WO2010041735A1 - 可変ベーンの製造方法 - Google Patents

可変ベーンの製造方法 Download PDF

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Publication number
WO2010041735A1
WO2010041735A1 PCT/JP2009/067621 JP2009067621W WO2010041735A1 WO 2010041735 A1 WO2010041735 A1 WO 2010041735A1 JP 2009067621 W JP2009067621 W JP 2009067621W WO 2010041735 A1 WO2010041735 A1 WO 2010041735A1
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WO
WIPO (PCT)
Prior art keywords
sintered product
product
shaft
wing
variable vane
Prior art date
Application number
PCT/JP2009/067621
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English (en)
French (fr)
Japanese (ja)
Inventor
喜光 寒川
中川　勝則
Original Assignee
株式会社Ihi
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by 株式会社Ihi filed Critical 株式会社Ihi
Priority to CN200980139862.XA priority Critical patent/CN102177324B/zh
Priority to EP09819268.5A priority patent/EP2343441B1/de
Publication of WO2010041735A1 publication Critical patent/WO2010041735A1/ja

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D17/00—Regulating or controlling by varying flow
    • F01D17/10—Final actuators
    • F01D17/12—Final actuators arranged in stator parts
    • F01D17/14—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits
    • F01D17/16—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes
    • F01D17/162—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes for axial flow, i.e. the vanes turning around axes which are essentially perpendicular to the rotor centre line
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D17/00—Regulating or controlling by varying flow
    • F01D17/10—Final actuators
    • F01D17/12—Final actuators arranged in stator parts
    • F01D17/14—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits
    • F01D17/16—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes
    • F01D17/165—Final actuators arranged in stator parts varying effective cross-sectional area of nozzles or guide conduits by means of nozzle vanes for radial flow, i.e. the vanes turning around axes which are essentially parallel to the rotor centre line
    • 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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/22—Manufacture essentially without removing material by sintering

Definitions

  • the present invention relates to a method of manufacturing a variable vane incorporated in a turbocharger used for an automobile engine or the like. More specifically, for a sintered product obtained by metal powder injection molding (MIM method), a mold for correcting the height and thickness of the wing part, a mold for correcting the shape of the wing part, and a mold for correcting the shaft part It is related with the manufacturing method of the variable vane which can be pressed by this and can make a wing
  • MIM method metal powder injection molding
  • Turbochargers used in automobile engines, etc. amplify the exhaust gas flow rate so that the engine can efficiently obtain output even at low speed rotation, and the exhaust side turbine rotates using this exhaust energy.
  • the engine is designed to rotate the intake side turbine directly connected to the exhaust side turbine to force air into the engine, and use multiple variable vanes as components to adjust the exhaust gas flow rate and flow velocity. I have.
  • This variable vane is composed of a central axis of rotation and a wing portion for adjusting the flow rate and flow velocity of exhaust gas, and the wing portion becomes thinner toward the tip.
  • this variable vane has been manufactured by cutting.
  • the processing time is very long, and it is very inefficient with about 100 to 500 pieces per machine.
  • Patent Document 1 a steel material as a material is manufactured by a cold forging process and a polishing process.
  • Patent Document 2 a product is manufactured by using a lost wax or a material manufactured by the MIM method, using a rolling method for the shaft and a press in the height direction.
  • Patent Document 3 a product is manufactured by polishing a shaft portion using a sintered product of the MIM method.
  • Patent Document 1 since a forging process and a polishing process are required, it is sufficient to prepare a stainless steel plate material. However, in terms of time required for post-processing and effective use of the material, it is possible to improve production speed and cost during mass production. There is a limit to down. Moreover, when it becomes a complicated thin shape, it is difficult to produce a desired product shape by forging.
  • Patent Document 2 a material made by lost wax or the MIM method is manufactured by pressing and a rolling process.
  • a material processing method is not mentioned, and post-processing that occurs in the axial rolling process is inevitable.
  • the accuracy is improved by uniaxial pressing from the top in the height direction.
  • dimensional variations and deformations of more than ⁇ 0.5% of the product dimensions occur during degreasing and sintering. Therefore, even if the dimensional accuracy is improved by pressing in the height direction, it is difficult to correct the deformation of the vane portion, and as a result, many places must be cut and polished.
  • the dimensional variation of the product obtained by the conventional MIM manufacturing method occurs ⁇ 0.05 mm.
  • deformation of about ⁇ 0.05 mm occurs in the width direction of the wing, even if the height can be set to a desired size by pressing, when pressed in the width direction (thickness direction) of the wing Therefore, the shape of the blade portion having the calculated height and width cannot be obtained unless the sintered product has excellent dimensional accuracy not only in the height direction but also in the width direction.
  • the variation of the coaxiality in the conventional MIM sintered product occurs about ⁇ 0.05 mm, so the dimensional accuracy of the shaft is kept within the dimensions by machining and pressing.
  • machining of the wings is inevitable.
  • Patent Document 3 does not mention the processing method by the MIM method, and polishing processing is unavoidable in order to improve the accuracy of the perpendicularity between the shaft portion and the polishing vane portion. In addition, it is difficult to obtain a highly accurate product only by the pressing method when twisting warpage occurs in the wing portion.
  • an object of the present invention is to provide a method capable of producing a variable vane with high dimensional accuracy only by a pressing method without performing a cutting process in order to solve the above-described problem.
  • the present inventor prepared a sintered product having a shape approximate to the final product, and having a certain relationship with the desired final product.
  • the height and thickness direction (width direction) of the wings are set to the desired product dimensions at the same time.
  • the concentricity between the wings and the shaft is desired.
  • the roundness of the shaft is set to the desired product size, so that the desired dimensional accuracy (target size ⁇ 0.01 mm) can be obtained without cutting.
  • the present invention is a method of manufacturing a variable vane having a flat wing portion and a cylindrical shaft portion located below the wing portion, Pressing a sintered product having a shape close to the desired final product,
  • the sintered product is an integrally formed product of a blade part and a shaft part, the height of the blade part is + 0.3% to + 0.9% and the thickness of the blade part is ⁇ 0.6% to -0.0%, shaft diameter is + 0.3% to + 0.9%, length from lower end of wing to lower end of shaft is -0.6% to -0.0% %,
  • the sintered density is 95% or more
  • the pressing step includes a three-stage process, In the first pressing step, the sintered product is pressed by a lower die having a shaft portion insertion hole and an upper die having a shape other than the lower end surface of the wing portion, and the height and thickness of the wing portion are adjusted, In the second pressing step, the blade portion and the shaft portion of the sintered product are simultaneously pressed by an upper die and
  • the upper die and the lower die each having the shape of a semi-cylindrical body corresponding to the shaft portion of the variable vane, the shaft portion of the sintered product from a direction 90 degrees different from the second press step.
  • the roundness of the shaft portion is adjusted by pressing.
  • the mold used in the first press step is a lower mold for holding a sintered product by inserting a shaft part below the wing part, and an upper mold having a shape other than the lower end surface of the wing part (that is, the wing part)
  • the shape in the height direction and the thickness direction can be defined simultaneously).
  • the upper mold is a mold including the shape of the shaft part above the wing part in addition to the shape of the wing part.
  • the mold used in the second press process consists of an upper mold and a lower mold each having a shape in which variable vanes (wing section and shaft section) are divided on a plane that divides the thickness of the wing section into two parts.
  • the mold used in the third press step is composed of an upper mold and a lower mold each having a semi-cylindrical shape corresponding to the shaft portion of the variable vane, and the shaft portion positioned below the blade portion of the sintered product is provided.
  • the roundness of the shaft portion is obtained by pressing up and down while rotating 90 degrees from the second press step.
  • each dimension of the blade part and the shaft part is within the above-mentioned dimension range as a sintered product to be pressed with respect to the desired final product size.
  • each dimension of the shaft part and the wing part can be kept within a desired dimensional accuracy (target dimension ⁇ 0.01 to 0.05 mm or less).
  • a sintered product having a relative density of 95% or more it is possible to produce a variable vane having a mechanical strength that can withstand high-temperature use and can keep the dimensional accuracy after pressing to a desired dimensional accuracy. it can.
  • the sintered product is more preferably a sintered product having a relative density of 98% or more. Further, if a multi-forming machine capable of press bending from the 360 degree direction is used, the first press process to the third press process can be performed continuously, and the press process can be saved.
  • an injection molding material is obtained by pulverization or pelletization, and the molding material is produced by injection molding the molding material.
  • adding (b) to 30 to 60 Vol% with respect to (a + b) thus, a sintered product suitable for manufacturing the variable vane can be obtained.
  • the degreasing step is performed at a maximum temperature of 800 ° C. or less in any one of a reduced pressure inert gas atmosphere, an atmospheric pressure inert gas atmosphere and an atmospheric pressure hydrogen atmosphere, and the sintering step is performed under a reduced pressure inert gas atmosphere and a pressurized inert gas. It is preferably performed at 1000 ° C. or higher and 1500 ° C. or lower in any of an atmosphere, an atmospheric pressure inert gas atmosphere, and an atmospheric pressure hydrogen atmosphere.
  • the relative density in the manufacturing process of the sintered product, after producing a primary sintered product having a relative density of 94% or more, it is preferable to set the relative density to 98% or more by a hot isostatic pressing method.
  • a variable vane with high dimensional accuracy can be manufactured only by pressing a sintered product without performing machining.
  • a sintered product for variable vane production with higher dimensional accuracy than the prior art can be obtained by the MIM method. Can be manufactured.
  • A indicates a variable vane having a flat upper surface of the wing portion
  • B indicates a variable vane having a shaft portion on the upper side of the wing portion.
  • (a) is a front view
  • (b) is a right side view
  • (c) is a bottom view
  • (d) is a perspective view.
  • A indicates a variable vane having a flat upper surface of the wing portion
  • B indicates a variable vane having a shaft portion on the upper side of the wing portion.
  • blade part is flat in three steps is shown.
  • the process which presses the variable vane in which a shaft part also exists in the upper part of a wing part in three steps is shown.
  • transformed after degreasing is shown.
  • variable vane used in the turbocharger has a blade portion (nozzle vane portion) that adjusts the flow rate of exhaust gas and a shaft portion (vane shaft portion) that rotatably supports the blade portion.
  • the shaft portion is connected to at least one side (lower side) from the rotation center position near the center of the wing portion.
  • the shaft portion has a cylindrical shape
  • the wing portion has a flat plate shape, and has a wedge shape that becomes thinner toward the tip.
  • the wing portion is thin and asymmetrically curved in order to easily adjust the flow rate of the exhaust gas, so that the stability of incorporation and the stability during operation can be improved.
  • the opposite end surface connected to the wing portion has a planar shape as a molding surface, and the boundary between the end surface and the peripheral wall surface of the shaft portion is a curved surface. .
  • the end portion of the shaft portion is a curved surface, the stability of incorporation and the stability of rotation can be improved.
  • FIG. 1A A product manufacturing method is shown in FIG. 2 (manufacturing flowchart).
  • variable vanes In the production of variable vanes, it is necessary to first produce a sintered product having a shape that approximates the desired final product. Using a molding material obtained by adding an organic binder, a molded body is prepared by molding in advance with a mold in consideration of the shrinkage rate after sintering of the product.
  • the metal used in the variable vane has corrosion resistance and is made of a heat-resistant steel metal material.
  • SUS310 and SCH21 (HK30) with Ni and Cr contents of Ni: 19.0 to 22.0 wt% and Cr: 23.0 to 27.0 wt%, respectively Is mainly used.
  • Inconel which is a Ni-based alloy, is used.
  • a metal powder made of such a metal material an alloy powder produced by a water atomizing method or a gas atomizing method is usually used. In addition to the alloy powder produced by the atomizing method, the alloy powder is adjusted to be an alloy component during sintering. Element powders may be added according to the composition.
  • water atomized powder can be produced in a larger amount than gas atomized powder, so the manufacturing cost is also low, but because the powder shape tends to be irregular, the tap density tends to be low, and The amount of oxygen also increases.
  • the manufacturing cost of the gas atomized powder is increased, it is easy to obtain a spherical powder and the tap density is increased. For this reason, the water atomized powder and the gas atomized powder may be mixed and used in consideration of the cost and the tap density.
  • the average particle size of the metal powder (a) according to the present invention is preferably 1 to 20 ⁇ m.
  • the average particle size is less than 1 ⁇ m, the amount of binder added increases as the surface area of the powder increases, and deformation during degreasing increases.
  • the amount of the binder is increased, the shrinkage rate at the time of sintering is increased, the dimensional variation after the sintering is increased, and it is difficult to obtain a product with high dimensional accuracy in the subsequent pressing process.
  • the powder particle diameter exceeds 20 ⁇ m, it becomes difficult to stably obtain a sintered density (relative density) of 95% or more, the strength is remarkably lowered, and it cannot be used as a product.
  • a more preferable average particle diameter is 5 to 12 ⁇ m, and further desirably 8 to 10 ⁇ m.
  • the average particle diameter means an average diameter of 50% cumulative weight measured using a particle size distribution measuring apparatus using a laser diffraction / scattering method.
  • a particle size distribution measuring apparatus a SALD-2000 model manufactured by Shimadzu Corporation can be used.
  • the metal powder (a) according to the present invention preferably has a tap density of 3.5 g / m 3 or more.
  • the tap density is more preferably 4.0 g / m 3 or more, and still more preferably 4.2 g / m 3 or more.
  • the upper limit is not particularly limited, but a sufficient effect can be obtained at a tap density of 5.0 g / m 3 or less.
  • the tap density can be measured by a measuring method described in “Metal Powder Tap Density Test Method” JPMA P 08 published by Japan Powder Metallurgy Industry Association.
  • an organic binder containing 5 to 40% by volume of polyacetal (b1) and 5 to 40% by volume of polypropylene (b2) is used as the organic binder (b).
  • polyacetal and polypropylene in the organic binder By using polyacetal and polypropylene in the organic binder, the amount of deformation during degreasing can be suppressed as compared with conventional binders using polyethylene, ethylene vinyl acetate, and acrylic resin.
  • Polyacetal is indispensable as a substance that increases the strength of the molded body, prevents deformation of the molded body at 600 ° C. or lower during sintering, and does not leave carbides after sintering.
  • Polypropylene imparts toughness to the shaped body and prevents cracking of the sintering and separation of the added low melting point compound.
  • Polypropylene also has the property that no carbides remain after sintering.
  • the addition amount of polyacetal and polypropylene is less than 5 Vol% with respect to the total amount (b) of the organic binder, deformation during degreasing becomes large, and the prescribed dimensional accuracy after sintering cannot be obtained.
  • the addition amount of polyacetal and polypropylene exceeds 40 Vol% with respect to the total amount (b) of the organic binder, the viscosity at the time of molding increases and the molding material cannot be completely filled in the mold.
  • a more preferable polyacetal content is 10 to 30% by volume, and a more preferable polypropylene content is 10 to 30% by volume.
  • materials other than polyacetal and polypropylene the following organic materials can be used.
  • Fatty acid ester, fatty acid amide, phthalic acid ester, paraffin wax, microcrystalline wax, polyethylene wax, polypropylene wax, carnauba wax, montan wax, urethanized wax, maleic anhydride to impart fluidity and improve degreasing Modified waxes and polyglycol compounds are used.
  • Particularly preferred materials include paraffin wax, fatty acid ester, and polypropylene wax.
  • polyethylene amorphous polyolefin
  • ethylene vinyl acetate copolymer acrylic resin, polyvinyl butyral resin, glycidyl methacrylate resin, and the like
  • Particularly preferred materials include polyethylene and amorphous polyolefin.
  • the organic binder is added to the total amount (a + b) of the metal powder (a) and the organic binder (b) in order to provide the fluidity and flexibility.
  • (B) is preferably 30 to 60% by volume (Vol%), more preferably 35 to 50% by volume.
  • the organic binder and metal powder having the above ratio are heated and kneaded at about 160 to 180 ° C. for about 2 hours to completely disperse and mix the metal powder with the organic binder. Then, it is taken out and formed into a pellet having a diameter of about 5 mm by an extruder or a pulverizer, and used as a molding material.
  • the blades For sintered products, considering the dimensional change due to pressing, the blades have a desired dimension of + 0.3% to + 0.9% of the final product in the height direction and the desired dimension of the final product in the thickness direction.
  • the shaft is in the range of -0.6% to -0.0%, and for the shaft, the diameter is + 0.3% to + 0.9% of the desired size as the final product, and the shaft below the wing It is necessary to make the length of the part to be in the range of ⁇ 0.6% to ⁇ 0.0% of the desired dimension as the final product.
  • molding it is necessary to determine a metal mold
  • the thickness of the wing portion of the variable vane gradually decreases from the rear end side (left side in FIG. 1) to the front end side (right side in FIG. 1).
  • the thickness varies depending on the measurement location.
  • the thickness of the blade portion in the range of ⁇ 0.6% to ⁇ 0.0% with respect to the target dimension of the final product means that the final product and the sintered product (having a shape approximate to the final product) ) Means that the difference is within the above range.
  • the height of the wing part, the diameter of the shaft part, and the length from the lower end of the wing part to the lower end of the shaft part also vary depending on the measurement location, the final product and sintered product as well as the thickness of the wing part Means that the difference is within the above range.
  • Molds are mounted on an injection molding machine and molded, but the number of molded products obtained should be from 1 to 8 with a single mold, taking into account the size and mass production quantity of the product. Can do.
  • the capacity of the injection molding machine is appropriately adjusted according to the number of molds to be taken and the size of the product.
  • molding is performed using a molding machine having a clamping force of about 20 to 100 tons.
  • the injection speed and pressure are adjusted so that defects such as bubbles and cracks do not occur in the molded body, and the mold is provided with a gas escape to effectively release the air in the mold and the gas generated from the molding material. There is a need. If there is no effective gas escape, air or gas generated from the molding material is taken into the molded body, and bubbles are generated in the molded body.
  • the obtained molded body is put into a degreasing furnace, and the added organic binder is removed.
  • the degreasing furnace for removing the organic binder is performed using any one of a reduced pressure inert gas atmosphere, an atmospheric pressure inert gas atmosphere, and an atmospheric pressure hydrogen gas atmosphere.
  • the degreasing sintering is performed. Can be done consistently.
  • a batch type degreasing furnace or a continuous (belt type, pusher type, walking beam type) degreasing furnace can be used.
  • it is effective to perform degreasing using a jig having a shape along the shape of the molded body so as to prevent deformation to a minimum in view of the fact that the amount of deformation increases during degreasing.
  • the degreasing atmosphere is performed at any one of a reduced pressure inert gas atmosphere, an atmospheric pressure inert gas atmosphere, and an atmospheric pressure hydrogen atmosphere at a maximum temperature of 800 ° C. or less.
  • a depressurized inert gas atmosphere, an atmospheric pressure inert gas atmosphere, and an atmospheric pressure hydrogen atmosphere are used as the degreasing atmosphere.
  • Nitrogen or argon is used as the inert gas, but it is desirable to use nitrogen gas in consideration of cost.
  • the temperature rising rate during degreasing is preferably 50 ° C./hr from room temperature to 400 ° C. or less in consideration of deformation during degreasing. Moreover, the deformation
  • the degreasing temperature is 800 ° C. or lower. However, when the temperature is about 300 ° C., about 30% of the organic binder tends to remain, and when the temperature is 600 ° C. or higher, the organic binder is easily removed completely.
  • the degreasing temperature is more preferably 400 ° C to 500 ° C.
  • a sintering furnace having a degreasing function as a method for preventing the collapse of these molded bodies, and it is possible to shift to sintering without lowering the temperature even after the degreasing. Also, by connecting a continuous (belt type, pusher type, walking beam type) sintering furnace as well as a continuous type (belt type, pusher type, walking beam type) degreasing furnace, without interrupting sintering from degreasing Processing can be performed continuously.
  • any one of a reduced pressure inert gas atmosphere, an atmospheric pressure inert gas atmosphere, a pressurized inert gas atmosphere, and an atmospheric pressure hydrogen atmosphere is used as the sintering atmosphere.
  • the inert gas a stainless material is often used as a material during sintering. Therefore, it is preferable to use argon gas in consideration of nitriding of the material.
  • the sintering temperature is 1000 ° C. or higher and 1500 ° C. or lower. However, if the sintering temperature is lower than 1000 ° C., the sintering is insufficient.
  • the sintered density In order for the sintered density to be 95% or more, it is preferably 1200 to 1400 ° C, and more preferably 1250 ° C to 1380 ° C. In addition, it is desirable to maintain the maximum temperature for about 2 to 4 hours in consideration of improvement of the sintering density during sintering and dimensional variation during sintering. As in the degreasing process, deformation occurs at high temperatures in the sintering process, so it is effective to use a jig for preventing deformation of the sintered product.
  • degreasing and sintering considering the production volume, batch type degreasing furnaces and sintering furnaces are used for small quantities of various products, and degreasing and sintering are performed in a pusher type continuous furnace and walking when the number increases.
  • degreasing and sintering are performed in a pusher type continuous furnace and walking when the number increases.
  • the relative density of the sintered product By setting the density of the sintered product to 95% or more in terms of relative density, the mechanical strength and hardness at high temperatures can be maintained. If the relative density is less than 95%, the mechanical strength at high temperatures, particularly the elongation and hardness, are lowered, and continuous use at high temperatures is difficult.
  • the relative density of the sintered product can be measured by the Archimedes method.
  • the obtained sintered product is further subjected to a hot isostatic pressing method (HIP method) in order to further increase the sintered density to improve the mechanical strength and to improve the reliability of the mechanical strength in a high temperature range.
  • HIP method hot isostatic pressing method
  • It is effective to be processed at a low temperature of about 10 ° C. to 100 ° C. below the sintering temperature and a high pressure of about 10 MPa to 180 MPa, so that there is no pinhole inside and a relative density of 98% or more is achieved.
  • a sintered product can be obtained stably.
  • a sintered HIP apparatus that can perform a pressure treatment of up to about 6 MPa during the sintering process, a sintered product having a relative density of 98% or more can be obtained without using the HIP method in the subsequent process.
  • the sintered product after sintering or after the HIP process is formed into a desired final product size by the pressing process shown in FIGS.
  • the first press step the height and width (thickness) direction of the wing are simultaneously set to the desired product dimensions
  • the second press step the concentricity between the wing and the shaft is set to the desired product dimensions.
  • the mold consists of a lower mold that holds the sintered product and an upper mold that simultaneously defines the height direction and width direction of the wings.
  • the upper mold By pressing the upper mold toward the lower mold, While the wing is compressed downward, the upper surface of the wing is compressed and the side surface swells and deforms, and the side surface follows the mold shape, so that the desired wing height and side and wing shape As well as the perpendicularity of the axis with respect to the wing.
  • the mold consists of an upper mold and a lower mold each having a shape obtained by dividing the wing part and the shaft part of the variable vane into two parts (dividing the wing part thickness into two parts) and sintering.
  • the product is fixed in the horizontal direction with the lower die, and the upper die is pressed toward the lower side to compress the wing and shaft at the same time, so that the axis is perpendicular to the wing and the axis is coaxial with the wing.
  • the mold is composed of an upper die and a lower die each having a shape (semi-columnar shape) obtained by dividing the shaft portion below the wing portion into two in the axial direction.
  • the roundness of the shaft is obtained by rotating the shaft 90 degrees and pressing up and down.
  • the desired variable vane can be obtained without performing the cutting process by post-processing the above-described sintered product through these three-stage pressing processes.
  • Die steel, high-speed steel, and cemented carbide are used as the die material used for the press in consideration of the service life.
  • parts feeders and progressive feeders in the press process to save labor, the processing capacity per hour can be greatly improved compared to conventional machining, and the processing capacity per hour is 300-600. It can be increased to about one.
  • a multi-forming machine capable of press bending from the 360 degree direction can be used in the press process, which makes it possible to save labor in the process.
  • the processing capacity of about 10 to 50 per hour can be dramatically improved to about 500 to 1000 per hour.
  • the surface roughness of the product after pressing can be improved by barrel polishing or electrolytic polishing as needed, and burrs can be removed.
  • the post-processing does not perform a cutting process and a polishing process by machining, and the desired dimensional accuracy is excellent.
  • a variable vane having a shape to be manufactured can be manufactured.
  • the manufacturing loss of the material can be suppressed to 5% or less even when compared with the conventional punching process of lost wax and plate material. Due to the automated process, the production efficiency is more than 5 to 10 times that of the conventional machining method.
  • the MIM method it becomes possible to mass-produce variable vanes having a thinner and more complex shape, which was difficult to obtain easily in the past.
  • a sintered product according to the present invention was produced.
  • the molding material, heat-kneading conditions, injection molding conditions, degreasing conditions, sintering conditions, etc. were as follows. 100 compacts were molded, degreased and sintered, and dimensional variations were measured.
  • Metal powder SUS310 Average particle size 9.2 ⁇ m Tap density 4.2g / m 3 ⁇
  • Organic binder composition Polyacetal 15Vol%, Polypropylene 25Vol%, Amorphous polyolefin 10Vol%, Paraffin wax 35Vol%, Acrylic resin 10Vol%, Fatty acid ester 5Vol% ⁇ Metal powder: 60Vol% Organic binder 40Vol% ⁇ Heat kneading: 180 °C for 2 hours ⁇ Injection molding conditions: 180 °C Mold temperature: 40 °C Degreasing conditions: Maximum temperature 500 ° C (nitrogen) held for 2 hours Total time 24 hours Sintering conditions: Maximum temperature 1350 ° C (argon, reduced pressure atmosphere) held for 2 hours
  • A1 is the height of the wing
  • B1 is the thickness of the wing
  • C1 is the diameter of the shaft
  • D1 is the length of the shaft located below the wing (length from the lower end of the wing to the lower end of the shaft) Indicates.
  • Desired final product dimension A1 6.0mm (target dimension) ⁇ 0.01mm (5.99mm-6.01mm)
  • B1 2.5mm (target dimension) ⁇ 0.03mm (2.47mm to 2.53mm)
  • C1 4.0mm (target dimension) ⁇ 0.01mm (3.99mm to 4.01mm)
  • D1 10.0mm (target dimension) ⁇ 0.05mm (9.95mm to 10.05m)
  • the molding machine used was a molding machine with a clamping pressure of 30 tons.
  • the dimensions of the manufactured sintered product were as follows. The dimension measurement was performed using a tool microscope. Dimension of sintered product manufactured A1: 6.024mm-6.044mm (target size + 0.4%-+ 0.73%) B1: 2.485mm-2.494mm (target size -0.60%--0.24%) C1: 4.018mm to 4.030mm (target size + 0.45% to + 0.75%) D1: 9.955mm-9.980mm (target dimension -0.45%--0.2%) Concentricity of shaft and wing: 0.035mm, perpendicularity: 0.042mm Parallelism of wing: 0.038mm Sintered product density: 96.0%
  • a pressing process was performed by the process shown in FIG.
  • the dimensions after the pressing process were as follows.
  • a sintered product according to the present invention was produced.
  • the molding material, heat-kneading conditions, injection molding conditions, degreasing conditions, sintering conditions, etc. were as follows. 100 compacts were molded, degreased and sintered, and dimensional variations were measured.
  • Metal powder HK30 Average particle size 8.7 ⁇ m Tap density 4.3g / m 3 ⁇
  • Organic binder composition Polyacetal 20Vol%, Polypropylene 20Vol%, Amorphous polyolefin 10Vol%, Paraffin wax 35Vol%, Acrylic resin 10Vol%, Fatty acid ester 5Vol% ⁇ Metal powder: 60Vol% Organic binder 40Vol% ⁇ Heat kneading: 180 °C for 2 hours ⁇ Injection molding conditions: 180 °C Mold temperature: 40 °C ⁇ Degreasing conditions: Maximum temperature 500 ° C (nitrogen) held for 2 hours Total time 24 hours ⁇ Sintering conditions: Maximum temperature 1350 ° C (argon, reduced pressure atmosphere) held for 2 hours ⁇ HIP treatment: Processing temperature 1200 ° C (argon, 100 MPa) 2 Time hold
  • A2 is the height of the wing
  • B2 is the thickness of the wing
  • C2 is the diameter of the shaft
  • D2 is the length of the shaft located below the wing.
  • Desired final product dimension A2 6.0mm (target dimension) ⁇ 0.01mm (5.99mm-6.01mm)
  • B2 2.5mm (target dimension) ⁇ 0.03mm (2.47mm to 2.53mm)
  • C2 4.0mm (target dimension) ⁇ 0.01mm (3.99mm to 4.01mm)
  • D2 10.0mm (target dimension) ⁇ 0.05mm (9.95mm to 10.05m)
  • the molding machine used was a molding machine with a clamping pressure of 30 tons.
  • the dimensions of the manufactured sintered product were as follows. The dimension measurement was performed using a tool microscope. C2a indicates the diameter of the shaft portion located below the wing portion, and C2b indicates the diameter of the shaft portion located above the wing portion.
  • a pressing process was performed by the process shown in FIG.
  • the dimensions after the pressing process were as follows.
  • Example 3 From the results of Example 3, the sintered product before pressing had a wing height of + 0.3% to + 0.9% and a wing thickness of the desired final product dimensions (target dimensions). -0.6% to -0.0%, shaft diameter is + 0.3% to + 0.9%, and the length from the lower end of the wing to the lower end of the shaft is -0.6% to -0. It has been found that when it is in the range of 0% and the sintered density is 95% or higher, the final product with the desired dimensional tolerance can be obtained only by the pressing process.
  • Example 2 Of the organic binder components of Example 1, an attempt was made to produce a sintered product in the same manner as in Example 1 except that an organic binder in which polyacetal was replaced with ethylene vinyl acetate resin was used. However, after degreasing, the molded body was not able to proceed to the subsequent sintering and pressing processes because the wing portion was tilted by 30 degrees or more as shown in FIG.
  • metal powder having an average particle diameter of 1 to 20 ⁇ m and a tap density of 3.5 g / m 3 or more was used.
  • an organic binder containing 5 to 40% by volume of polyacetal and 5 to 40% by volume of polypropylene was used, and the amount of the organic binder was set to 30 to 60% by volume with respect to the total amount of the metal powder and the organic binder. In some cases, it was found that a sintered product suitable for use in the pressing step according to the present invention was obtained.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Powder Metallurgy (AREA)
  • Supercharger (AREA)
PCT/JP2009/067621 2008-10-09 2009-10-09 可変ベーンの製造方法 WO2010041735A1 (ja)

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WO2010098117A1 (ja) * 2009-02-25 2010-09-02 株式会社Ihi ノズルベーンの製造方法
US9533353B2 (en) 2012-02-24 2017-01-03 Hoeganaes Corporation Lubricant system for use in powder metallurgy

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JP5857688B2 (ja) * 2011-11-30 2016-02-10 セイコーエプソン株式会社 射出成形用組成物および焼結体の製造方法
JP5970794B2 (ja) 2011-11-30 2016-08-17 セイコーエプソン株式会社 射出成形用組成物および焼結体の製造方法
WO2014050530A1 (ja) * 2012-09-28 2014-04-03 株式会社Ihi 可変ノズルユニット、可変容量型過給機、及び動力伝達部材の製造方法
CN104117677B (zh) * 2013-04-23 2017-02-08 昆山广兴电子有限公司 一种金属扇轮的制造方法
DE102014112377A1 (de) * 2014-08-28 2016-03-03 Robert Bosch Automotive Steering Gmbh Herstellverfahren für komponenten eines schwenkmotors für ein lenksystem
US9995166B2 (en) * 2014-11-21 2018-06-12 General Electric Company Turbomachine including a vane and method of assembling such turbomachine
KR101649584B1 (ko) * 2015-12-28 2016-08-19 한국피아이엠(주) 금속과립분말을 이용한 내열부품 제조방법
CN106735236A (zh) * 2016-12-06 2017-05-31 江苏精研科技股份有限公司 金属注射成型后处理滚光工艺
JP7049149B2 (ja) * 2018-03-28 2022-04-06 三菱重工航空エンジン株式会社 翼の製造方法
US11661861B2 (en) 2021-03-03 2023-05-30 Garrett Transportation I Inc. Bi-metal variable geometry turbocharger vanes and methods for manufacturing the same using laser cladding

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US9533353B2 (en) 2012-02-24 2017-01-03 Hoeganaes Corporation Lubricant system for use in powder metallurgy

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HUE028680T2 (en) 2016-12-28
EP2343441B1 (de) 2015-12-23
JP4317906B1 (ja) 2009-08-19
EP2343441A4 (de) 2014-09-17
CN102177324A (zh) 2011-09-07
JP2011157816A (ja) 2011-08-18
CN102177324B (zh) 2013-06-19

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