUWVRNNDJLEP-UHFFFAOYSA-K antimony(3+);dioxido-sulfanylidene-sulfido-$l^{5}-phosphane Chemical compound [Sb+3].[O-]P([O-])([S-])=S BHPUWVRNNDJLEP-UHFFFAOYSA-K 0.000 description 1
- QZVZCEVBUGOXCL-UHFFFAOYSA-K antimony(3+);tricarbamothioate Chemical compound [Sb+3].NC([O-])=S.NC([O-])=S.NC([O-])=S QZVZCEVBUGOXCL-UHFFFAOYSA-K 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 125000004429 atom Chemical group 0.000 description 1
- 238000000889 atomisation Methods 0.000 description 1
- FSVHTWITPYPMHK-UHFFFAOYSA-L barium(2+);2-carboxyphenolate Chemical compound [Ba+2].OC1=CC=CC=C1C([O-])=O.OC1=CC=CC=C1C([O-])=O FSVHTWITPYPMHK-UHFFFAOYSA-L 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 229940092714 benzenesulfonic acid Drugs 0.000 description 1
- 150000001721 carbon Chemical group 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- ATKSBPAZPZLUGA-UHFFFAOYSA-L cobalt(2+);dicarbamothioate Chemical compound [Co+2].NC([O-])=S.NC([O-])=S ATKSBPAZPZLUGA-UHFFFAOYSA-L 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000002274 desiccant Substances 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 1
- 239000011133 lead Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- YQCIWBXEVYWRCW-UHFFFAOYSA-N methane;sulfane Chemical compound C.S YQCIWBXEVYWRCW-UHFFFAOYSA-N 0.000 description 1
- 229910052961 molybdenite Inorganic materials 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 229910052982 molybdenum disulfide Inorganic materials 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- UFWIBTONFRDIAS-UHFFFAOYSA-N naphthalene-acid Natural products C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 1
- SZSYQLRPXONCRW-UHFFFAOYSA-L nickel(2+);dicarbamothioate Chemical compound [Ni+2].NC([O-])=S.NC([O-])=S SZSYQLRPXONCRW-UHFFFAOYSA-L 0.000 description 1
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000009702 powder compression Methods 0.000 description 1
- 238000004445 quantitative analysis Methods 0.000 description 1
- 238000005029 sieve analysis Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- FFGBONIXSFSIPS-UHFFFAOYSA-M silver;carbamothioate Chemical compound [Ag+].NC([O-])=S FFGBONIXSFSIPS-UHFFFAOYSA-M 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- GWQWBFBJCRDINE-UHFFFAOYSA-M sodium;carbamodithioate Chemical compound [Na+].NC([S-])=S GWQWBFBJCRDINE-UHFFFAOYSA-M 0.000 description 1
- 238000007655 standard test method Methods 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 150000004763 sulfides Chemical class 0.000 description 1
- 125000004434 sulfur atom Chemical group 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- 150000003624 transition metals Chemical class 0.000 description 1
- 239000010723 turbine oil Substances 0.000 description 1
Images
Classifications
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- B22F1/0062—
-
- 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
- C22C33/0207—Using a mixture of prealloyed powders or a master alloy
-
- 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—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/102—Metallic powder coated with organic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0094—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with organic materials as the main non-metallic constituent, e.g. resin
-
- 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
-
- B22F2001/0066—
-
- 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
- B22F3/02—Compacting only
- B22F2003/023—Lubricant mixed with the metal powder
-
- 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
- B22F2301/10—Copper
-
- 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
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/40—Carbon, graphite
-
- 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
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/45—Others, including non-metals
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M2227/00—Organic non-macromolecular compounds containing atoms of elements not provided for in groups C10M2203/00, C10M2207/00, C10M2211/00, C10M2215/00, C10M2219/00 or C10M2223/00 as ingredients in lubricant compositions
- C10M2227/06—Organic compounds derived from inorganic acids or metal salts
Definitions
- the present invention relates to a mixed powder for powder metallurgy containing an iron-based powder, an auxiliary raw material, and a lubricant, the lubricant being a liquid lubricant containing an organic metal component.
- Powder metallurgy is conventionally known that uses an iron-based powder to produce a sintered body.
- the powder metallurgy includes the steps of: mixing an iron-based powder, an auxiliary raw material, and the like; compressing a mixed powder for powder metallurgy obtained in the mixing step by a forming die; and sintering a powder compact obtained in the compressing step (hereinafter referred to as a compact) to below the melting point of the iron-based material, thereby fabricating a sintered body.
- a solid or liquid lubricant is generally known to be added.
- known examples of the solid lubricant include ethylene-bis-stearic acid amide, zinc stearate, etc.
- the solid lubricant is added to reduce friction resistance between a wall surface of the forming die and the compact, thereby removing the compact from the forming die by a small removing force.
- a liquid lubricant is added to further improve the powder properties.
- an organic liquid lubricant such as an oleic acid, a spindle oil, and a turbine oil
- a drying oil including an ester derived from a multi-polyunsaturated fatty acid and a polyol as well as a desiccant are added, or a drying oil having a viscosity in a specific range is added to improve the powder properties.
- Patent Document 3 Japanese Translation of PCT International Application Publication No. JP-T-2008-503653
- sintered parts especially iron-based sintered parts
- the reduction in the thickness and weight decreases the strength of the sintered parts.
- a compact is required to have higher density.
- such a compact is also required to have excellent removability from a forming die.
- a mixed powder for powder metallurgy as a raw material needs to have a low dust generating property in a forming step of the compact.
- the present invention has been made in view of the foregoing matter, and it is an object of the present invention to provide a mixed powder for powder metallurgy that has a low dust generating property and that produces therefrom a compact with high density and enables easy removal of the compact from a forming die.
- the inventors have found that using a liquid lubricant containing an organic metal component as the lubricant in the mixing step of the powder metallurgy enhances the density of the compact.
- a mixed powder for powder metallurgy according to the present invention contains an iron-based powder, an auxiliary raw material, and a lubricant, the lubricant being a liquid lubricant containing an organic metal component.
- the lubricant preferably contains at least one of metal salicylates, metal sulfonates, metal phenates, metal thiocarbamates, and metal thiophosphonates.
- the lubricant preferably contains, as the organic metal component, at least one of alkali metals, alkaline earth metals, molybdenum, and zinc.
- the lubricant is preferably contained in a proportion of 0.01 parts by mass or more and 1 part by mass or less relative to 100 parts by mass of the iron-based powder.
- the mixed powder for powder metallurgy in the invention contains the liquid lubricant that contains the organic metal component, whereby the compact formed from the mixed powder has high density and can be removed easily from the forming die.
- the mixed powder can demonstrate the low dust generating property in the forming step for the compact.
- FIG. 1 is a cross-sectional view of an instrument for measurement of a graphite scattering ratio in Examples.
- a mixed powder for powder metallurgy (hereinafter simply referred to as a “mixed powder” in some cases) in the present invention contains an iron-based powder, an auxiliary raw material, and a lubricate; the lubricate is a liquid lubricate that contains an organic metal component.
- the mixed powder for powder metallurgy in the present invention is formed of the iron-based powder, the auxiliary raw material, and the lubricant; the lubricant is preferably a liquid lubricant containing an organic metal component.
- the iron-based powder is a raw-material powder containing iron as a principal component, and in other words, is a main raw material of the mixed powder.
- the iron-based powder may be either a pure iron powder or an iron alloy powder.
- the term “iron alloy powder” as used herein means a pure ion powder to which an element, such as copper, nickel, chromium, molybdenum, and sulfur is positively added.
- the iron alloy powder may be a partial alloy powder in which an alloy powder, such as copper, nickel, chromium, or molybdenum, is partially dispersed and attached to the surface of the iron-based powder.
- the iron alloy powder may be a prealloyed powder obtained from a molten iron or a molten steel that contains an alloy component.
- the iron-based powder is normally manufactured by performing atomization on a molten iron or steel.
- the iron-based powder may be a reduced iron powder prepared by reducing iron ore and mill scale.
- the mean particle size of the iron-based powder is not limited and may be one that makes the iron-based powder usable as a main raw material for powder metallurgy.
- the mean particle size of the iron-based powder is 40 ⁇ m or more and 120 ⁇ m or less.
- the mean particle size of a metal powder is a particle size at a cumulative undersize amount of 50% when measuring the particle size distribution based on “Standard Test Method for Sieve Analysis of Metal Powder” described in Japan Powder Metallurgy Association Standard JPMA P 02-1992.
- auxiliary raw material can be selected as appropriate, depending on the desired properties, and can be arbitrarily determined according to various properties required for end products as long as it does not inhibit the effects of the invention.
- auxiliary raw material can include metal powders made of copper, nickel, chromium, molybdenum, etc., and inorganic powders made of phosphorus, sulfur, graphite, manganese sulfide, talc, calcium fluoride, etc. These auxiliary raw materials may be contained alone or in combination.
- the auxiliary raw material preferably contains an inorganic powder, and more preferably contains a graphite powder.
- the auxiliary raw material in use may be a combination of a metal powder and an inorganic powder, and preferably contains a metal powder and a graphite powder, and most preferably contains a copper powder and a graphite powder.
- Such an auxiliary raw material is preferably contained in a proportion of 10 parts or less by mass in total relative to 100 parts by mass of the iron-based powder as the main raw material, more preferably 5 parts or less by mass, and further more preferably 3 parts or less by mass.
- the content of the auxiliary raw material relative to the iron-based powder exceeds 10 parts by mass, the density of the compact produced from the mixed powder for powder metallurgy (hereinafter referred to as a compact density) is decreased, which might result in adverse effects, including the reduction in the strength of the sintered body.
- the lower limit of the content of the auxiliary raw material is not particularly limited, and thus may be, for example, one part or more by mass.
- the auxiliary raw materials can be preferably contained in the following ranges. Note that each of the following ranges indicates the content of the auxiliary raw material relative to 100 parts by mass of the iron-based powder.
- Copper 0.1 parts by mass or more and 10 parts by mass or less, and more preferably 1 part by mass or more and 4 parts by mass or less
- Graphite 0.1 parts by mass or more and 3 parts by mass or less, and more preferably 0.2 parts by mass or more and 1 part by mass or less
- Nickel 0.1 parts by mass or more and 10 parts by mass or less, and more preferably 0.5 parts by mass or more and 4 parts by mass or less
- Chromium 0.1 parts by mass or more and 8 parts by mass or less, and more preferably 0.2 parts by mass or more and 5 parts by mass or less
- Molybdenum 0.1 parts by mass or more and 5 parts by mass or less, and more preferably 0.2 parts by mass or more and 3 parts by mass or less
- Phosphor 0.01 parts by mass or more and 3 parts by mass or less, and more preferably 0.05 parts by mass or more and 1 part by mass or less
- Sulfur 0.01 parts by mass or more and 2 parts by mass or less, and more preferably 0.03 parts by mass or more and 1 part by mass or less
- Manganese sulfide 0.05 parts by mass or more and 3 parts by mass or less, and more preferably 0.1 parts by mass or more and 1 part by mass or less
- Talc 0.05 parts by mass or more and 3 parts by mass or less, and more preferably 0.1 parts by mass or more and 1 part by mass or less
- Calcium Fluoride 0.05 parts by mass or more and 3 parts by mass or less, and more preferably 0.1 parts by mass or more and 1 part by mass or less
- the liquid lubricant containing the organic metal component is used as the lubricant.
- the organic metal component is present at an interface between respective powder particles in the mixed powder, which can enhance the lubricity between the adjacent powder particles. Accordingly, cavities in the compact become fewer, enhancing the compact density. As the density of the compact becomes higher, that is, as the cavities within the compact become fewer, the strength of a sintered body obtained from such a compact becomes higher.
- the lubricity between adjacent powder particles is insufficient, failing to adequately increase a compact density.
- the powder used as the auxiliary raw material has a smaller specific weight and a smaller particle size, compared to the iron-based powder as the main raw material, and thus might generate dust in the forming step of the compact, including the above-mentioned mixing step and the compressing step.
- the use of the liquid lubricant containing the organic metal component can enhance the lubricity between the adjacent powder particles, thereby reducing the dust generating properties in the above-mentioned mixing step and compressing step, that is, enhancing the adhesion of the auxiliary raw material to the iron base.
- the compact is formed from the mixed powder containing the lubricant used in the present invention, by means of the forming die.
- Such a compact can be easily removed from the forming die due to the high lubricity between the powder and the wall surface of the forming die and the reduced friction resistance between the compact and the wall surface of the forming die.
- the expression “contains an organic metal component” as used in the present invention means that a carbon atom and a metal atom are contained.
- the organic metal component included in the liquid lubricant preferably contains at least one of alkali metals, alkaline earth metals, and transition metals; more preferably contains at least one of alkali metals, alkaline earth metals, molybdenum, and zinc; further more preferably contains at least one of alkaline earth metals, molybdenum, and zinc; and most preferably contains at least one of calcium, barium, molybdenum, and zinc.
- the liquid lubricant preferably contains at least one of a liquid lubricant containing a metal salicylate and a liquid lubricant containing a sulfur atom, and more preferably contains at least one of metal salicylates, metal sulfonates, metal phenates, metal thiocarbamates, and metal thiophosphonates.
- the liquid lubricant particularly preferably contains at least one of calcium salicylate, calcium sulfonate, and thiocarbamic molybdenum. Calcium salicylate and calcium sulfonate are more likely to be adsorbed in the powder. When using thiocarbamic molybdenum, a lubricant film of MoS 2 is formed near the surface of the powder.
- liquid lubricant containing the organic metal component As mentioned above, in the present invention, it is important to use the liquid lubricant containing the organic metal component as the lubricant.
- a solid lubricant or a liquid lubricant not containing an organic metal component may be added.
- the metal salicylate preferably contains an alkaline earth metal salicylate, and more preferably contains at least one of calcium salicylate and barium salicylate.
- alkaline earth metal salicylate can include alkaline earth metal salts of alkyl salicylic acids.
- the metal salicylates may be used alone or in combination.
- the content of the alkaline earth metal is preferably in a range of 1 to 30% by mass, more preferably 3 to 25% by mass, further preferably 5 to 20% ⁇ by mass, and particularly preferably 10 to 15% ⁇ by mass.
- the alkaline earth metal salicylate may be a commercially available product, for example, trade name M7125, manufactured by INFINEUM (calcium salicylate, calcium content of 12.5% by mass).
- the metal sulfonate preferably contains an alkaline earth metal sulfonate, and more preferably contains at least one of a calcium sulfonate and a barium sulfonate.
- alkaline earth metal sulfonate can include alkaline earth metal salts of an alkyl benzene sulfonic acid or an alkyl naphthalene sulfonic acid, which is obtained by sulfonating an alkyl benzene or an alkyl naphthalene, respectively.
- Metal sulfonates may be used alone or in combination.
- the content of the alkaline earth metal is preferably in a range of 1 to 30% by mass, more preferably 3 to 25% by mass, and further preferably 5 to 20% by mass.
- a calcium sulfonate in use may be a commercially available product.
- Examples of the calcium sulfonate can include ADDITIN®RC4242 (calcium content: 16% by mass), manufactured by LANXESS K.K., and MORESCO Amber®SC45 (calcium content: 2.7% by mass), manufactured by MORESCO Corporation.
- a barium sulfonate in use may be a commercially available product. Examples of the barium sulfonate can include ADDITIN® RC4103 (barium content: 8% by mass), manufactured by LANXESS K.K., and MORESCO Amber® SB50N (barium content: 6.8% by mass), manufactured by MORESCO Corporation.
- the metal phenate is preferably an alkaline earth metal phenate, and more preferably at least one of calcium phenates and barium phenates.
- alkaline earth metal phenate can include alkaline earth metal salts of alkylphenols and alkylphenol sulfides.
- Metal phenates may be used alone or in combination.
- the content of the alkaline earth metal is preferably in a range of 1 to 30% by mass, more preferably 3 to 25% by mass, and further preferably 5 to 20% by mass.
- a metal phenate in use may be a commercially available product.
- the metal phenate can include Lubrizol6499 (calcium content: 9.2% by mass, and sulfur content: 3.25% by mass), and Lubrizol6500 (calcium content: 7.2% by mass, and sulfur content: 2.6% by mass), manufactured by LUBRIZOL Corporation.
- the metal thiocarbamate is preferably one represented by formula (1) below:
- R 1 and R 2 may be the same or different from each other, and represent a hydrogen atom, an alkyl group or alkenyl group having a carbon number of 1 to 22, or an aryl group having a carbon number of 6 to 22. Note that R 1 and R 2 are not hydrogen atoms at the same time.
- M a represents molybdenum, zinc, antimony, copper, nickel, silver, cobalt, lead, tellurium, or sodium. Furthermore, a represents a valence of M a .
- metal thiocarbamates can include molybdenum thiocarbamate (MoDTC), zinc thiocarbamate (ZnDTC), antimony thiocarbamate (SbDTC), copper thiocarbamate (CuDTC), nickel thiocarbamate (NiDTC), silver thiocarbamate (AgDTC), cobalt thiocarbamate (CoDTC), lead thiocarbamate (PbDTC), tellurium thiocarbamate (TeDTC), and sodium dithiocarbamate (NaDTC), preferably, molybdenum thiocarbamate (MoDTC), zinc thiocarbamate (ZnDTC), copper thiocarbamate (CuDTC), and more preferably molybdenum thiocarbamate (MoDTC). Metal thiocarbamates may be used alone or in combination.
- MoDTC in use may be a commercially available product.
- the MoDTC can include SAKURA-LUBE® 200 (molybdenum content: 4.1% by mass, and sulfur content: 4.6% by mass), SAKURA-LUBE® 165 (molybdenum content: 4.5% by mass, and sulfur content: 5.0% by mass), and SAKURA-LUBE® 525 (molybdenum content: 10% by mass, and sulfur content: 11% by mass), manufactured by ADEKA Corporation.
- the molybdenum content is preferably in a range of 1 to 20% by mass, more preferably 3 to 15% by mass, and further preferably 7 to 12% ⁇ by mass.
- the sulfur content is preferably in a range of 1 to 20% ⁇ by mass, more preferably 3 to 15% by mass, and further preferably 7 to 12% by mass.
- the metal thiophosphonate is preferably one represented by formula (2) below.
- R 3 and R 4 may be the same or different from each other, and represent a hydrogen atom, an alkyl group or an alkenyl group having a carbon number of 1 to 22. Note that R 3 and R 4 are not hydrogen atoms at the same time.
- M b represents zinc, molybdenum, or antimony. Furthermore, b represents a valence of M b .
- metal thiophosphonate metal thiophosphoric acid salts
- metal thiophosphonate can include zinc dithiophosphate (ZnDTP), molybdenum dithiophosphate (MoDTP), and antimony dithiophosphate (SbDTP), preferably zinc dithiophosphate (ZnDTP), and more preferably zinc dialkyldithiophosphates.
- Metal thiophosphonates may be used alone or in combination.
- ZnDTP in use may be a commercially available product.
- Examples of the ZnDTP can include ADEKA KIKU-LUBE® Z-112 (zinc content: 7% by mass, and sulfur content: 14% by mass), manufactured by ADEKA Corporation.
- the zinc content is preferably in a range of 1 to 20% by mass, more preferably 3 to 15% by mass, and further preferably 5 to 10% by mass.
- the sulfur content is preferably in a range of 1 to 25% ⁇ by mass, more preferably 5 to 20% ⁇ by mass, and further preferably 10 to 15% by mass.
- Manufacturing methods for the metal salicylates, metal sulfonates, metal phenates, metal thiocarbamates, and metal thiophosphonates are not particularly limited, and can be the well-known manufacturing methods and the like.
- the liquid lubricant is preferably contained in a proportion of 0.01 parts by mass or more and 1 part by mass or less relative to 100 parts by mass of the iron-based powder, more preferably 0.1 parts by mass or more and 0.8 parts by mass or less, and further preferably 0.3 parts by mass or more and 0.7 parts by mass or less.
- the content of the liquid lubricant is less than 0.01 parts by mass, the sufficient fluidity might not be obtained, whereas when the content of the liquid lubricant exceeds 1 part by mass, the high-density compact might not be obtained because of the excessive content of the liquid lubricant.
- the fabrication method of the mixed powder for powder metallurgy in the present invention involves mixing the auxiliary raw material and the above-mentioned predetermined lubricant with the iron-based powder as the main raw material.
- the mixing method is not particularly limited, and the well-known mixing methods can be employed.
- the mixing method preferably involves stirring and mixing, for example, by a mixing tool, such as a mixer, a high-speed mixer, a nauta mixer, a V-blender, or a double cone blender.
- Mixing conditions are not particularly limited, and may be those conventionally used in accordance with various conditions, including equipment and production size.
- the mixing conditions are set, for example, such that when using a mixer with blade, the rotation speed of the blade is controlled to be a peripheral speed in a range of approximately 2 m/s or more and approximately 10 m/s or less, and that a mixing time is controlled in a range of approximately 0.5 minutes or more and approximately 20 minutes or less.
- the mixing conditions are preferably controlled in a range of 2 rpm or more and 50 rpm or less for a mixing time of one minute or more and 60 minutes or less.
- the mixing temperature is not particularly limited, but set, for example, at 40° C. or more and 60° C. or less.
- the mixing temperature is preferably set at 60° C. or lower in terms of the convenience of a heating apparatus.
- the mixing under such conditions can prepare the mixed powder for powder metallurgy in which various kinds of raw-material powders are homogeneously mixed together.
- the above-mentioned mixed powder is used to produce a compact by an ordinary pressure-forming method using a powder compression molding machine.
- Specific forming conditions are not particularly limited because they depend on the kinds and added amounts of the components contained in the mixed powder, the shape of the compact, the forming temperature of 25° C. or more and 150° C. or less, the forming pressure, and the like.
- the pressure of 490 MPa or more and 686 MPa or less is applied thereto, whereby the compact can be formed.
- the above-mentioned compact is used and sintered by the ordinary sintering method to produce a sintered body.
- Specific sintering conditions are varied depending on the kinds and added amounts of the components contained in the compact, the types of final products, and the like.
- the compact is preferably sintered at a temperature of 1000° C. or more and 1300° C. or less for 5 minutes or more and 60 minutes or less under an atmosphere of N 2 , N 2 —H 2 , hydrocarbon, etc.
- a copper powder 2.0 parts by mass of a copper powder, 0.8 parts by mass of a graphite powder, and 0.5 parts by mass of a lubricant are blended into 100 parts by mass of an iron-based powder to prepare a mixed powder.
- the mixed powder as a raw material is subjected to press-forming to produce a compact.
- the theoretical density of the compact is approximately 7.81 g/cm 3 (which is the compact density, provided that there is no cavity in the compact).
- the upper limit of the compact density is approximately 7.35 g/cm 3 .
- the use of the liquid lubricant containing the organic metal component can set the compact density at 7.40 g/cm 3 or more.
- the reason for this is that the liquid lubricant used in the present invention tends to spread over between powder particles, compared with a lubricant conventionally used, to sufficiently cover the particle surfaces of the iron-based powder.
- the liquid lubricant is supposed to effectively reduce the friction between the powder particles in the compression step of the powder.
- the compact density is preferably 7.45 g/cm 3 or more. Note that specific forming methods for the compact will be described later.
- the graphite scattering ratio was measured from the content of graphite in the mixed powder before and after the circulation of dried air gas in a factory, whereby the adherability of the graphite was evaluated.
- 25 g of a mixed powder was put into a funnel-shaped glass pipe 2 having an inner diameter of 16 mm and a height of 106 mm equipped with a mesh membrane filter 1 of 10 ⁇ m in pore size.
- N 2 gas at the room temperature was allowed to flow through the gas pipe 2 from its lower side at a flow rate of 0.8 L/min for 20 minutes, and thus the graphite scattering ratio (%) was determined by the following formula.
- graphite content (%) in the mixed powder means the graphite content in percent by mass in the mixed powder. This means that as the graphite scattering ratio is lower, the graphite adherability becomes higher (the dust generating property becomes lower). Note that the graphite content in the mixed powder was determined by quantitative analysis on carbons in the mixed powder using CS-200 (trade name) manufactured by LECO Corporation, which is a carbon-sulfur simultaneous analysis device.
- A a graphite scattering ratio of less than 5%
- the mixed powder which was used as the raw material, was compacted by a forming die at a pressure of 10 t/cm 2 at the ordinary temperature (25° C.) to thereby fabricate a columnar compact having ⁇ 25 mm diameter and 15 mm length.
- JSPM standard 1-64 a metal powder compressibility testing method
- a removal pressure was determined by dividing a load that was required to remove the obtained compact from the forming die when measuring the compact density (2), by a contact area between the forming die and the compact. The measured removal pressure was evaluated based on the following criterion.
- a pure iron powder having a particle size of 40 ⁇ m or more and 120 ⁇ m or less (“Atmel 300M” manufactured by KOBE STEEL Ltd) was prepared. To 100 parts by mass of this pure iron powder, 2.0 parts by mass of a copper powder and 0.8 parts by mass of a graphite powder were added and mixed together by a V-blender, thereby producing a mixture. Then, calcium salicylate (M7125, manufactured by INFINEUM, and having a calcium content of 12.5% by mass) was added as a liquid lubricant to the mixture, and blended by using the V-blender, thereby producing a mixed powder for powder metallurgy.
- the liquid lubricant was controlled to be 0.50 parts by mass relative to 100 parts by mass of pure iron powder.
- Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, calcium sulfonate (ADDITIN® RC4242, manufactured by LANXESS K.K., and having a calcium content of 16% by mass) was added.
- Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate, barium sulfonate (ADDITIN® RC4103, manufactured by LANXESS K.K., and having a barium content of 8% by mass) was added as the liquid lubricant.
- barium sulfonate ADITIN® RC4103, manufactured by LANXESS K.K., and having a barium content of 8% by mass
- a mixed powder for powder metallurgy was produced in substantially the same way as that in Example 1 except that in place of calcium salicylate, molybdenum dialkyldithiocarba mate (ADEKA SAKURA-LUBE® 525, manufactured by ADEKA Corporation, and having a molybdenum content of 10% by mass and a sulfur content of 11% by mass) was added as the liquid lubricant.
- molybdenum dialkyldithiocarba mate ADEKA SAKURA-LUBE® 525, manufactured by ADEKA Corporation, and having a molybdenum content of 10% by mass and a sulfur content of 11% by mass
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate, zinc dialkyldithiophosphate (ADEKA KIKU-LUBE® Z-112, manufactured by ADEKA Corporation, and having a zinc content of 7% by mass and a sulfur content of 14% by mass) was added as the liquid lubricant.
- ADEKA KIKU-LUBE® Z-112 zinc dialkyldithiophosphate
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, a polyol ester for lubricating oil (UNISTAR® HP-281R, manufactured by YUKA SANGYO Co., Ltd) was added.
- a polyol ester for lubricating oil (UNISTAR® HP-281R, manufactured by YUKA SANGYO Co., Ltd) was added.
- Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, an ester for lubricating oil (UNISTAR® M-182A, manufactured by YUKA SANGYO Co., Ltd) was added.
- an ester for lubricating oil (UNISTAR® M-182A, manufactured by YUKA SANGYO Co., Ltd) was added.
- Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, a complex ester (UNISTAR® TOE-500, manufactured by YUKA SANGYO Co., Ltd) was added.
- a complex ester (UNISTAR® TOE-500, manufactured by YUKA SANGYO Co., Ltd) was added.
- Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of the liquid lubricant, ethylene-bis-stearic acid amide, which was a solid lubricant, was added.
- Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of the liquid lubricant, zinc stearate, which was a solid lubricant, was added.
- Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- the mixed powder for powder metallurgy in the present invention uses, as the lubricant, the liquid lubricant containing the organic metal component, whereby the compact formed from the mixed powder has the high density and can be removed easily from the forming die. Furthermore, the mixed powder had the low dust generating property in the forming step of the compact. Therefore, the sintered body formed from the mixed powder for powder metallurgy in the invention has the sufficient strength even though it was reduced in thickness and weight. Thus, the sintered body can be used as a complicated thinned part.
Abstract
Description
- The present invention relates to a mixed powder for powder metallurgy containing an iron-based powder, an auxiliary raw material, and a lubricant, the lubricant being a liquid lubricant containing an organic metal component.
- Powder metallurgy is conventionally known that uses an iron-based powder to produce a sintered body. In general, the powder metallurgy includes the steps of: mixing an iron-based powder, an auxiliary raw material, and the like; compressing a mixed powder for powder metallurgy obtained in the mixing step by a forming die; and sintering a powder compact obtained in the compressing step (hereinafter referred to as a compact) to below the melting point of the iron-based material, thereby fabricating a sintered body.
- In the mixing step, a solid or liquid lubricant is generally known to be added. Among them, known examples of the solid lubricant include ethylene-bis-stearic acid amide, zinc stearate, etc. When intended to remove the compact produced in the compression step from the forming die, the solid lubricant is added to reduce friction resistance between a wall surface of the forming die and the compact, thereby removing the compact from the forming die by a small removing force.
- On the other hand, a liquid lubricant is added to further improve the powder properties. For example, in a technique disclosed in Patent Document 1, an organic liquid lubricant, such as an oleic acid, a spindle oil, and a turbine oil, is used together with a solid lubricant. Furthermore, in techniques disclosed in
Patent Documents 2 and 3, a drying oil (liquid lubricant) including an ester derived from a multi-polyunsaturated fatty acid and a polyol as well as a desiccant are added, or a drying oil having a viscosity in a specific range is added to improve the powder properties. -
- Patent Document 1: Japanese Unexamined Patent Application Publication No. 2007-2340
- Patent Document 2: Japanese Translation of PCT International Application Publication No. JP-T-2008-533298
- Patent Document 3: Japanese Translation of PCT International Application Publication No. JP-T-2008-503653
- With the reduced weight of automobiles, sintered parts (especially iron-based sintered parts) have been recently developed to reduce their thickness and weight. However, the reduction in the thickness and weight decreases the strength of the sintered parts. To avoid the decrease in the strength of the sintered part, a compact is required to have higher density. Furthermore, such a compact is also required to have excellent removability from a forming die. On the other hand, a mixed powder for powder metallurgy as a raw material needs to have a low dust generating property in a forming step of the compact. Even the use of the liquid lubricants described in Patent Documents 1 to 3, however, has been found to fail to produce a mixed powder for powder metallurgy that has a low dust generating property and that can form therefrom a compact with high density and enables easy removal of the compact from the forming die.
- The present invention has been made in view of the foregoing matter, and it is an object of the present invention to provide a mixed powder for powder metallurgy that has a low dust generating property and that produces therefrom a compact with high density and enables easy removal of the compact from a forming die.
- The inventors have found that using a liquid lubricant containing an organic metal component as the lubricant in the mixing step of the powder metallurgy enhances the density of the compact.
- That is, a mixed powder for powder metallurgy according to the present invention contains an iron-based powder, an auxiliary raw material, and a lubricant, the lubricant being a liquid lubricant containing an organic metal component.
- The lubricant preferably contains at least one of metal salicylates, metal sulfonates, metal phenates, metal thiocarbamates, and metal thiophosphonates.
- The lubricant preferably contains, as the organic metal component, at least one of alkali metals, alkaline earth metals, molybdenum, and zinc.
- The lubricant is preferably contained in a proportion of 0.01 parts by mass or more and 1 part by mass or less relative to 100 parts by mass of the iron-based powder.
- The mixed powder for powder metallurgy in the invention contains the liquid lubricant that contains the organic metal component, whereby the compact formed from the mixed powder has high density and can be removed easily from the forming die. The mixed powder can demonstrate the low dust generating property in the forming step for the compact.
-
FIG. 1 is a cross-sectional view of an instrument for measurement of a graphite scattering ratio in Examples. - A mixed powder for powder metallurgy (hereinafter simply referred to as a “mixed powder” in some cases) in the present invention contains an iron-based powder, an auxiliary raw material, and a lubricate; the lubricate is a liquid lubricate that contains an organic metal component. Preferably, the mixed powder for powder metallurgy in the present invention is formed of the iron-based powder, the auxiliary raw material, and the lubricant; the lubricant is preferably a liquid lubricant containing an organic metal component.
- The iron-based powder is a raw-material powder containing iron as a principal component, and in other words, is a main raw material of the mixed powder. The iron-based powder may be either a pure iron powder or an iron alloy powder. The term “iron alloy powder” as used herein means a pure ion powder to which an element, such as copper, nickel, chromium, molybdenum, and sulfur is positively added. Note that the iron alloy powder may be a partial alloy powder in which an alloy powder, such as copper, nickel, chromium, or molybdenum, is partially dispersed and attached to the surface of the iron-based powder. Alternatively, the iron alloy powder may be a prealloyed powder obtained from a molten iron or a molten steel that contains an alloy component. The iron-based powder is normally manufactured by performing atomization on a molten iron or steel. The iron-based powder may be a reduced iron powder prepared by reducing iron ore and mill scale.
- The mean particle size of the iron-based powder is not limited and may be one that makes the iron-based powder usable as a main raw material for powder metallurgy. For example, the mean particle size of the iron-based powder is 40 μm or more and 120 μm or less. The mean particle size of a metal powder is a particle size at a cumulative undersize amount of 50% when measuring the particle size distribution based on “Standard Test Method for Sieve Analysis of Metal Powder” described in Japan Powder Metallurgy Association Standard JPMA P 02-1992.
- The above-mentioned auxiliary raw material can be selected as appropriate, depending on the desired properties, and can be arbitrarily determined according to various properties required for end products as long as it does not inhibit the effects of the invention.
- Examples of the auxiliary raw material can include metal powders made of copper, nickel, chromium, molybdenum, etc., and inorganic powders made of phosphorus, sulfur, graphite, manganese sulfide, talc, calcium fluoride, etc. These auxiliary raw materials may be contained alone or in combination. The auxiliary raw material preferably contains an inorganic powder, and more preferably contains a graphite powder. The auxiliary raw material in use may be a combination of a metal powder and an inorganic powder, and preferably contains a metal powder and a graphite powder, and most preferably contains a copper powder and a graphite powder.
- Such an auxiliary raw material is preferably contained in a proportion of 10 parts or less by mass in total relative to 100 parts by mass of the iron-based powder as the main raw material, more preferably 5 parts or less by mass, and further more preferably 3 parts or less by mass. When the content of the auxiliary raw material relative to the iron-based powder exceeds 10 parts by mass, the density of the compact produced from the mixed powder for powder metallurgy (hereinafter referred to as a compact density) is decreased, which might result in adverse effects, including the reduction in the strength of the sintered body. On the other hand, the lower limit of the content of the auxiliary raw material is not particularly limited, and thus may be, for example, one part or more by mass.
- For example, the auxiliary raw materials can be preferably contained in the following ranges. Note that each of the following ranges indicates the content of the auxiliary raw material relative to 100 parts by mass of the iron-based powder.
- Copper: 0.1 parts by mass or more and 10 parts by mass or less, and more preferably 1 part by mass or more and 4 parts by mass or less
- Graphite: 0.1 parts by mass or more and 3 parts by mass or less, and more preferably 0.2 parts by mass or more and 1 part by mass or less
- Nickel: 0.1 parts by mass or more and 10 parts by mass or less, and more preferably 0.5 parts by mass or more and 4 parts by mass or less
- Chromium: 0.1 parts by mass or more and 8 parts by mass or less, and more preferably 0.2 parts by mass or more and 5 parts by mass or less
- Molybdenum: 0.1 parts by mass or more and 5 parts by mass or less, and more preferably 0.2 parts by mass or more and 3 parts by mass or less
- Phosphor: 0.01 parts by mass or more and 3 parts by mass or less, and more preferably 0.05 parts by mass or more and 1 part by mass or less
- Sulfur: 0.01 parts by mass or more and 2 parts by mass or less, and more preferably 0.03 parts by mass or more and 1 part by mass or less
- Manganese sulfide: 0.05 parts by mass or more and 3 parts by mass or less, and more preferably 0.1 parts by mass or more and 1 part by mass or less
- Talc: 0.05 parts by mass or more and 3 parts by mass or less, and more preferably 0.1 parts by mass or more and 1 part by mass or less
- Calcium Fluoride: 0.05 parts by mass or more and 3 parts by mass or less, and more preferably 0.1 parts by mass or more and 1 part by mass or less
- In the present invention, it is important to use the liquid lubricant containing the organic metal component as the lubricant. When using the liquid lubricant containing the organic metal component, the organic metal component is present at an interface between respective powder particles in the mixed powder, which can enhance the lubricity between the adjacent powder particles. Accordingly, cavities in the compact become fewer, enhancing the compact density. As the density of the compact becomes higher, that is, as the cavities within the compact become fewer, the strength of a sintered body obtained from such a compact becomes higher. On the other hand, when using a liquid lubricant not containing an organic metal component, the lubricity between adjacent powder particles is insufficient, failing to adequately increase a compact density.
- The powder used as the auxiliary raw material has a smaller specific weight and a smaller particle size, compared to the iron-based powder as the main raw material, and thus might generate dust in the forming step of the compact, including the above-mentioned mixing step and the compressing step. However, the use of the liquid lubricant containing the organic metal component can enhance the lubricity between the adjacent powder particles, thereby reducing the dust generating properties in the above-mentioned mixing step and compressing step, that is, enhancing the adhesion of the auxiliary raw material to the iron base.
- Furthermore, the compact is formed from the mixed powder containing the lubricant used in the present invention, by means of the forming die. Such a compact can be easily removed from the forming die due to the high lubricity between the powder and the wall surface of the forming die and the reduced friction resistance between the compact and the wall surface of the forming die.
- The expression “contains an organic metal component” as used in the present invention means that a carbon atom and a metal atom are contained. The organic metal component included in the liquid lubricant preferably contains at least one of alkali metals, alkaline earth metals, and transition metals; more preferably contains at least one of alkali metals, alkaline earth metals, molybdenum, and zinc; further more preferably contains at least one of alkaline earth metals, molybdenum, and zinc; and most preferably contains at least one of calcium, barium, molybdenum, and zinc.
- The liquid lubricant preferably contains at least one of a liquid lubricant containing a metal salicylate and a liquid lubricant containing a sulfur atom, and more preferably contains at least one of metal salicylates, metal sulfonates, metal phenates, metal thiocarbamates, and metal thiophosphonates. The liquid lubricant particularly preferably contains at least one of calcium salicylate, calcium sulfonate, and thiocarbamic molybdenum. Calcium salicylate and calcium sulfonate are more likely to be adsorbed in the powder. When using thiocarbamic molybdenum, a lubricant film of MoS2 is formed near the surface of the powder. The use of such a liquid lubricant tends to enhance its lubricity between the adjacent powder particles, making it easier to re-arrange the powder particles. Thus, the use of calcium salicylate, calcium sulfonate, or thiocarbamic molybdenum reduces the cavities inside the compact, thereby making it possible to further increase the compact density.
- As mentioned above, in the present invention, it is important to use the liquid lubricant containing the organic metal component as the lubricant. In addition to the liquid lubricant containing the organic metal component, a solid lubricant or a liquid lubricant not containing an organic metal component may be added.
- The metal salicylate preferably contains an alkaline earth metal salicylate, and more preferably contains at least one of calcium salicylate and barium salicylate. Examples of the alkaline earth metal salicylate can include alkaline earth metal salts of alkyl salicylic acids. The metal salicylates may be used alone or in combination.
- In the alkaline earth metal salicylate, the content of the alkaline earth metal is preferably in a range of 1 to 30% by mass, more preferably 3 to 25% by mass, further preferably 5 to 20%© by mass, and particularly preferably 10 to 15%© by mass.
- The alkaline earth metal salicylate may be a commercially available product, for example, trade name M7125, manufactured by INFINEUM (calcium salicylate, calcium content of 12.5% by mass).
- The metal sulfonate preferably contains an alkaline earth metal sulfonate, and more preferably contains at least one of a calcium sulfonate and a barium sulfonate. Examples of the alkaline earth metal sulfonate can include alkaline earth metal salts of an alkyl benzene sulfonic acid or an alkyl naphthalene sulfonic acid, which is obtained by sulfonating an alkyl benzene or an alkyl naphthalene, respectively. Metal sulfonates may be used alone or in combination.
- In the alkaline earth metal sulfonate, the content of the alkaline earth metal is preferably in a range of 1 to 30% by mass, more preferably 3 to 25% by mass, and further preferably 5 to 20% by mass.
- A calcium sulfonate in use may be a commercially available product. Examples of the calcium sulfonate can include ADDITIN®RC4242 (calcium content: 16% by mass), manufactured by LANXESS K.K., and MORESCO Amber®SC45 (calcium content: 2.7% by mass), manufactured by MORESCO Corporation. A barium sulfonate in use may be a commercially available product. Examples of the barium sulfonate can include ADDITIN® RC4103 (barium content: 8% by mass), manufactured by LANXESS K.K., and MORESCO Amber® SB50N (barium content: 6.8% by mass), manufactured by MORESCO Corporation.
- The metal phenate is preferably an alkaline earth metal phenate, and more preferably at least one of calcium phenates and barium phenates. Examples of the alkaline earth metal phenate can include alkaline earth metal salts of alkylphenols and alkylphenol sulfides. Metal phenates may be used alone or in combination.
- In the alkaline earth metal phenate, the content of the alkaline earth metal is preferably in a range of 1 to 30% by mass, more preferably 3 to 25% by mass, and further preferably 5 to 20% by mass.
- A metal phenate in use may be a commercially available product. Examples of the metal phenate can include Lubrizol6499 (calcium content: 9.2% by mass, and sulfur content: 3.25% by mass), and Lubrizol6500 (calcium content: 7.2% by mass, and sulfur content: 2.6% by mass), manufactured by LUBRIZOL Corporation.
- The metal thiocarbamate is preferably one represented by formula (1) below:
-
[R1R2N—CS—S—]aMa (1) - where in formula (1), R1 and R2 may be the same or different from each other, and represent a hydrogen atom, an alkyl group or alkenyl group having a carbon number of 1 to 22, or an aryl group having a carbon number of 6 to 22. Note that R1 and R2 are not hydrogen atoms at the same time. Ma represents molybdenum, zinc, antimony, copper, nickel, silver, cobalt, lead, tellurium, or sodium. Furthermore, a represents a valence of Ma.
- Examples of the metal thiocarbamates (metal thiocarbamic acid salts) can include molybdenum thiocarbamate (MoDTC), zinc thiocarbamate (ZnDTC), antimony thiocarbamate (SbDTC), copper thiocarbamate (CuDTC), nickel thiocarbamate (NiDTC), silver thiocarbamate (AgDTC), cobalt thiocarbamate (CoDTC), lead thiocarbamate (PbDTC), tellurium thiocarbamate (TeDTC), and sodium dithiocarbamate (NaDTC), preferably, molybdenum thiocarbamate (MoDTC), zinc thiocarbamate (ZnDTC), copper thiocarbamate (CuDTC), and more preferably molybdenum thiocarbamate (MoDTC). Metal thiocarbamates may be used alone or in combination.
- MoDTC in use may be a commercially available product. Examples of the MoDTC can include SAKURA-LUBE® 200 (molybdenum content: 4.1% by mass, and sulfur content: 4.6% by mass), SAKURA-LUBE® 165 (molybdenum content: 4.5% by mass, and sulfur content: 5.0% by mass), and SAKURA-LUBE® 525 (molybdenum content: 10% by mass, and sulfur content: 11% by mass), manufactured by ADEKA Corporation.
- In the MoDTC, the molybdenum content is preferably in a range of 1 to 20% by mass, more preferably 3 to 15% by mass, and further preferably 7 to 12%© by mass. In the MoDTC, the sulfur content is preferably in a range of 1 to 20%© by mass, more preferably 3 to 15% by mass, and further preferably 7 to 12% by mass.
- The metal thiophosphonate is preferably one represented by formula (2) below.
-
[(R3O)(R4O)—PS—S]bMb (2) - where in formula (2), R3 and R4 may be the same or different from each other, and represent a hydrogen atom, an alkyl group or an alkenyl group having a carbon number of 1 to 22. Note that R3 and R4 are not hydrogen atoms at the same time. Mb represents zinc, molybdenum, or antimony. Furthermore, b represents a valence of Mb.
- Examples of the metal thiophosphonate (metal thiophosphoric acid salts) can include zinc dithiophosphate (ZnDTP), molybdenum dithiophosphate (MoDTP), and antimony dithiophosphate (SbDTP), preferably zinc dithiophosphate (ZnDTP), and more preferably zinc dialkyldithiophosphates. Metal thiophosphonates may be used alone or in combination.
- ZnDTP in use may be a commercially available product. Examples of the ZnDTP can include ADEKA KIKU-LUBE® Z-112 (zinc content: 7% by mass, and sulfur content: 14% by mass), manufactured by ADEKA Corporation.
- In the ZnDTP, the zinc content is preferably in a range of 1 to 20% by mass, more preferably 3 to 15% by mass, and further preferably 5 to 10% by mass. In the ZnDTP, the sulfur content is preferably in a range of 1 to 25%© by mass, more preferably 5 to 20%© by mass, and further preferably 10 to 15% by mass.
- Manufacturing methods for the metal salicylates, metal sulfonates, metal phenates, metal thiocarbamates, and metal thiophosphonates are not particularly limited, and can be the well-known manufacturing methods and the like.
- The liquid lubricant is preferably contained in a proportion of 0.01 parts by mass or more and 1 part by mass or less relative to 100 parts by mass of the iron-based powder, more preferably 0.1 parts by mass or more and 0.8 parts by mass or less, and further preferably 0.3 parts by mass or more and 0.7 parts by mass or less. When the content of the liquid lubricant is less than 0.01 parts by mass, the sufficient fluidity might not be obtained, whereas when the content of the liquid lubricant exceeds 1 part by mass, the high-density compact might not be obtained because of the excessive content of the liquid lubricant.
- Now, a description will be given of fabrication methods for the mixed powder for powder metallurgy, the compact, and the sintered body by using the above-mentioned components.
- The fabrication method of the mixed powder for powder metallurgy in the present invention involves mixing the auxiliary raw material and the above-mentioned predetermined lubricant with the iron-based powder as the main raw material. The mixing method is not particularly limited, and the well-known mixing methods can be employed. The mixing method preferably involves stirring and mixing, for example, by a mixing tool, such as a mixer, a high-speed mixer, a nauta mixer, a V-blender, or a double cone blender.
- Mixing conditions are not particularly limited, and may be those conventionally used in accordance with various conditions, including equipment and production size. Preferably, the mixing conditions are set, for example, such that when using a mixer with blade, the rotation speed of the blade is controlled to be a peripheral speed in a range of approximately 2 m/s or more and approximately 10 m/s or less, and that a mixing time is controlled in a range of approximately 0.5 minutes or more and approximately 20 minutes or less. When using the V-blender or a double-cone mixer, preferably, the mixing conditions are preferably controlled in a range of 2 rpm or more and 50 rpm or less for a mixing time of one minute or more and 60 minutes or less.
- The mixing temperature is not particularly limited, but set, for example, at 40° C. or more and 60° C. or less. The mixing temperature is preferably set at 60° C. or lower in terms of the convenience of a heating apparatus. The mixing under such conditions can prepare the mixed powder for powder metallurgy in which various kinds of raw-material powders are homogeneously mixed together.
- Then, the above-mentioned mixed powder is used to produce a compact by an ordinary pressure-forming method using a powder compression molding machine. Specific forming conditions are not particularly limited because they depend on the kinds and added amounts of the components contained in the mixed powder, the shape of the compact, the forming temperature of 25° C. or more and 150° C. or less, the forming pressure, and the like. For example, after filling the mixed powder for powder metallurgy in the present invention, into the forming die, the pressure of 490 MPa or more and 686 MPa or less is applied thereto, whereby the compact can be formed.
- Finally, the above-mentioned compact is used and sintered by the ordinary sintering method to produce a sintered body. Specific sintering conditions are varied depending on the kinds and added amounts of the components contained in the compact, the types of final products, and the like. However, the compact is preferably sintered at a temperature of 1000° C. or more and 1300° C. or less for 5 minutes or more and 60 minutes or less under an atmosphere of N2, N2—H2, hydrocarbon, etc.
- In the beginning, 2.0 parts by mass of a copper powder, 0.8 parts by mass of a graphite powder, and 0.5 parts by mass of a lubricant are blended into 100 parts by mass of an iron-based powder to prepare a mixed powder. The mixed powder as a raw material is subjected to press-forming to produce a compact. The theoretical density of the compact is approximately 7.81 g/cm3 (which is the compact density, provided that there is no cavity in the compact). When using the conventional manufacturing method, the upper limit of the compact density is approximately 7.35 g/cm3. However, the use of the liquid lubricant containing the organic metal component can set the compact density at 7.40 g/cm3 or more. The reason for this is that the liquid lubricant used in the present invention tends to spread over between powder particles, compared with a lubricant conventionally used, to sufficiently cover the particle surfaces of the iron-based powder. Thus, the liquid lubricant is supposed to effectively reduce the friction between the powder particles in the compression step of the powder. The compact density is preferably 7.45 g/cm3 or more. Note that specific forming methods for the compact will be described later.
- Now, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the examples below, and can be carried out while being appropriately modified within a range that can adapt to the intention described above and below. All these are included in the technical range of the present invention. Evaluation methods used in the examples are as follows.
- The graphite scattering ratio was measured from the content of graphite in the mixed powder before and after the circulation of dried air gas in a factory, whereby the adherability of the graphite was evaluated. As shown in
FIG. 1 , 25 g of a mixed powder was put into a funnel-shapedglass pipe 2 having an inner diameter of 16 mm and a height of 106 mm equipped with a mesh membrane filter 1 of 10 μm in pore size. N2 gas at the room temperature was allowed to flow through thegas pipe 2 from its lower side at a flow rate of 0.8 L/min for 20 minutes, and thus the graphite scattering ratio (%) was determined by the following formula. The term “graphite content (%) in the mixed powder” as used in the formula below means the graphite content in percent by mass in the mixed powder. This means that as the graphite scattering ratio is lower, the graphite adherability becomes higher (the dust generating property becomes lower). Note that the graphite content in the mixed powder was determined by quantitative analysis on carbons in the mixed powder using CS-200 (trade name) manufactured by LECO Corporation, which is a carbon-sulfur simultaneous analysis device. -
Graphite Scattering Ratio (%)=[1−(graphite content (%) in the mixed powder after the N2 gas circulation/graphite content (%) in the mixed powder before the N2 gas circulation]×100 - Then, the graphite adherability was evaluated by using the measured graphite scattering ratio based on the following criterion.
- A: a graphite scattering ratio of less than 5%
- B: a graphite scattering ratio of 5%© or more, and less than 10%
- C: a graphite scattering ratio of 10% or more
- (2) Compact Density (g/cm3)
- The mixed powder, which was used as the raw material, was compacted by a forming die at a pressure of 10 t/cm2 at the ordinary temperature (25° C.) to thereby fabricate a columnar compact having Φ25 mm diameter and 15 mm length. In conformity with JSPM standard 1-64 (a metal powder compressibility testing method), the density of the compact fabricated in the way above was measured. The measured compact density was evaluated based on the following criterion.
- A: Compact density of 7.45 g/cm3 or more
- B: Compact density of 7.40 g/cm3 or more, and less than 7.45 g/cm3
- C: Compact density of less than 7.40 g/cm3
- A removal pressure was determined by dividing a load that was required to remove the obtained compact from the forming die when measuring the compact density (2), by a contact area between the forming die and the compact. The measured removal pressure was evaluated based on the following criterion.
- A: Removal Pressure of less than 35 MPa
- B: Removal Pressure of 35 MPa or more
- A pure iron powder having a particle size of 40 μm or more and 120 μm or less (“Atmel 300M” manufactured by KOBE STEEL Ltd) was prepared. To 100 parts by mass of this pure iron powder, 2.0 parts by mass of a copper powder and 0.8 parts by mass of a graphite powder were added and mixed together by a V-blender, thereby producing a mixture. Then, calcium salicylate (M7125, manufactured by INFINEUM, and having a calcium content of 12.5% by mass) was added as a liquid lubricant to the mixture, and blended by using the V-blender, thereby producing a mixed powder for powder metallurgy. At this time, the liquid lubricant was controlled to be 0.50 parts by mass relative to 100 parts by mass of pure iron powder. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, calcium sulfonate (ADDITIN® RC4242, manufactured by LANXESS K.K., and having a calcium content of 16% by mass) was added. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate, barium sulfonate (ADDITIN® RC4103, manufactured by LANXESS K.K., and having a barium content of 8% by mass) was added as the liquid lubricant. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in substantially the same way as that in Example 1 except that in place of calcium salicylate, molybdenum dialkyldithiocarba mate (ADEKA SAKURA-LUBE® 525, manufactured by ADEKA Corporation, and having a molybdenum content of 10% by mass and a sulfur content of 11% by mass) was added as the liquid lubricant. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate, zinc dialkyldithiophosphate (ADEKA KIKU-LUBE® Z-112, manufactured by ADEKA Corporation, and having a zinc content of 7% by mass and a sulfur content of 14% by mass) was added as the liquid lubricant. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, a polyol ester for lubricating oil (UNISTAR® HP-281R, manufactured by YUKA SANGYO Co., Ltd) was added. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, an ester for lubricating oil (UNISTAR® M-182A, manufactured by YUKA SANGYO Co., Ltd) was added. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of calcium salicylate as the liquid lubricant, a complex ester (UNISTAR® TOE-500, manufactured by YUKA SANGYO Co., Ltd) was added. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of the liquid lubricant, ethylene-bis-stearic acid amide, which was a solid lubricant, was added. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
- In this example, a mixed powder for powder metallurgy was produced in the same way as that in Example 1 except that in place of the liquid lubricant, zinc stearate, which was a solid lubricant, was added. Various types of evaluations were performed on such a mixed powder by the above-mentioned evaluation methods. The results of the evaluations are shown in Table 1 below.
-
TABLE 1 Graphite adherability Graphite Compact density Removal pressure Lubricant scattering ratio Evaluation (g/cm3) Evaluation (MPa) Evaluation Example 1 Calcium salicylate 0% A 7.45 A 30 A Example 2 Calcium sulfonate 0% A 7.45 A 27 A Example 3 Barium sulfonate 0% A 7.40 B 27 A Example 4 Molybdenum dialkyldithiocarbamate 0% A 7.45 A 30 A Example 5 Zinc dialkyldithiophosphate 0% A 7.40 B 27 A Comparative Polyol ester for lubricating oil 0% A 7.35 C 32 A Example 1 Comparative Ester for lubricating oil 0% A 7.35 C 32 A Example 2 Comparative Complex ester 0% A 7.35 C 32 A Example 3 Comparative Ethylene-bis-stearic acid amide 5% B 7.35 C 27 A Example 4 Comparative Zinc stearate 5% B 7.35 C 30 A Example 5 - Based on the results shown in Table 1, the following consideration can be made.
- The compacts formed from the mixed powders in Examples 1 to 5 that used the liquid lubricants containing the organic metal components had a high density and could be easily removed from the forming die. In the forming step of the compact, the graphite adherability of each of the mixed powder was high. On the other hand, in Comparative Examples 1 to 3 that used the liquid lubricants not containing the organic metal components, the compact density did not become sufficiently high. In Comparative Examples 4 and 5 that used the solid lubricants, the graphite adherability in the forming step of the compacts was inferior while the compact density did not become sufficiently high.
- The mixed powder for powder metallurgy in the present invention uses, as the lubricant, the liquid lubricant containing the organic metal component, whereby the compact formed from the mixed powder has the high density and can be removed easily from the forming die. Furthermore, the mixed powder had the low dust generating property in the forming step of the compact. Therefore, the sintered body formed from the mixed powder for powder metallurgy in the invention has the sufficient strength even though it was reduced in thickness and weight. Thus, the sintered body can be used as a complicated thinned part.
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JP2006124777A (en) * | 2004-10-28 | 2006-05-18 | Kobe Steel Ltd | Powder mixture for powder metallurgy and green compact molding |
JP2010285633A (en) * | 2009-06-09 | 2010-12-24 | Kobe Steel Ltd | Method of producing powder mixture for powder metallurgy, and method of producing sintered body |
JP2012199568A (en) * | 2011-03-04 | 2012-10-18 | Sumitomo Electric Ind Ltd | Green compact, production method of green compact, reactor, converter, and power converter |
KR101992634B1 (en) * | 2012-10-05 | 2019-06-25 | 에이케이켐텍 주식회사 | Method of Preparation of Excellent Lubricous Lubricant Composition |
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2016
- 2016-01-13 JP JP2016004423A patent/JP6655994B2/en active Active
- 2016-12-15 US US15/380,060 patent/US20170197245A1/en not_active Abandoned
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2017
- 2017-01-06 KR KR1020170002121A patent/KR20170084996A/en active Search and Examination
- 2017-01-09 CN CN201710015358.5A patent/CN106964770B/en active Active
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US20040081574A1 (en) * | 2002-10-25 | 2004-04-29 | George Poszmik | Powder metallurgy lubricants, compositions, and methods for using the same |
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US20180079006A1 (en) * | 2015-03-27 | 2018-03-22 | Sumitomo Electric Sintered Alloy, Ltd. | Heat-treating method for compact, and dust core |
Also Published As
Publication number | Publication date |
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JP6655994B2 (en) | 2020-03-04 |
CN106964770B (en) | 2021-05-28 |
CN106964770A (en) | 2017-07-21 |
KR20170084996A (en) | 2017-07-21 |
JP2017125230A (en) | 2017-07-20 |
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