WO2012053486A1 - 放電加工用電極 - Google Patents
放電加工用電極 Download PDFInfo
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- WO2012053486A1 WO2012053486A1 PCT/JP2011/073855 JP2011073855W WO2012053486A1 WO 2012053486 A1 WO2012053486 A1 WO 2012053486A1 JP 2011073855 W JP2011073855 W JP 2011073855W WO 2012053486 A1 WO2012053486 A1 WO 2012053486A1
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- borate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
- B23H7/22—Electrodes specially adapted therefor or their manufacture
- B23H7/24—Electrode material
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- 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
- B22F3/26—Impregnating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
- B23H1/04—Electrodes specially adapted therefor or their manufacture
- B23H1/06—Electrode material
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/045—Alloys based on refractory metals
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1094—Alloys containing non-metals comprising an after-treatment
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
- C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
- C22C32/0031—Matrix based on refractory metals, W, Mo, Nb, Hf, Ta, Zr, Ti, V or alloys thereof
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0089—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass
Definitions
- the present invention relates to an electric discharge machining electrode suitable as a machining electrode mainly used for die-sinking electric discharge machining.
- the electrode for electric discharge machining materials mainly made of non-metallic materials such as carbon and materials mainly made of metals such as Cu are mainly used.
- the electrode for electric discharge machining such as carbon or Cu
- it is easy to increase the machining speed by increasing the discharge condition but the electrode itself is heavily consumed, and the shape of the electrode is reflected in the workpiece. For this reason, it is not desirable for applications that require precision, such as electric discharge machining of cemented carbide members for molds.
- a composite material of Cu or Ag, which is a highly conductive material, and W (tungsten), which is a high melting point metal and excellent as an arc resistance component, has been used conventionally.
- Patent Document 1 describes an electrode for electric discharge machining in which an alkaline earth metal borate (a complex oxide composed of an alkaline earth metal and boron) is contained in a Cu—W alloy. By adding 0.05 to 5% by mass of an alkaline earth metal borate to the Cu—W alloy, electron emission is improved, and an effect of stabilizing discharge can be expected. Further, Patent Document 1 shows an effect that processing efficiency can be improved, there is no hygroscopic property, it is chemically stable, and electrode consumption is reduced.
- an alkaline earth metal borate a complex oxide composed of an alkaline earth metal and boron
- Patent Document 2 discloses a technique of adding 0.05 to 0.2% by mass of Ni and 0.1 to 1.0% by mass of oxidized Ce in an alloy such as Cu—W, Ag—W, or Cu—WC. It is shown. It is stated that if the amount of Ni is small, sintering does not proceed easily, and that the addition of an appropriate amount of Ce oxide is highly effective in extending the life.
- Patent Document 3 uses 0.05% by mass or more of W particles having a particle size of more than 1 ⁇ m and less than 3 ⁇ m, excluding Ni, Cu, W and borides and oxides thereof, and using 70% or more of the entire W particles.
- the produced electrode material for electric discharge machining having a V skeleton hardness (HV) of 22 or more is shown. Since it does not contain an alkaline earth metal, sintering is easily promoted, and a sintered body can be obtained without adding a small amount of Ni or adding it at all. Thus, it is described that the effects of reduction of electrode consumption, improvement of processing speed, and improvement of workability of the electrode itself can be obtained.
- Patent Document 4 discloses an electrode for electric discharge machining made of a Cu—W alloy containing a complex oxide of alkaline earth metal (and alkali metal, rare earth metal, etc.) and W. Further, it is described that the sinterability is improved by adding 5 mol% or less of at least one of Fe, Co, and Ni to this material. It is stated that by uniformly dispersing the complex oxide containing W, abnormal discharge is unlikely to occur, the electrode consumption rate is lowered, and the processing speed can be improved.
- any of the conventional methods described above is considered to be able to achieve a certain effect in terms of improving the machining speed and reducing the consumption of the electrode for electric discharge machining.
- the demand for increasing the machining speed and reducing the electrode consumption continues, and there is a demand for a better electrode for electric discharge machining.
- borate has a function of improving discharge characteristics.
- the addition of borate has a negative effect on the sinterability of the material, so that sintering does not proceed sufficiently and residual pores are likely to be generated inside.
- electric discharge machining is performed using an electrode having residual pores, there arises a problem that the machining accuracy of the workpiece is lowered.
- the present invention has been made to solve the above-described problems, and an object of the present invention is to provide an electrode for electric discharge machining that can suppress the electrode consumption rate and enables high-speed machining and high-precision machining.
- the electrode for electric discharge machining of the present invention is an electrode for electric discharge machining used for electric discharge machining, and includes the following (A), (B) and (C), and the mass of (A), (B) and (C) Is an electrode for electric discharge machining made of a material occupying 95% by mass to 100% by mass of the total mass.
- (A) is 5 to 40 parts by mass of M1
- (B) is an M2 metal that is 100 parts by mass in total with (A), and must contain M2, and M2 M2 metal containing an iron group metal alloy or an iron group metal simple substance
- (C) is 0.05 to 8 externals with respect to 100 parts by mass of the total mass of (A) and (B).
- M1 is at least one of Cu or Ag or an alloy thereof;
- M2 is at least one of W or Mo or an alloy thereof;
- M3 is Mg, Ca, Sr, Ba, and rare earth It is at least one selected from the group consisting of metal
- the total of the mass of the simple substance of the iron group metal and the mass of the alloy of M2 and the iron group metal is the sum of the mass of (A) and the mass of (B). 0.05 to 2.5% by mass.
- the electrode for electric discharge machining further includes the following (D) and (E), and the sum of the masses of (A), (B), (C), and (D), (E): However, it consists of the material which occupies 95 mass% or more and 100 mass% or less of total mass.
- (D) is the sum of the mass of (A) and the mass of (B) when the total of the mass of (A) and the mass of (B) is 100 parts by mass.
- a composite oxide having an external mass part of 0.1 to 5 and containing M2, the iron group metal, and at least one of Ca, Sr, Ba and rare earth metal, E) is 0.1 with respect to the sum of the mass of (A) and the mass of (B) when the total of the mass of (A) and the mass of (B) is 100 parts by mass. 3 parts by mass of boron oxide.
- the total volume of 1 is 1, it is 0.1 volume part or more and 0.99 volume part or less.
- the 3rd borate which occupies z volume part is included.
- the borate when the total volume of the borate of (C) is 1 part by volume, the borate is added to grain boundaries of M1, M2, a simple substance of an iron group metal, and an alloy of M2 and an iron group metal. 0.5 volume part or more of the product is dispersed.
- the average particle size of the borate (C) is more than 0 ⁇ m and 20 ⁇ m or less, and the maximum particle size is more than 0 ⁇ m and 150 ⁇ m or less.
- the electrode for electric discharge machining according to the present invention is excellent in electron emission characteristics, and if this is used, the machining speed can be improved. Further, the consumption rate of the electrode for electric discharge machining is relatively low, and the surface accuracy of the workpiece can be improved.
- the electrode for electric discharge machining of the present invention among Cu (or Ag) -W (or Mo) based alloys, among the alkaline earth metal elements Ca, Sr, Ba and rare earth metals belonging to the periodic table group 2a having excellent electron emission characteristics.
- at least one composite boric oxide (M3 x B y O z, but M3 is Mg, Ca, Sr, Ba, at least one rare earth metal) are dispersed in the alloy structure in the form of.
- the sinterability is improved by adding an iron group metal (Fe, Co, Ni).
- the electrode for electric discharge machining includes the following materials (A) to (C).
- A) 5 to 40 parts by mass of M1.
- B) 100 parts by mass of M2 metal in total with (A), which always contains M2, and further contains an alloy of M2 and an iron group metal and / or a simple substance of an iron group metal.
- C) 0.5 to 8 parts by mass of M3 borate based on 100 parts by mass of the total mass of (A) and (B).
- M1 is at least one of Cu and Ag or an alloy thereof
- M2 is at least one of W and Mo or an alloy thereof
- M3 is Mg, Ca, Sr, At least one metal selected from the group consisting of Ba and rare earth metals.
- the iron group metal means at least one of Fe, Co and Ni
- the rare earth metal means a lanthanide element such as Sc, Y and La, Ce, Sm and the like (lanthanoids including lanthanum) such as a group 3a metal.
- M1-M2 which is typically Cu—W
- an iron group metal and / or an alloy of M2 and an iron group metal
- M3 By containing borate in a predetermined ratio, both improvement in processing speed and suppression of electrode consumption are achieved.
- the present inventor has studied the case of using alkaline earth metal borates of Mg, Ca, Sr and Ba and rare earth metal borates as additives particularly effective for improving the processing speed. It was.
- An M1-M2 composite material for example, Cu-W
- a borate to which a borate is added has poor sinterability and easily retains pores in the material, similar to a material containing boron or boride.
- the presence of the pores makes it impossible to discharge a part of the workpiece (part corresponding to the pore) in the same manner as other parts, and as a result, the surface accuracy of the workpiece is deteriorated. Therefore, it is necessary to avoid the generation of pores in the material as much as possible.
- an iron group metal such as Fe, Co, and Ni.
- An iron group metal has a lower melting point than W or Mo, and produces an alloy with W or Mo even at a low temperature. Therefore, it has a function of helping sintering, facilitating manufacturing, and improving the surface accuracy of the workpiece.
- the M1-M2 composite material will be described by taking the case of using Cu and W as an example.
- the M1-M2 composite material does not react with each other to form an alloy, but Cu is infiltrated into the W skeleton by capillary action. can get.
- the M1-M2 composite material thus obtained and the material containing the additive may be referred to as “M1-M2 alloy” for convenience.
- an electrode for electric discharge machining is provided, which is made of a material that occupies 95% by mass to 100% by mass of the total mass.
- the ratio of the mass of M1 and M2 is an important factor in the M1-M2 alloy used for the electrode for electric discharge machining.
- M1 is highly conductive but has a low melting point, and M2 is the opposite.
- An M1-M2 alloy containing a large amount of M1 increases the amount of electrode consumed by an arc generated during discharge.
- M2 metals M2, iron group metals, and alloys of M2 and iron group metals
- M1 is set to 40 parts by mass or less with respect to 60 parts by mass of M2 metal.
- M1-M2 alloy containing a large amount of M2 (or M2 metal) when M2 is too much, the conductivity of M2 is inferior to that of M1, so that the processing speed of the workpiece cannot be sufficiently increased. Moreover, if M1 is less than 5 parts by mass, it is difficult to manufacture at low cost by the infiltration method. Therefore, it is industrially preferable that the mass ratio of M1 and M2 (or M2 metal) does not lower the amount of M1 to 5:95 or more. This amount means that M1 is 5 parts by mass and M2 is 95 parts by mass.
- the mass of M1 and M2 is preferably set to 60 to 95 parts by mass of M2 (or M2 metal) with respect to 5 to 40 parts by mass of M1.
- M2 metal of (B) is 100 parts by mass in total with M1 of (A).
- the M2 metal includes M2, an iron group metal, and an alloy of M2 and an iron group metal.
- the mass of the M2 metal means the sum of the mass of the M2, the mass of the iron group metal (simple substance), and the mass of the alloy of M2 and the iron group metal (hereinafter, the alloy of M2 and the iron group metal is referred to as “M2 -Sometimes called "iron group alloy").
- the M2 metal is typically composed of about 95% by mass or more of M2.
- the electrode for electric discharge machining according to the embodiment of the present invention contains an iron group metal, but the iron group metal easily forms an alloy with M2 of W or Mo at a low temperature. Therefore, even when the (C) borate, which is a factor inhibiting the sintering described later, is added, the sintering proceeds easily, and a dense M1-M2 alloy can be obtained.
- iron group metals are basically alloyed with W or Mo M2, they often do not remain alone after sintering, but some of them depend on conditions such as the amount, temperature, heating rate, and atmosphere. May remain alone. Therefore, as the mass of the “iron group metal” in (B), a value of 0 part by mass can be taken when it does not exist alone. Conversely, since the iron group metal does not react with M2 at all, the mass of M2 and the mass of the alloy of M2 and the iron group metal (M2-iron group alloy) cannot take the value of 0 part by mass. . Since the alloyed M2 and the iron group metal are similar to M2 in the electric discharge machining behavior, they are added to the mass of (B) together with M2.
- the mass of the iron group metal is also included in the mass of the M2 metal in (B).
- (C) is a borate for improving discharge characteristics, and 0.05 to 8 parts by mass of M3 borate with respect to 100 parts by mass of the total mass of (A) and (B).
- Alkaline earth metals such as borides and oxides of Ca, Sr, Ba, and rare earth metals are all known to improve discharge characteristics due to their low work function. Bring improved properties. Further, borate has a small function of inhibiting infiltration with borides and oxides. The more borate, the better the discharge characteristics and the higher the processing speed.
- the sinterability of the M1-M2 alloy gradually deteriorates, and if added to an amount exceeding 8 external parts by mass, even if an iron group metal is added (alloy with M2 in the sintered body) Or, it exists as a single metal). Sinterability is not sufficiently improved, and the shape cannot be maintained, or even if it can be formed, it tends to collapse to such an extent that it cannot be processed. Moreover, in order for the effect of improving the discharge characteristics to appear, it is necessary to add at least 0.05 external mass part.
- the sum of the above (A), (B), and (C) occupies 95% by mass to 100% by mass of the total mass of the electrode for electric discharge machining. If it is less than 5 mass%, components other than (A), (B), and (C) can be allowed in a range that does not affect the sinterability and discharge characteristics.
- metals such as Cr, Ti, V, Ta, Re and Au, alkali metals such as Na and K, alkaline earth metals such as Ca, Ba and Sr, carbon, rare earth metals, and oxides and borides thereof
- carbides and nitrides such as WC, TiN, Si 3 N 4 , and SiC may be included as long as they are less than 5% by mass.
- boron oxide such as B 2 O
- B 2 O boron oxide
- the total mass of the iron group metal alone and the mass of the alloy of M2 and the iron group metal is 0.05 to 2.5 parts by mass with respect to the total mass of (A) and (B). Is preferably set to occupy.
- the iron group metal is alloyed with W or Mo as described above, its sinterability can be increased, and the number and size of the pores can be lowered to such an extent that they are not harmful to use as a discharge electrode. it can.
- the iron group metal is dissolved in Cu or Ag, so that the melting point is lowered. As a result, the consumption rate of the electrode for electric discharge machining is increased, which is not desirable.
- a desirable upper limit amount in order not to cause a significant increase in consumption of the electrode for electric discharge machining is that the total amount of the mass of the iron group metal and the mass of the alloy of M2 (for example, W) and the iron group metal is (A), ( It is 2.5 parts by mass with respect to the total mass of B).
- the total of the mass of the iron group metal remaining and the mass of the alloy of M2 and the iron group metal is less than 0.05 parts by mass with respect to the total mass of (A) and (B)
- the problem of poor sintering due to the presence of the borate shown in C) occurs, and pores tend to remain. Therefore, the total of the mass of the iron group metal alone and the mass of the alloy of M2 and the iron group metal is set to 0.05 to 2.5 parts by mass with respect to the total mass of (A) and (B). It is desirable that
- the sum of the masses of (A), (B), and (C) and the masses of (D) and (E) shown below is 95% by mass or more and 100% by mass of the total mass. % Or less of the material.
- (D) is a composite oxide of M2, an iron group metal, and at least one of Ca, Sr, Ba, and a rare earth metal, and a composite having 0.1 to 5 parts by mass It is an oxide.
- (E) is 0.1 to 3 parts by mass of boron oxide (provided that the total mass of (A) and (B) is 100 parts by mass).
- M2, iron group metal, and alkaline earth metal may form a composite oxide in the presence of oxygen.
- Sr (Ni ⁇ W) 0.5 O 3 and Ba (Co ⁇ W) 0.5 O 3 correspond to this.
- the oxygen source is O released from a part of borate, or oxygen contained in a trace amount in M1 and M2.
- (E) will be described.
- B may be oxidized to produce boron oxide such as B 2 O.
- composite oxides and boron oxide have an effect of improving the discharge characteristics, although not as much as borate.
- the upper limit of the amount of oxygen is naturally limited by the amount of borate and the like. If the composite oxide is present in an amount exceeding 5 parts by mass, it is undesirable because it adversely affects the surface roughness of the workpiece as an aggregate. For the same reason, it is not desirable that boron oxide is present in an amount exceeding 3 parts by mass. If both are 0.1 parts by mass or less, there is no significant difference in the effect even when compared to an electrode for electric discharge machining that is not contained at all.
- 1 is set, it is preferably set to be 0.5 volume part or more and 0.99 volume part or less.
- the second borate represented by the formula (1) may contain y volume part, and may contain z volume part of a third borate different from both the first borate and the second borate, and preferably X, y, and z satisfy the following relational expressions (1) to (3).
- (2) x + y ⁇ 0.5, (3)
- x + y + z 1
- z ⁇ 0.1 may be further satisfied.
- Ca, Sr, Ba, and rare earth metal borates can take multiple forms.
- a borate such as is typical, but a plurality of other forms can be taken.
- the amount thereof is It is desirable that it is 0.1 volume part or less with respect to the volume of the whole oxide.
- the total of the former two is preferably 0.5% by volume or more, and more preferably 0.9 part by volume or more.
- M1 borate of (C) when the total volume of one kind or two or more kinds of borates of Mg, Ca, Sr, Ba and rare earth metal is 1 part by volume, M1, 0.5 volume part or more thereof may be dispersed in the grain boundary of M2, iron group metal, or alloy of M2 and iron group metal.
- the boron oxide is present in grains such as M1 (Cu, Ag), M2 (W, Mo), etc., and when it is present at the grain boundary, the discharge characteristics are different. There was a trend. Therefore, it is advantageous in terms of the characteristics of the electrode for electric discharge machining to exist at the grain boundary as much as possible. Therefore, it is preferable that at least half of the volume of borate is present at the grain boundaries.
- the average particle size of one or more of Mg, Ca, Sr and Ba is 20 ⁇ m or less (excluding 0 ⁇ m), and the maximum particle size is It may be 150 ⁇ m or less.
- the latter is more suitable for increasing the processing speed in the state where a small number of boric oxides with a large particle size are exposed on the surface and the state where a large number of boric oxides with a small particle size are exposed on the surface. . Further, since the latter can perform uniform discharge over the entire surface, the surface roughness of the workpiece can be reduced. If the same amount of borate is used, the smaller the average particle size, the more borate exposed on the surface. Accordingly, the average particle size should be small, and the upper limit of the average particle size at this time is preferably 20 ⁇ m or less, and more preferably 10 ⁇ m or less. The maximum value is preferably 150 ⁇ m or less. If these sizes are exceeded, the surface roughness of the workpiece may be adversely affected. The average particle size and the maximum particle size can be estimated from, for example, the area and the number of particles contained in a certain area in a micrograph.
- the electrode for electric discharge machining according to the embodiment of the present invention described above can be obtained by, for example, the steps described below.
- M2 Skeleton Manufacture The M2 skeleton is manufactured from a state in which an iron group metal powder and a borate powder are mixed with W2 or Mo powder which is M2. That is, the components of the electrode for electrical discharge machining other than Cu and Ag (M1) are added at the stage of manufacturing the M2 skeleton.
- W powder and Mo powder having a purity of about 0.1 to 100 ⁇ m and a purity of 99% or more.
- borate powder it is necessary to prepare the desired borate powder before this mixing step.
- the borate powder according to the present embodiment is prepared by mixing Mg, Ca, Sr, Ba, a rare earth metal oxide or carbonate, and a boron-containing substance such as boron carbide or boron carbonate, and performing a heat treatment in an oxidizing atmosphere. Can be obtained by performing Depending on the oxygen concentration and the heat treatment temperature at this time, borates having different forms (the numbers of a, b and c are different) can be obtained. Further, by pulverizing the obtained borate with an attritor or the like in a non-reducing atmosphere such as an oxidizing atmosphere, a borate powder having a smaller particle diameter can be obtained.
- the obtained borate powder, M2 powder, and iron group metal powder are mixed.
- an attritor, a blender, a Henschel mixer, a ball mill, a raking machine, or the like can be used.
- W or Mo powder is easily oxidized, it is desirable to use a methanol atmosphere or the like.
- the mixing step needs to be sufficiently performed so that the iron group metal powder and the borate powder are uniformly mixed.
- components other than (A), (B), (C), (D), and (E) can be intentionally included.
- an oxide or a boride it can be carried out in the same process as the borate.
- a low-melting-point metal such as Al or Cr is contained, it can be performed in the same process as Cu described later.
- description in the case of intentionally adding components other than (A), (B), (C), (D), and (E) will be omitted.
- the mixed powder obtained by mixing is added with a molding binder as necessary, and then subjected to a die press or cold isostatic press molding at about 5 to 150 MPa to obtain a reducing atmosphere such as an H 2 atmosphere.
- the temperature is about 900 to 1600 ° C., and the required time varies greatly depending on the size of the molded body, but it is heated for 5 minutes to 6 hours. It is sufficient if the M2 particles that have come into contact with each other have reached the state where necking has started after heating. At this point, the pores between the M2 particles are in a continuous state and have sufficient strength for handling.
- the added iron group metal forms an alloy with W or Mo, so that it is useful for helping necking of M2 particles and promoting densification of the skeleton. It is also useful for increasing.
- borate such as SrB 2 O 4
- borate has low wettability with M2 and hinders softening and necking of M2 particles. For this reason, by addition of a borate, it is easy to collapse and it becomes easy to become an M2 skeleton having a problem in handling properties.
- an iron group metal is added as described above, an M2 skeleton having sufficient strength for handling and subsequent manufacturing processing can be obtained even when a borate is added.
- the diameter of the continuous pores existing in the M2 skeleton is small to some extent, it is possible to infiltrate them into the M2 skeleton by a capillary phenomenon by setting the temperature to be higher than the melting point of Cu or Ag.
- Infiltration is performed by using a heat-resistant container such as ceramics or carbon and burying the M2 skeleton in a sufficient amount of M1 for infiltration or in a state where the M1 is melted and in contact with the M2 skeleton. Is called. In this state, heating is performed to a melting point of Cu of 1084 ° C. or a melting point of Ag of 962 ° C. or higher in a reducing atmosphere such as an H 2 atmosphere. If M1 is sufficiently infiltrated into the M2 skeleton by capillary action, the material is completed.
- a heat-resistant container such as ceramics or carbon
- the electric discharge machining electrode of the embodiment of the present invention can be obtained.
- Example 1 As raw materials to form a W skeleton, 79 parts by mass of W with an average particle size of 4 ⁇ m, 1 part by mass of Ni with an average particle size of 1 ⁇ m and 0.4 ⁇ m of Sr borate with an average particle size of 7 ⁇ m Prepared.
- the mixed powder was die-pressed at a pressure of 50 MPa to obtain a rod-shaped molded body.
- a skeleton was obtained by providing a concave portion where the molded body can be sufficiently accommodated in a heat-resistant container, placing the molded body therein, and performing sintering at 1150 ° C. in an H 2 atmosphere for 60 minutes.
- sample 1 This sample is designated as sample 1.
- a WC-based cemented carbide containing 18% by mass Co and having a relative density of 99.8% or more is used as a workpiece (workpiece).
- Die-carved EDM DIAX-M35K was used. Machining conditions are set as a machining machine machining condition pack “No. 9405 (conditions for machining cemented carbides)”, and detailed conditions are machined according to the conditions shown in Table 1 below. The surface roughness of the cemented carbide was evaluated.
- the machining volume of the cemented carbide as the workpiece was set to 100%, and the consumption rate (volume%) of the electrode for electric discharge machining was obtained by comparison with it.
- the measurement measured each mass of the workpiece of a cemented carbide, and the electrode for electrical discharge machining before and after the process, and calculated
- the surface roughness of the workpiece after processing reflects the unevenness of the electrode for electric discharge machining.
- surface roughness due to components other than W and Cu for example, unevenness due to the influence of pores and borate particles.
- Ry maximum height, JIS 1994 version
- Comparative sample 1 is a composite material of Cu or Ag and W only
- Comparative sample 2 is a composite material of Cu-W-borate
- Comparative sample 3 is a composite of Cu (Ag) -W-iron group metal Materials
- Comparative sample 4 is a composite material of Cu-W-iron group metal-oxide
- Comparative sample 5 is a composite material of Cu-W-iron group metal-boride
- Comparative sample 6 is Cu (Ag)- W-iron group metal-oxide-boride composite.
- the branch numbers of the respective comparative samples indicate the composition differences (the same applies hereinafter).
- the iron group metals of Comparative Samples 3 to 6 were added as iron group metals at the time of addition, but a part or all of them formed an alloy with W after infiltration.
- the mixed raw materials M1 (Cu or Ag), M2 (W, Mo), and iron group metal total 100 parts by mass, borate, oxide and boride as “additives” 100 parts by mass Is expressed as a mass part (sometimes referred to as an external mass part).
- the samples marked with * in the table are comparative samples outside the scope of the present invention.
- the samples marked with * in the table are comparative samples outside the scope of the present invention.
- the samples marked with * in the table are comparative samples outside the scope of the present invention.
- the samples marked with * in the table are comparative samples outside the scope of the present invention.
- the composite material consisting only of Cu-W as in Comparative Sample 1 was clearly inferior to Sample 1 in both processing speed and consumption rate. This is due to the fact that no additive that improves discharge characteristics is added.
- the surface roughness was slightly inferior to Sample 1. This is because the components other than Cu and W, particularly insulating components, are not contained, so that the processing can uniformly process the surface of the workpiece, and as a result, good flatness is obtained.
- Comparative sample 2 was inferior to sample 1 in terms of processing speed, wear rate, and surface roughness.
- the surface roughness was greatly inferior. This is considered to be due to the fact that an additive called borate, which has good discharge characteristics, is added, but infiltration is unlikely to proceed due to the influence of the additive, and pores remain in a certain size inside.
- Comparative sample 3 had a slightly inferior surface roughness compared to sample 1, but was inferior to sample 1 in terms of processing speed and consumption rate. It is considered that the processing speed and the wear rate are greatly inferior due to the absence of an additive having a high discharge characteristic such as that added to Sample 1. The surface roughness was slightly inferior to that of sample 1 and * slightly superior to comparative sample 1.
- Comparative Sample 4 and * Comparative Sample 5 were inferior in processing speed, wear rate, and surface roughness compared to Sample 1. Among these, the processing speed was greatly inferior. Compared with the borate used in the present application, it can be confirmed that the discharge characteristics of the electrode for electric discharge machining to which boride and oxide are added are not improved as much as the borate is added. It was. The surface roughness was slightly inferior to that of Sample 1.
- Example 2 a sample in which the mass ratio of M1 and M2 metal is changed, and one or more borates of iron group metal, alloy of M2 and iron group metal, Mg, Ca, Sr, Ba, rare earth metal The same test as that of the sample 1 was performed using the sample selected from the different types.
- Samples marked with * in the table are comparative samples outside the scope of the present invention.
- the sample with ** in the table has a composition containing 5% by mass of Cr as * C.
- the samples marked with * in the table are comparative samples outside the scope of the present invention.
- the samples marked with * in the table are comparative samples outside the scope of the present invention.
- the samples marked with * in the table are comparative samples outside the scope of the present invention.
- Sample 104-9 and Sample 104-21 were found to have iron group metal in the sintered body by adjusting the amount of added iron group metal. Even when compared with the examples, the performance was equivalent.
- the sum of the mass of the single iron group metal and the mass of the alloy of M2 and the iron group metal is 0.05 to 2.5 parts by mass with respect to the mass (100 parts by mass) of (A) + (B). All samples showed sufficient performance. Samples in this range showed excellent properties in terms of processing speed, wear rate, and surface roughness. Further, the total of the mass of the iron group metal element and the mass of the M2-iron group gold alloy exceeds 2.5 parts by mass with respect to the total of 100 parts by mass of (A) + (B), and 5 parts by mass. Sample 104-22 was slightly inferior to the sample in the above range in terms of consumption rate. This is considered to be due to the fact that the mass of the iron group metal having a low melting point and the alloy of M2 and the iron group metal having a low melting point compared to M2 is relatively large, so that the consumption due to the discharge easily proceeds.
- Sample 160 is an example containing 5 external mass% Cr as a composition not included in (A), (B), and (C).
- Cr is 4.7% by mass
- the remaining 95.3% by mass is the sum of (A), (B), and (C).
- This sample also showed excellent performance over the comparative sample.
- compositions other than (A), (B), and (C) can be allowed up to 5% by mass of the electrode for electric discharge machining.
- Example 3 As starting materials, (A): 20 parts by mass of Cu, (B): 79.5 parts by mass of W and 0.5 parts by mass of Ni, and (C): 0.5 external parts by mass of SrB 2 O. using a 4, other conditions except for changing the atmosphere of infiltration from a H 2 atmosphere to a mixed atmosphere of H 2 and Ar is
- a 4 other conditions except for changing the atmosphere of infiltration from a H 2 atmosphere to a mixed atmosphere of H 2 and Ar is
- sample 200 This sample is designated as sample 200.
- Sr, Ni, W, and O were observed in the same part along with Cu, W, W—Ni alloy, and Sr 2 B 2 O 5. It was. Then, when it investigated by X-ray diffraction, it was confirmed that they are Sr (Ni ⁇ W) 0.5 O 3 and B 2 O.
- the peak ratio was determined by X-ray diffraction, converted to a mass ratio, and the masses of (A) and (B) were converted to 100 parts by mass.
- the components were as follows.
- the characteristics of the electrode for electric discharge machining containing (D): Sr (Ni ⁇ W) 0.5 O 3 and (E): B 2 O in the above-mentioned range were substantially the same as those of Sample 1.
- the manufacture and observation are difficult, and presence of (D) and (E) was not able to be confirmed in a sample.
- Example 4 The same starting materials as in sample 105 in Example 2 were used, but by adjusting the oxygen concentration and the firing time in the firing atmosphere in the Sr borate production process, Sr borates having different forms were obtained. It was. Table 10 shows the oxygen concentration and firing time during firing.
- the obtained Sr borate was used as a raw material, and the other processes and evaluations were performed in the same manner as the sample 105 of Example 2.
- Table 11 shows the evaluation results and the Sr borate morphology of the electrode material for electric discharge machining.
- the form of Sr borate was investigated by X-ray diffraction.
- sample 155 has a low ratio of 0.4 part by volume of Sr 2 B 2 O 5 and contains a large amount of other borate. In this case, the characteristics were almost the same as those of the sample 5, and did not reach the samples 151 to 154.
- Example 5 As shown in Table 12, a plurality of samples similar to the sample 104 were produced by changing the mixing time of the M2 powder, the iron group metal powder, and the borate powder in the Henschel mixer. As a result, five types of sample Nos. 1 and 2 differed in the ratio of borate present at grain boundaries such as M1 (Cu) and M2 (W). 301-305 were obtained. A schematic diagram of the obtained sample is shown in FIG. As can be seen from FIG. 1, these samples had a basic structure in which tungsten (and an alloy of tungsten and an iron group metal) were necked and Cu was filled between the particles. Moreover, although many borates existed granularly in those grain boundaries, some existed also in the particle
- the ratio of the borate present is determined by observing each sample with an SEM (scanning electron microscope) and measuring the area of the borate present in the crystal grain boundary and the borate present in the particle (crystal). It was calculated from the ratio. With respect to the discharge characteristics of these samples, it was advantageous that the ratio of borate present at the grain boundaries was 0.5 parts by volume or more.
- the sample 305 was superior in both processing speed and consumption rate compared to the comparative example, but was inferior to the samples 301 to 304.
- Example 6 The borate particles, which are raw materials for the skeleton, were pulverized with an attritor before mixing. Five particle sizes were obtained by changing the grinding time. The respective particle sizes are shown in Table 13.
- Samples 401 to 405 were prepared using these five types of borate powders having different particle diameters. Each sample consists of 20 parts by mass of Cu, 79 parts by mass of W, 1 part by mass of Ni, and 1.4 external parts by mass of SrB 2 O 4 . Only the particle size of the borate is different. When these were tested and evaluated in the same manner as in Example 2, the results shown in Table 14 were obtained.
- the desirable range was that the average particle size was 20 ⁇ m or less and the maximum particle size was 150 ⁇ m or less, as can be seen in the borate samples 401-404.
- the sample 405 is clearly superior to the comparative example in both processing speed and consumption rate, but inferior to the samples 401 to 402.
- Cu (Ag) —W (Mo) -based material includes Mg, Ca, Sr, Ba, Sc, Y, a lanthanide borate, and an iron group.
- An electrode for electric discharge machining is produced by adding an appropriate amount of metal.
- the discharge characteristics can be particularly improved by mainly using a borate represented by “M3 2 B 2 O 5 ” or “M3B 2 O 4 ” as the borate.
- the electrode for electric discharge machining of the present invention is suitably used as an electrode used for die-sinking electric discharge machining, for example.
Abstract
Description
(A):5~40質量部のM1。
(B):(A)と合計して100質量部のM2金属であって、M2を必ず含み、さらに、M2と鉄族金属の合金および/または鉄族金属の単体を含むM2金属。
(C):(A)と(B)の合計質量100質量部に対して0.5~8外部質量部のM3のホウ酸化物。
(1)x≧0.1、y≧0.1
(2)x+y≧0.5、
(3)x+y+z=1
なお、z≦0.1をさらに満たしていても良い。
a=1、b=2、c=4
a=1、b=1、c=3
a=1、b=4、c=7
a=1、b=6、c=10
a=1、b=8、c=13
a=2、b=3、c=11
a=2、b=2、c=5
a=3、b=2、c=6
a=3、b=4、c=9
a=3、b=10、c=18
a=9、b=2、c=6
などのホウ酸化物が代表的であるが、それ以外にも複数の形態を取り得る。
M2スケルトンは、M2であるWまたはMoの粉末に鉄族金属粉末、ホウ酸化物粉末を混合した状態のものから作製される。すなわち、Cu、Ag(M1)以外の放電加工用電極の成分は、M2スケルトンを製造する段階で添加される。
(1)で得られたM2スケルトンに、M1であるCu、Agを溶浸する。
Wスケルトンを形成するべき原料として、平均粒子径4μmで79質量部のW、平均粒子径が1μmで1質量部のNiおよび平均粒子径が7μmで0.4外部質量部のSrのホウ酸化物を準備した。
次に、M1とM2金属との質量比を変化させた試料や、また、鉄族金属、M2と鉄族金属の合金、Mg、Ca、Sr、Ba、希土類金属の1つ以上のホウ酸化物において、異なる種類が選択された試料を用いて、試料1と同様の試験を行った。
表中の**のついた試料は、*CとしてCrを5外部質量%含む組成である。
出発原料として、(A):20質量部のCuと、(B):79.5質量部のWおよび0.5質量部のNiと、(C):0.5外部質量部のSrB2O4とを用い、溶浸の雰囲気をH2雰囲気からH2とArの混合雰囲気へと変更すること以外の他の条件は試料1と同様にして試料の作製を行った。この試料に対して、試料1と同様の試験および評価を行ったところ、下に示すように、放電加工用電極として好適に利用できることが確認された。
加工速度90.0mm/sec、消耗率8.9%、面粗さ15.0Ry(μm)
(A)Cu=20.0質量部
(B)W=79.2質量部、Ni=0質量部、W-Ni合金=0.8質量部
(C)SrB2O4とSr2B2O5の合計=0.3外部質量部
(D)Sr(Ni・W)0.5O3=0.1外部質量部
(E)B2O=0.1外部質量部
実施例2中の試料105と同様の出発原料を用いたが、Srのホウ酸化物の製造工程における焼成雰囲気の酸素濃度および焼成時間を調整することにより、形態の異なるSrのホウ酸化物を得た。焼成時の酸素濃度と焼成時間を表10に示す。
表12に示すように、M2粉末、鉄族金属粉末、ホウ酸化物粉末の、ヘンシェルミキサーでの混合時間を変えて、試料104と同様の試料を複数作製した。その結果、M1(Cu)およびM2(W)などの粒界に存在するホウ酸化物の割合が互いに異なる、5種類の試料No.301~305が得られた。得られた試料の模式図を図1に示す。図1からわかるように、これらの試料は、タングステン(およびタングステンと鉄族金属の合金)同士がネッキングし、その粒子同士の間にCuが充填された基本組織を有していた。また、ホウ酸化物はそれらの粒界に粒状で多く存在したが、一部はWやCuの粒子中にも存在した。このホウ酸化物の存在する率は、それぞれの試料をSEM(走査型電子顕微鏡)観察し、前記結晶粒界に存在するホウ酸化物と、粒子(結晶)内に存在するホウ酸化物との面積比から求めた。これら試料の放電特性は、粒界に存在するホウ酸化物の割合が0.5体積部以上であるほうが有利であった。試料305は、比較例に比べて、加工速度、消耗率ともに優れているが、試料301~304よりは劣る結果となった。
スケルトン用の原料であるホウ酸化物の粒子を、アトライターにて混合前に粉砕した。粉砕時間を変えることによって5種類の粒子径を得た。それぞれの粒子径を表13に示す。
Claims (7)
- 放電加工に用いる放電加工用電極であって、下記の(A)、(B)および(C)を含み、
前記(A)、(B)および(C)の質量の和が総質量の95質量%以上100質量%以下を占める材料からなる放電加工用電極であって、
(A):5~40質量部のM1、
(B):前記(A)と合計して100質量部となるM2金属であって、M2を必ず含み、かつ、M2と鉄族金属の合金または鉄族金属の単体を含むM2金属、および
(C):前記(A)と前記(B)との合計質量100質量部に対して、0.05~8外部質量部のM3のホウ酸化物
ただし、M1はCuまたはAgのうちの少なくとも1つまたはそれらの合金
M2はWまたはMoのうちの少なくとも1つまたはそれらの合金
M3はMg、Ca、Sr、Ba、および希土類金属からなる群から選択された少なくとも1つ
である、放電加工用電極。 - 前記鉄族金属の単体の質量と、前記M2と鉄族金属の合金の質量との合計が、前記(A)の質量と前記(B)の質量との合計に対して、0.05~2.5質量%である請求項1に記載の放電加工用電極。
- 下記の(D)および(E)をさらに含み、
前記(A)、(B)、(C)および前記(D)、(E)の質量の和が、総質量の95質量%以上100質量%以下を占める材料からなり、
(D):前記(A)の質量と前記(B)の質量との合計を100質量部としたときに、前記(A)の質量と(B)の質量との合計に対して0.1~5外部質量部の複合酸化物であって、前記M2と、前記鉄族金属と、Ca、Sr、Baおよび希土類金属のうちの少なくとも1つとを含む複合酸化物
(E):前記(A)の質量と前記(B)の質量との合計を100質量部としたときに、前記(A)の質量と(B)の質量との合計に対して0.1~3質量部の酸化ホウ素
である、請求項1または2に記載の放電加工用電極。 - 前記(C)のホウ酸化物は、M3aBbOcで表すことができ、
a=2、b=2、c=5であるホウ酸化物の割合が、ホウ酸化物の全体積を1とした場合に0.5体積部以上0.99体積部以下である請求項1から3のいずれかに記載の放電加工用電極。 - 前記(C)のホウ酸化物は、M3aBbOcで表すことができ、
a=2、b=2、c=5で示され、x体積部を占める第1のホウ酸化物と、
a=1、b=2、c=4で示され、y体積部を占める第2のホウ酸化物と、
前記第1のホウ酸化物と前記第2のホウ酸化物とのいずれとも異なる第3のホウ酸化物であって、z体積部を占める第3のホウ酸化物とを含み、
前記x、y、zは、下記(1)~(3)の関係式を満たす、請求項1から4のいずれかに記載の放電加工用電極。
(1)x≧0.1、y≧0.1
(2)x+y≧0.5
(3)x+y+z=1 - 前記(C)のホウ酸化物の総体積を1体積部とした場合に、M1、M2、鉄族金属の単体、M2と鉄族金属の合金の粒界に、前記ホウ酸化物の0.5体積部以上が分散している請求項1から5のいずれかに記載の放電加工用電極。
- 前記(C)のホウ酸化物の平均粒子径が0μm超20μm以下であり、かつ、最大粒子径が0μm超150μm以下である請求項1から6のいずれかに記載の放電加工用電極。
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JP2006315134A (ja) * | 2005-05-13 | 2006-11-24 | Allied Material Corp | 放電加工用Cu−W系合金電極材 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2014192007A (ja) * | 2013-03-27 | 2014-10-06 | Nippon Tungsten Co Ltd | 電気接点材料 |
JP2015168028A (ja) * | 2014-03-06 | 2015-09-28 | 学校法人慶應義塾 | 炭素系高硬度材の放電加工用工具電極、放電加工方法及び装置 |
Also Published As
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US20130264314A1 (en) | 2013-10-10 |
CN103003016B (zh) | 2013-11-06 |
CN103003016A (zh) | 2013-03-27 |
JPWO2012053486A1 (ja) | 2016-05-26 |
JP5054854B2 (ja) | 2012-10-24 |
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