US20190076987A1 - Surface treatment method for metal product and metal product - Google Patents

Surface treatment method for metal product and metal product Download PDF

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US20190076987A1
US20190076987A1 US16/084,356 US201716084356A US2019076987A1 US 20190076987 A1 US20190076987 A1 US 20190076987A1 US 201716084356 A US201716084356 A US 201716084356A US 2019076987 A1 US2019076987 A1 US 2019076987A1
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metal article
ejection
treated
nano
region
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Keiji Mase
Shozo ISHIBASH
Yusuke Kondo
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Fuji Manufacturing Co Ltd
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Fuji Manufacturing Co Ltd
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Assigned to FUJI MANUFACTURING CO., LTD. reassignment FUJI MANUFACTURING CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ISHIBASHI, SHOZO, KONDO, YUSUKE, MASE, KEIJI
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/10—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for compacting surfaces, e.g. shot-peening
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/02—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for sharpening or cleaning cutting tools, e.g. files
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor

Definitions

  • the present invention relates to a method for surface treatment of a metal article and to a metal article subjected to surface treatment by the method.
  • the present invention relates to a surface treatment method to strengthen a surface of a metal article by ejecting fine particles against the metal article under predetermined conditions to make a crystal structure in the vicinity of the surface of the metal article to a nano-crystal structure, and to a metal article having a surface strengthened by such a method.
  • the strength of a metal material being inversely proportional to the square root of crystal grain diameter is known as a Hall-Petch relationship. Micronization of the crystal grain diameter to give such an effect is also utilized in surface strengthening of metal articles.
  • a metal article having a crystal grain diameter in the vicinity of the surface micronized to nano crystal grain diameter not only has dramatically increased surface hardness, but also has been reported to achieve improved wear resistance and corrosion resistance.
  • nano-crystallization of metal articles enabling such strengthening of the surface
  • successful examples by ball milling, falling weight processing, particle colliding processing, and shot peening has been reported.
  • nano-crystallization by shot peening is attracting particular attention due to being a low cost and easy method.
  • Patent Document 1 and Non-Patent Document 1 examples of surface treatment are introduced in Patent Document 1 and Non-Patent Document 1.
  • the respective conditions therein are surface treatment by ejecting shot made from high speed steel (SKH59) with an average particle diameter 45 ⁇ m at 0.5 MPa for 30 seconds against a soft material, in this case SS400 steel (HV 1.20 GPa (HV122)); and surface treatment by shot peening under the same conditions against a hard material, in this case SCr420 carburized and quenched steel (initial hardness HV 7.55 GPa (HV770)) in Patent Document 1 and Non-Patent Document 1.
  • SCr420 carburized and quenched steel initial hardness HV 7.55 GPa (HV770)
  • Patent Document 1 and Non-Patent Document 1 when attempting to generate nano-crystallization in the surface structure of a metal article using shot peening, it has been reported that there is a significant difference between nano-crystal structures (lamellar processing structures) created by treating a metal article configured from a soft material, and nano-crystal structures (not accompanied with lamellar processing structures) created by treating a metal article configured from a hard material.
  • nano-crystal structures created in the surface of a metal article made from a hard material are reported to be generated as nano-crystal structures by a physical state and formed uniformly along the surface in a zone extending to a particular depth from the surface.
  • the nano-crystal structures accompanying such lamellar processing structures are not contiguously distributed along the surface of the metal article.
  • peripheral work-hardening regions are exposed at the surface, and sometimes the lamellar processing structures (nano-crystal structures) penetrate to positions deeper than the work-hardening regions.
  • Patent Document 1 is limited to treat metal articles made from hard steels having an initial hardness exceeding HV 7.0 GPa (HV714). There is no disclosure therein of a method applicable to a soft material for forming a uniform nano-crystal structure continuously along the surface thereof.
  • a first objective of the present invention is to provide a method for surface treatment of a metal article in which the surface treatment method is capable of forming a uniform nano-crystal structure continuously along the surface of the metal article, without forming the lamellar processing structures described above, even when the metal article is made from a soft material.
  • a second objective of the present invention is to provide a surface treatment method of a metal article that is: capable of being applied commonly to metal articles spanning from those made of soft materials to those made of hard materials, irrespective of the hardness of the base metal of the metal article to be treated: and capable of forming a uniform nano-crystal structure continuously along the surface of the metal article.
  • the surface of the workpiece is physically cut into and parted by the cutting-edge of the cutting tool, and a portion of the workpiece is scraped off.
  • Performing cutting by continuously pressing-in the cutting-edge while removing the swarf (chip) generated by such scraping leads to a high pressure being generated between the chip and the rake face of the cutting tool.
  • the accompanying large frictional resistance and associated cutting heat physically and chemically changes the chip such that a portion of the chip accumulates to a leading portion of the cutting-edge. Accumulation formed by the chip accumulated to the cutting-edge of the cutting tool accordingly forms what is referred to as a “built-up edge”, which differs from the original cutting-edge.
  • Such built-up edge formation is not desirable due to it leading to a dulling of the cutting-edge of the cutting tool, to a reduction in processing precision, and the like.
  • the accumulation of material to be processed typified by such a built-up edge is something that is not confined to cutting tools such as drills, end mills, hobs, broaches, milling cutters, and the like. Accumulation of material to be processed also occurs with cutting-edge portions in general of machining tools that include a cutting-edge (edge) for cutting and parting, such as punching tools like punches.
  • protrusions at the outer peripheries of the dimples result in the initial wear for a sliding member being raised.
  • the protrusions at the outer periphery of the dimples are accordingly undesirable due to causing cut metal to accumulate by initial wear, and due to causing a deterioration in the slidability such as abrasive wear and the like.
  • Such a phenomenon is generated for sliding members in general, such as bearings, shafts, gears, etc.
  • Applying the treatment of the present invention to sliding members imparts hardness and residual stress to the sliding member.
  • the treatment has, moreover, been confirmed to be a treatment method that improves the slidability, and makes the generation of projections less liable to occur at the outer periphery of dimples which would raise the initial wear of the sliding member.
  • the present invention also has the objectives of: being utilized as a surface treatment method to prevent material to be processed from accumulating to cutting-edge portions of machining tools; and being utilized as a surface treatment method to raise the hardness and impart residual stress to sliding members, and to improve the slidability of sliding members.
  • a method for surface treatment of a metal article according to the present invention is the method comprising:
  • substantially spherical ejection particles having a median diameter d50 of from 1 ⁇ m to 20 ⁇ m and a falling time through air of not less than 10 sec/m against a metal article at an ejection pressure of from 0.05 MPa to 0.5 MPa;
  • nano-crystal structure layer continuously along a surface of the metal article in a zone to a prescribed depth from the surface of metal article by uniform micronization to nano-crystals having an average crystal grain diameter of not greater than 300 nm; and imparting compressive residual stress to the surface of the metal article.
  • Median diameter d50 refers to the diameter at a cumulative mass 50 percentile, namely, to a diameter that when employed as a particle diameter to divide a group of particles into two, results in the total mass of particles in the group of particles of larger diameter being the same as the total mass of particles in the group of particles of smaller diameter. This is the same definition as “particle diameter at a cumulative 50% point” in JIS R 6001 (1987).
  • the ejection velocity of the ejection particles is not less than 80 m/sec.
  • the material of the metal article may be either aluminum or an aluminum alloy.
  • the crystal grain diameter of the nano-crystal structure layer can be micronized to a crystal grain diameter not greater than 100 nm.
  • the metal article may be a machining tool, and a region to be treated may be a cutting-edge (edge) of the machining tool and the vicinity of the cutting-edge, preferably, a range of at least 1 mm from the cutting edge, more preferably, a range of at least 5 mm from the cutting edge; and dimples having an equivalent diameter of from 1 ⁇ m to 18 ⁇ m, preferably, 1 ⁇ m to 12 ⁇ m and a depth of from 0.02 ⁇ m to 1.0 ⁇ m or less than 1.0 ⁇ m may be formed on the region to be treated by ejecting the ejection particles, such that a projected surface area of the dimples occupies not less than 30% of a surface area of the region to be treated.
  • the metal article may be a sliding member employed to slide against another member, such as a bearing, shaft, or gear, at least a sliding portion of the sliding member is a region to be treated; and dimples having an equivalent diameter of from 1 ⁇ m to 18 ⁇ m, preferably, 1 ⁇ m to 12 ⁇ m and a depth of from 0.02 ⁇ m to 1.0 ⁇ m or less than 1.0 ⁇ m may be formed on the region to be treated by ejecting the ejection particles, such that a projected surface area of the dimples occupies not less than 30% of a surface area of the region to be treated.
  • equivalent diameter in the present invention refers to the diameter of a circle determined by converting the projected surface area for a single dimple formed on the region to be treated into a circular surface area (“projected surface area” in the present specification means the surface area of the outline of the dimple).
  • a metal article according to the present invention is the metal article comprising: a base metal having a hardness not greater than HV714 (HV 7.0 GPa); a nano-crystal structure layer formed continuously along a surface of the metal article in a zone to a prescribed depth from the surface of metal article by uniform micronization to nano-crystals having an average crystal grain diameter of not greater than 300 nm; and a compressive residual stress being imparted to the surface of the metal article.
  • the metal article according to the present invention is configured from either aluminum or an aluminum alloy, and a crystal grain diameter of the nano-crystal structure layer is not greater than 100 nm.
  • the metal article may be a machining tool; the nano-crystal structure layer may be formed on a surface of a region to be treated including a cutting-edge and a vicinity of the cutting-edge; and dimples having an equivalent diameter of from 1 ⁇ m to 18 ⁇ m and a depth of from 0.02 ⁇ m to 1.0 ⁇ m or less than 1.0 ⁇ m may be formed such that a projected surface area of the dimples occupies not less than 30% of a surface area of the region to be treated.
  • the metal article may be a sliding member; the nano-crystal structure layer may be formed on a surface of a sliding portion of the sliding member that makes sliding contact with another member: and dimples having an equivalent diameter of from 1 ⁇ m to 18 ⁇ m and a depth of from 0.02 ⁇ m to 1.0 ⁇ m or less than 1.0 ⁇ m may be formed such that a projected surface area of the dimples occupies not less than 30% of a surface area of the region to be treated.
  • a uniform nano-crystal structure layer can be formed continuously even on metal articles made from soft materials, in which hitherto it has not been possible to form a uniform nano-crystal structure layer continuously due to the formation of lamellar processing structures.
  • this surface treatment also imparts a high compressive residual stress equal to or higher than that imparted when large ejection particles of comparatively large particle diameter are ejected at high ejection pressure.
  • ejection particles that have a small median diameter of from 1 ⁇ m to 20 ⁇ m and have a falling time through air of not less than 10 sec/m have a small mass. Although this means that stress is concentrated in the vicinity of the surface of the metal article and does not propagate deeply, the surface deformation of the metal article on being collided can also be made small. Such ejection particles are easily carried on an airflow, and can therefore be propelled at a velocity close to the airflow velocity. This enables such ejection particles to be ejected at similar velocities to the velocity of airflow flowing inside an ejection nozzle, at velocities of 80 m/sec or greater, for example.
  • the colliding energy required to obtain nano-crystal structures can be achieved even when ejecting with a comparatively low ejection pressure of about 0.05 MPa.
  • the surface hardness increasing effect on a metal article is substantially saturated when the ejection pressure is about 0.1 MPa, and there is substantially no further increase in hardness observed from ejecting at ejection pressures of 0.1 MPa and greater.
  • Nano-crystal structures can be obtained irrespective of the base metal hardness of the metal article even with comparatively weak ejection pressures not exceeding 0.5 MPa. Compressive residual stress can also be imparted therewith that is of the same level to when ejection particles of 50 ⁇ m or greater are ejected at high pressure as described in the related art.
  • the lamellar processing structures such as those explained with reference to FIG. 1 are not formed even for metal articles made from soft materials such as aluminum alloys.
  • This thereby enables a nano-crystal structure layer to be formed uniformly and continuously.
  • This is thought to enable a nano-crystal structure layer to be formed uniformly and continuously using a lower ejection pressure than the ejection pressure indicated in the related art documents, even for a metal article made from a hard material.
  • the surface treatment method of the present invention enables a uniform nano-crystal structure layer to be formed continuously along a surface without forming the lamellar processing structures described above, even for metal articles made from aluminum or aluminum alloys, which have particularly low hardness from among metal materials. Due to being able to achieve a finer crystal grain diameter of 100 nm or less for the nano-crystal structure layer formed when treating aluminum or an aluminum alloy, a higher degree of surface strengthening effect can be obtained.
  • the region to be treated is a cutting-edge (edge) of a machining tool such as a cutting tool and in the vicinity of the cutting-edge
  • the equivalent diameter of dimples formed by the ejection of ejection particles onto the region to be treated is from 1 ⁇ m to 18 ⁇ m, and preferably from 1 ⁇ m to 12 ⁇ m
  • the depth of such dimples is from 0.02 ⁇ m to 1.0 ⁇ m or less than 1.0 ⁇ m
  • the projected surface area of such dimples is not less than 30% of the surface area of the region to be treated.
  • FIG. 1 is an explanatory diagram illustrating a mechanism by which lamellar processing structures are formed in a soft material.
  • FIG. 2 are explanatory diagrams illustrating an example of application to a cutting-edge of a machining tool: (A) illustrates a state before treatment, and (B) illustrates a state after treatment.
  • FIG. 3 is an explanatory diagram of a portion (pressure receiving surface) where compressional force acts when collided by an ejection particle.
  • FIG. 4 is a Von Mises stress analysis image using FEM (5 ⁇ m ejection particles).
  • FIG. 5 is a Von Mises stress analysis image using FEM (10 ⁇ m ejection particles).
  • FIG. 6 is a Von Mises stress analysis image using FEM (20 ⁇ m ejection particles).
  • FIG. 7 is a Von Mises stress analysis image using FEM (50 ⁇ m ejection particles).
  • FIG. 8 is a Von Mises stress analysis image using FEM (100 ⁇ m ejection particles).
  • FIG. 9 is a graph illustrating a relationship between particle diameter of ejection particles and stress.
  • FIG. 10 is a graph illustrating a relationship between particle diameter of ejection particles and depth of maximum stress generation.
  • FIG. 11 is a graph illustrating relationships between ejection pressure and dynamic hardness.
  • FIG. 12 are SIM images of pre-hardened steel (“NAK 80”, manufactured by Daido Steel Co., Ltd): (A) illustrates a state before treatment, and (B) illustrates a state after the treatment of the present invention.
  • NAK 80 manufactured by Daido Steel Co., Ltd
  • FIG. 13 are SIM images of an alloy tool steel (SKD11): (A) illustrates a state before treatment, and (B) illustrates a state after treatment of the present invention.
  • FIG. 14 are SIM images of an aluminum alloy (A7075): (A) illustrates a state before treatment, and (B) illustrates a state after treatment of the present invention.
  • FIG. 15 is a grain diameter distribution diagram for pre-hardened steel (“NAK 80”, manufactured by Daido Steel Co., Ltd) treated by the method of the present invention.
  • FIG. 16 is a grain diameter distribution diagram for alloy tool steel (SKD11) treated by the method of the present invention.
  • FIG. 17 is a graph of measurement results of residual stress in pre-hardened steel (“NAK 80”, manufactured by Daido Steel Co., Ltd).
  • FIG. 18 is graph of measurement results of residual stress in alloy tool steel (SKD11).
  • FIG. 19 is a graph of measurement results of residual stress in aluminum alloy (A7075).
  • FIG. 20 is a graph of measured changes in friction with respect to elapsed time.
  • a metal article subjected to treatment by the surface treatment method of the present invention may be any article made from metal, and, as well as application to ferrous metals, application may also be made to metal articles made from non-ferrous metals and alloys thereof.
  • the metal article to be treated is not limited to a metal article configured from a hard base metal, and application may be made to a range of metals from comparatively soft metals of about HV20 to HV400 such as aluminum and alloys thereof, pre-hardened steels (“NAK 80”, manufactured by Daido Steel Co., Ltd: HV400) and the like, up to high hardness steels, such as SKD11 (HV697).
  • the method of the present invention is able to treat metal articles made from soft materials, in which hitherto it has been impossible to form a nano-crystal structured layer uniformly and continuously due to the formation of lamellar processing structures as explained with reference to FIG. 1 . From among such soft materials, it has been confirmed that the method can achieve a nano-crystal structure layer formed with an extremely fine crystal grain diameter, this being a crystal grain diameter of 100 nm or less, when metal articles made from aluminum and aluminum alloys, which have a particularly low hardness, are treated. A large surface strengthening effect can be obtained as a result.
  • a preferable application of the surface treatment method of the present invention is application to a cutting-edge of a machining tool such as cutting tool, or to the vicinity of the cutting-edge. This is due to not only being able to strengthen the cutting-edge portion, but also being able to prevent the material to be processed from accumulating to the cutting-edge.
  • ejection particles described later are ejected to the region to be treated where the ejection particles are ejected and caused to be collided thereto, i.e., a portion of the cutting-edge (edge) as illustrated in FIG. 2 where shearing starts when cutting or shearing, and a range of at least 1 mm from the cutting-edge, and preferably a range of at least 5 mm from the cutting edge (the range from the cutting-edge indicated by the double-dashed broken lines in the drawings). Dimples are also formed in this region accompanying the formation of a nano-crystal structure layer on the surface of this portion, as illustrated in FIG. 2(B) .
  • inclined faces on either side of the cutting-edge may be employed as the region to be treated.
  • the region to be treated may be solely provided on the inclined face that bears the greatest frictional resistance during cutting, or solely provided on the inclined face on the side that cut material might be accumulated thereto.
  • the region to be treated referred to above is at least a portion of the sliding member that slides against the other member.
  • the surface of the metal article to be treated may be in a burred state, or may be in a state in which processing marks such as tool marks remain formed thereon.
  • pre-polishing is performed in advance to polish to surface roughness having an arithmetic mean roughness (Ra) of 3.2 ⁇ m or less.
  • polishing may be performed by manual lapping or buffing.
  • pre-processing is preferably performed by blasting using an elastic abrasive.
  • Such an elastic abrasive is an abrasive having abrasive particles dispersed in an elastic body such as a rubber or an elastomer, or is an abrasive having abrasive particles supported on the surface of an elastic body.
  • Such an elastic abrasive can be caused to slide across the surface of a metal article by being ejected at an inclination thereto, or the like. The surface of the metal article can thereby be comparatively simply polished to a mirror finish, or polished to a state close to a mirror finish.
  • the abrasive particles dispersed in, or supported by, the elastic body of the elastic abrasive may be appropriately selected according to the surface state of the metal article etc.
  • An example of abrasive particles that may be employed therefor are silicon carbide and diamond abrasive particles of from 1000 grit to 10000 grit.
  • Substantially spherical ejection particles are ejected against the regions described above of the surface of the metal article where surface strengthening is to be performed, and are caused to collide these regions.
  • substantially spherical ejection particles employed in the surface treatment method of the present invention “substantially spherical” means that they do not need to be strictly “spherical”, and ordinary “shot” may be employed therefor. Particles of any non-angular shape, such as an elliptical shape and a barrel shape, are included in “substantially spherical ejection particles” employed in the present invention.
  • Materials that may be employed for the ejection particles include both metal-based and ceramic-based materials.
  • materials for metal-based ejection particles include steel alloys, cast iron, high-speed tool steels (HSS) (SKH), tungsten (W), stainless steels (SUS), boron (B), chromium boron steels (FeCrB), and the like.
  • materials for ceramic-based ejection particles include alumina (Al 2 O 3 ), zirconia (ZrO 2 ), zircon (ZrSiO 4 ), hard glass, glass, silicon carbide (SiC), and the like.
  • particles having a median diameter (d50) in a range of from 1 ⁇ m to 20 ⁇ m may be employed.
  • Iron-based ejection particles that may be employed have a median diameter (d50) in a range of from 1 ⁇ m to 20 ⁇ m, and preferably in a range of from 5 ⁇ m to 20 ⁇ m.
  • Ceramic-based ejection particles that may be employed have a median diameter (d50) in a range of from 1 ⁇ m to 20 ⁇ m, and preferably in a range of from 4 ⁇ m to 16 ⁇ m.
  • the ejection particles can be imparted with the property of having a long falling time through air (caused to float in air) by selecting a material density of the ejection particles. Ejection particles having such properties readily ride on an airflow, and can be propelled with a velocity similar to that the airflow velocity.
  • the ejection particles employed have a falling time in still air conditions of 10 sec/m or greater. This enables the ejection particles to be ejected at substantially the same velocity as the velocity of an airflow being ejected from an ejection nozzle of a blasting apparatus.
  • the falling time is longer, the lower the density of the material configuring the ejection particles.
  • the falling time is 10.6 sec for a particle diameter of 20 ⁇ m, and 41.7 sec for a particle diameter of 10 ⁇ m.
  • the falling time is 26.3 sec for a particle diameter of 20 ⁇ m, and 100 sec for a particle diameter of 10 ⁇ m.
  • the ejection particles employed are preferably ejection particles of a material having a hardness equivalent to or greater than that of the base metal of the metal article to be treated.
  • the ejection particles have a higher hardness than substantially all metal articles.
  • the density of ceramic-based ejection particles is also low, and the falling time as described above is long. This means that ceramic-based ejection particles are preferably employed due to being able to obtain a high ejection velocity.
  • a known blasting apparatus for ejecting abrasive together with a compressed gas may be employed as the ejection apparatus to eject the ejection particles described above toward the surface of region to be treated.
  • Such blasting apparatuses are commercially available, such as a suction type blasting apparatus that ejects abrasive using a negative pressure generated by ejecting compressed gas, a gravity type blasting apparatus that causes abrasive falling from an abrasive tank to be carried by compressed gas and ejected, a direct pressure type blasting apparatus in which compressed gas is introduced into a tank filled with abrasive and the abrasive is ejected by merging the abrasive flow from the abrasive tank with a compressed gas flow from a separately provided compressed gas supply source, and a blower type blasting apparatus that carries and ejects the compressed gas flow from such a direct pressure type blasting apparatus with a gas flow generated by a blower unit. Any one of the above may be employed to eject the ejection particles described above.
  • Substantially spherical ejection particles configured from one of the materials described above or the like, and having a median diameter d50 of from 1 ⁇ m to 20 ⁇ m and a falling time through air of not less than 10 sec/m are ejected against the metal article as described above at an ejection pressure of from 0.05 MPa to 0.5 MPa.
  • the lamellar processing structures as explained with reference to FIG. 1 need to be suppressed from being generated in order to form a uniform nano-crystal structure layer continuously along a surface of a metal article made from a soft material.
  • deformation of the metal article surface needs to be suppressed from occurring when collided by the ejection particles.
  • strain exceeding a critical value needs to be imparted in the vicinity of the surface of the metal article in order to generate nano-crystal structures, and that a large colliding force needs to be imparted to the surface of the metal article by collision of the ejection particles in order to impart strain exceeding the critical value.
  • the inventors of the present invention have accordingly investigated treatment conditions that enable these conflicting demands to be satisfied, i.e. the need to reduce the colliding force received by the metal article surface when collided by the ejection particles to suppress deformation of the surface of the metal article, with the need to also impart strain exceeding the critical value required to generate the nano-crystal structures.
  • Particles having a median diameter d50 of from 20 ⁇ m to 40 ⁇ m were caused to collide a surface, and the volume of protrusions on the surface was measured using a profile analyzing laser microscope. A comparison was then made between the protrusion volume and the ease of generation of the lamellar processing structures formed by folding. This was done because it was thought that the larger the protrusion volume, the larger the amount of folding that would be generated when collided by the particles.
  • VK-X250 A profile analyzing laser microscope (“VK-X250”, manufactured by Keyence Corporation) was employed as the measuring method, and measurements were taken of the surface at a measurement magnification of 1000 ⁇ .
  • the measured data was analyzed using a Multi-File Analysis Application (manufactured by Keyence Corporation).
  • the Multi-File Analysis Application is software that uses data measured by a laser microscope to perform various measurements, such as surface roughness, flatness measurements, profile measurements, volume/area measurements, etc.
  • the “image processing” function was used to set the reference plane (however, in cases in which the surface shape is a curved plane, the reference plane is set after the curved plane has been corrected to a flat plane by using plane shape correction). Then, the measurement mode was set to protrusion in the “volume/area measurement” function of the application, protrusions were measured with respect to the set “reference plane”, and the average value of the “volume” in the protrusion measurement results was set as a dimple protrusion volume.
  • the change in momentum ⁇ M here is equivalent to the impulse F ⁇ t (wherein ⁇ t is the duration of impulse).
  • colliding force F imparted to the surface of the metal article when collided by the ejection particle (1 particle) is:
  • the colliding force F of Equation 5 changes in proportional to a mass m of the ejection particle, and so the colliding force F gets larger as the ejection particle diameter increases.
  • the colliding force F also increases, as described above.
  • the surface area of the portion of the metal article surface undergoing deformation (the portion indicated by the reference sign S in FIG. 3 ) also increases when the surface of the metal article is collided with the ejection particles.
  • Equation 6 Taking the surface of the metal article where interaction with the ejection particles occurs (a circular shape horizontal plane) as a pressure receiving surface S, then relationships expressed by Equation 6 and Equation 7 below are satisfied between a radius a of the pressure receiving surface S, a radius r of the ejection particles, and a depth X of the depressions:
  • Equation 10 a surface area S (m 2 ) of the pressure receiving surface is given by Equation 10.
  • Equation 11 shows that the surface area of the pressure receiving surface S increases in proportional to the square of the diameter of the ejection particles.
  • indentations and protrusions are formed during colliding, and then the protrusions from out of these indentations and protrusions are folded over to form the lamellar processing structures.
  • These protrusions are formed by base metal at the depression portions explained with reference to FIG. 3 (the shaded portion in FIG. 3 ) being pushed out when collided by an ejection particle.
  • the colliding force F does not only increase with an increase in mass m of the ejection particles, but also increases with an increase in the ejection velocity v1.
  • the ejection velocity was computed with reference to ejection velocity computation equations in a paper regarding how the ejection velocity changes with respect to changes in particle diameters of ejection particles: “Measurement and Analysis of Shot Velocity in Pneumatic Shot Peening” by Ogawa, Asano, et al (Transactions of the Japan Society of Mechanical Engineers, Edition C. Volume 60. No. 571, 1994-3).
  • the colliding force F increases the larger the particle diameter of the ejection particles, however, accompanying such increases, the pressure receiving surface area S also increases.
  • large protrusions are formed on the surface of the metal article being collided with the ejection particles. This is thought to facilitate generation of the lamellar processing structures, which are thought to be generated by folding such protrusions.
  • the larger the particle diameter of the ejection particles the larger the value of the colliding force F.
  • the surface area of the pressure receiving surface S increases in proportional to the square of the diameter d of the ejection particles, as stated above. This means that when the colliding force F per unit surface area of the pressure receiving surface S (colliding force F/pressure receiving surface area S) is considered, then the force imparted per unit surface area actually decreases.
  • FEM analysis finite element method
  • results obtained from this simulation are illustrated as a graph in FIG. 9 of a relationship between change in stress and ejection particle diameter, and as a graph in FIG. 10 of a relationship between depth at which the maximum stress is generated and ejection particle diameter.
  • FEM analysis is a numerical analysis method for use in cases difficult to solve by analytical methods such as complex geometric models.
  • FEM analysis an area is divided into finite elements, simple formulae are established at the element level, and a solution for the whole system is obtained by using interpolation functions between elements to make an approximation thereof.
  • “Femap with NX Nastran” (sold by NST Co., Ltd.) was employed as analysis software.
  • Von Mises stress is equivalent stress based on shear strain energy theory. Von Mises stress is expressed as a scalar value without directionality, and in a stress field where complex loading acts in in plural directions, the Von Mises stress is a value for uniaxial tension or compressive stress.
  • the Von Mises stress is referenced as an indicator to determine whether or not a given material will yield. This means that there is no need to look at stress in other directions when comparing against yield stress, and yield determination is made using a single Von Mises stress. This was utilized to simulate stress arising from colliding with the ejection particles.
  • the center of the portions where a crescent shape can be seen represents the portion input with highest intensity stress.
  • An extremely high stress was imparted to portions in the vicinity of the surface in the simulation of ejection particles of 20 ⁇ m or less. However, stress is spread out and dispersed deeply as the particle diameter increases, resulting in a weaker intensity of stress (see FIG. 9 and FIG. 10 ).
  • indentations and protrusions which are the cause of lamellar processing structure formation as explained with reference to FIG. 1 , are not liable to be formed on the surface of the metal article when ejection particles of 20 ⁇ m or less are employed.
  • ejection particles of 20 ⁇ m or less are employed.
  • employing such ejection particles is thought to result in an effect by which compositional strain exceeding the critical value required to generate the nano-crystal structures is concentrated and generated in the vicinity of the surface of the metal articles.
  • Ferrous alloy ejection particles having a median diameter d50 of 20 ⁇ m were ejected against regions of 6 mm ⁇ 5 mm on test strips made from an alloy tool-steel (SKD11), a pre-hardened steel (“NAK80”, manufactured by Daido Steel Co., Ltd), and an aluminum alloy (A7075). Changes in surface hardness (dynamic hardness) were measured for each of the test strips.
  • test strips were produced for each of the materials and treated at different ejection pressures.
  • the dynamic hardness was measured at 30 points in the regions of 6 mm ⁇ 5 mm on the test strips, and the found hardness taken as the surface hardness (dynamic hardness) of each test strip.
  • FIG. 11 A graph of these measurement results is illustrated in FIG. 11 .
  • DHT dynamic hardness
  • DHT is the dynamic hardness
  • a is an indenter shape coefficient (3.8584)
  • P is the indentation load (mN)
  • D is the indentation depth.
  • the deformation of the metal article surface is suppressed to a minimum even when treating a metal article made from a soft material, and it is thought that this enables the lamellar processing structures explained with reference to FIG. 1 to be suppressed from being generated.
  • such ejection particles of small particle diameter have a small mass and the influence of inertia is small. There is accordingly no need for a large force to move such particles, and these ejection particles are easily carried on an ejected airflow even when the pressure of the transport gas is a low pressure. This enables the ejection particles to be ejected from the ejection nozzle easily with a velocity close to that of the compressed gas since the distance until the maximum velocity is achieved is short.
  • a hardness that is not less than 60% of the hardness at 0.1 MPa can still be imparted even when the pressure is 0.05 MPa.
  • iron-based ejection particles having a median diameter of 20 ⁇ m employed in the above tests have a falling time through air (inverse of terminal velocity according to Stokes' Law or Stokes' equation) that is 10.6 sec/m.
  • a good rise in surface hardness (dynamic hardness) could be obtained for ejection pressures within the range of from 0.05 MPa to 0.5 MPa.
  • the required ejection velocity can be achieved as long as the falling time through air is longer than that of these ejection particles so that the ejection particles are readily carried on an airflow, enabling nano-crystallization to be obtained at the surface of the metal article.
  • the ejection particles employed in method of the present invention are determined to be ejection particles having a median diameter of not greater than 20 ⁇ m, and having a falling time through air of not less than 10 sec/m.
  • the ejection velocity is not less than 80 m/sec for the above described iron-based ejection particles having a particle diameter of 20 ⁇ m.
  • the ejection particles are preferably ejected at an ejection velocity of not less than 80 m/sec.
  • the surface treatment of the method of the present invention was performed on the test strips made from a pre-hardened steel (“NAK80”, manufactured by Daido Steel Co., Ltd), an alloy tool-steel (SKD11), and an aluminum alloy (A7075).
  • NAK80 manufactured by Daido Steel Co., Ltd
  • SMD11 an alloy tool-steel
  • A7075 aluminum alloy
  • test strips that had been surface treated under the conditions described above was observed by the following method.
  • SIM scanning ion microscope
  • Electron back scatter diffraction analysis was employed (using an Electron Back Scatter Diffraction instrument manufactured by TSL Solutions Corporation) to observe crystal structure in the vicinity of the surface of each test strip, and to observe the crystal grain diameter and a crystal grain distribution therein.
  • a portable X-ray residual stress analyzer (“p-X360” manufactured by Pulsetech Industrial Co., Ltd) was employed to measure the residual stress at the outermost surface layer of each of the test strips.
  • FIG. 12 to FIG. 14 illustrate SIM images for each of the test strips.
  • FIG. 12 is an SIM image for a pre-hardened steel (NAK80)
  • FIG. 13 is an SIM image for an alloy tool-steel (SKD11).
  • FIG. 14 is an SIM image for an aluminum alloy (A7075).
  • the figure appended with A was captured for test strips before treatment
  • the figure appended with B was captured for test strips after treatment.
  • nano-crystal structures were formed continuously along the surface of the test strips within the field of view of SIM mages (about 10 ⁇ m), and the formation of a continuous nano-crystal structure layer was confirmed.
  • this nano-crystal structure even for the test strip to be treated made from the aluminum alloy (A7075) which is a soft material, was confirmed to be formed as a uniform nano-crystal structure without cracks or the like occurring in the structure, and without being accompanied by the formation of the lamellar processing structures explained with reference to FIG. 1 .
  • the surface treatment method of the present invention was capable of forming a uniform nano-crystal structure layer continuously along the surface, without being accompanied by the formation of the lamellar processing structures, in a zone of a particular depth (about 3 ⁇ m) from the surface for both test strips made from hard materials and test strips made from soft materials.
  • test strips formed in this manner with a nano-crystal structure layer in the vicinity of surface had, as explained with reference to FIG. 11 , a surface hardness (dynamic hardness) is increased by about 100 to 200 compared to untreated test strips (indicated at ejection pressure 0 MPa in FIG. 11 ). This confirmed that the effectiveness as a method for strengthening surfaces of metal articles formed from various materials from soft materials through to hard materials.
  • results obtained from EBSD analysis indicated a crystal grain diameter distribution in the vicinity of the surface of the pre-hardened steel (NAK80) test strip as illustrated in FIG. 15 , and a crystal grain diameter distribution in the vicinity of the surface of the alloy tool-steel (SKD11) test strip as illustrated in FIG. 16 .
  • the crystal grain diameter of the nano-crystal structure layer in the pre-hardened steel (NAK80) was in the range of from 100 nm to 500 nm.
  • the average crystal grain diameter in the crystal grain diameter distribution of this nano-crystal structure layer was found to be 240 nm (see FIG. 15 ).
  • the crystal grain diameter of the nano-crystal structure layer was confirmed to be in the range of from 100 nm to 500 nm. Moreover, the average crystal grain diameter in the crystal grain diameter distribution of this nano-crystal structure layer was found to be 223 nm (see FIG. 16 ).
  • the generated crystal grain diameter was much smaller than the resolution of EBSD.
  • crystallite analysis could not be performed by EBSD, due to the highest resolution by EBSD being 30 nm, since the finest crystal grains were observed in the test strips by SIM imaging, most of the crystal grains can logically be presumed to mainly be smaller than the 30 nm, which is the highest resolution of EBSD, in the nano-crystal structure layer formed on the surface of the aluminum alloy (A7075).
  • the crystal grain diameter of the nano-crystal structure layer formed on the surface of the aluminum alloy (A7075) is accordingly thought to be 100 nm or less.
  • the residual stress of the aluminum alloy (A7075) is illustrated in the graph of FIG. 19 .
  • This graph shows as a Comparative Example the results of residual stress measurements when ejection particles having a median diameter of 40 ⁇ m, this being larger than the range of the present invention, were ejected at an ejection pressure of 0.5 MPa.
  • Blanking punches made from SKD11 and having cutting-edge portions treated with the surface treatment method of the present invention (Examples 1 and 2), a blanking punch made from untreated SKD11 (untreated punch), and a blanking punch made from SKD11 surface treated under treatment conditions deviating from the treatment conditions of the present invention (Comparative Example 1) were employed for punch processing. The states of the cutting-edge portions were respectively observed after processing.
  • Example 2 Example 1 Surface Ejection method SF SF SF treatment Ejection particle HSS (Median Aluminum (Median HSS (Median Median diameter diameter D 50 : diameter D 50 : diameter D 50 : D 50 ( ⁇ m) 15 ⁇ m) 16 ⁇ m) 80 ⁇ m) Ejection pressure (MPa) 0.3 0.05 0.3 Nozzle diameter (mm) 7 7 7 Ejection duration (sec) 30 30 30 30
  • SF for “Ejection method” in Table 5 indicates a suction ejection method employing a “SFK-2” manufactured by Fuji Manufacturing Co., Ltd. as the blasting apparatus in these test examples.
  • Example 1 Hardly any observable damage. No occurrences of accumulation of material to be processed.
  • Example 2 Hardly any observable damage. No occurrences of accumulation. Comparative Multiple scratches having a striation shape.
  • performing the surface treatment of the present invention on punches made from SKD11 was seen to raise hardness, from a surface hardness of about 750 Hv when untreated to a hardness of about 950 Hv after surface treatment by the treatment of Example 1, that is, an uplift in hardness of about 21%.
  • Example 2 Moreover, the treatment of Example 2 was seen to raise hardness to about 870 Hv, that is, an uplift in hardness of about 16%.
  • the punches treated with the surface treatment method according to the present invention were capable of preventing material to be processed from accumulating to the cutting-edge as described above. This is thought to be a reason why good punching performance was exhibited over a prolonged period of time, and a reason why the lifespan of the punches was raised.
  • the diameter (equivalent diameter) and depths of the dimples were measured using a profile analyzing laser microscope (“VK-X250” manufactured by Keyence Corporation). Measurements of the metal article surface were made directly in cases in which direct measurement was possible. In cases in which direct measurement was not possible, methyl acetate was dripped onto a cellulose acetate film to cause the cellulose acetate film to conform to the metal article surface, and after subsequently drying and peeling off the cellulose acetate film, measurement was performed based on the inverted dimples transferred to the cellulose acetate film.
  • VK-X250 profile analyzing laser microscope
  • the “Multi-File Analysis Application” is an application that uses data measured by a laser microscope to measure surface roughness, line roughness, height and width, etc.
  • the application analyzes the equivalent circular diameter, depth, and the like, sets a reference plane, and is capable of performing image processing such as height inversion.
  • the “image processing” function is used to set the reference plane (however, in cases in which the surface shape is a curved plane, the reference plane is set after the curved plane has been corrected to a flat plane by using plane shape correction). Then, the measurement mode is set to indentation in the “volume/area measurement” function of the application, indentations are measured with respect to the set “reference plane”, and the “average depth” in the indentation measurement results and the average value of the results for “equivalent circular diameter” are set as the depth and equivalent diameter of the dimples.
  • the “equivalent circular diameter” and the “equivalent diameter” mentioned above are measured as the diameter of a circle determined by converting the projected surface area measured for an indentation (dimple) into a circular projected surface area.
  • the “reference plane” described above indicates a flat plane at the origin (reference) measurement for height data, and is employed mainly to measure depth, height, etc. in the vertical direction.
  • Example 3 Three types of flat sheets of SUS304, size 40 mm ⁇ 40 mm and thickness 2 mm, were prepared: sheets treated by the present invention (Example 3): untreated sheets having a mirror finish (Comparative Example 2); and sheets treated by related art (Comparative Example 3). The slidability of the sheets was then evaluated by friction-wear tests.
  • Ball-on-disc tests were performed on the SUS304 sheets treated under the conditions described above until a friction coefficient of 2.0 was achieved. The times until this occurred were measured and compared to evaluate slidability.
  • a ball-on-disc friction-wear tester was employed.
  • a ball of 3/16 inch diameter made from SUS304 was employed therein.
  • FIG. 20 A graph of measured changes to friction with respect to elapsed time is illustrated in FIG. 20 .

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JP6892415B2 (ja) * 2018-07-20 2021-06-23 株式会社不二機販 食品接触部材の表面処理方法
CN112372514B (zh) * 2020-09-29 2022-12-27 广东工业大学 一种刀具刃口加工方法

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