WO2016092827A1 - 粉末冶金用鉄基合金粉末および焼結鍛造部材 - Google Patents
粉末冶金用鉄基合金粉末および焼結鍛造部材 Download PDFInfo
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- WO2016092827A1 WO2016092827A1 PCT/JP2015/006109 JP2015006109W WO2016092827A1 WO 2016092827 A1 WO2016092827 A1 WO 2016092827A1 JP 2015006109 W JP2015006109 W JP 2015006109W WO 2016092827 A1 WO2016092827 A1 WO 2016092827A1
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/14—Treatment of metallic powder
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/17—Metallic particles coated with metal
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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
- B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0207—Using a mixture of prealloyed powders or a master alloy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0264—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5%
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/16—Ferrous alloys, e.g. steel alloys containing copper
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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
- B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
- B22F2003/175—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging by hot forging, below sintering temperature
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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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/10—Copper
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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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/35—Iron
Definitions
- the present invention relates to an iron-based alloy powder that is a raw material powder of a powder metallurgy product, and a sintered forged member manufactured by a sintering forging method using this iron-based alloy powder as a raw material.
- sintered and forged products are used for members that require particularly high strength, such as connecting rods for automobile engines.
- Patent Documents 1 to 4 Fe—Cu—C-based iron-base alloy powders in which Cu powder and graphite powder are mixed with pure iron powder are often used.
- a machinability improving agent such as MnS for improving machinability may be added to the raw material powder (Patent Documents 1, 4 and 5).
- Patent Documents 1, 2 and 5 studies on the optimization of the amount of Cu and the amount of C have been made (Patent Documents 1, 2 and 5), but the effect of improving the strength is limited.
- Patent Document 3 proposes an iron powder obtained by prealloying an alloy element such as Mo, Ni, or Cu.
- an alloy element such as Mo, Ni, or Cu.
- the alloy element expensive, but in order to form a hard structure such as martensite in the iron-base alloy powder, the sintered body using the iron-base alloy powder containing such an alloy element is machinable. Has the problem of getting worse.
- Patent Document 4 proposes a technique for improving the strength of a sintered body while maintaining the machinability of the sintered body by pre-alloying only Cu with iron powder.
- Patent Document 6 the hardness of the iron-based alloy powder particles is increased and the compressibility is decreased. For this reason, the intensity
- the molding of such iron-based alloy powder has a problem in that the molding die is easily worn away because a high compressive force is required, leading to a reduction in the lifetime of the molding die.
- Patent Document 6 a technique for ensuring compressibility by diffusing and adhering Cu particles to iron powder has been proposed, but the distribution of Cu after sintering tends to be uneven, The effect of strength improvement is limited. Further, as a measure for improving the strength of the sintered body, it is conceivable to increase the sintering temperature. However, in order to consume a large amount of energy, it is desired to lower the sintering temperature.
- the present invention solves the above-mentioned problems of the prior art and is superior in compressibility to conventional Cu prealloyed iron-based alloy powders, and at the same time, is sintered at a lower temperature than iron-based alloy powders mixed with conventional Cu powders.
- An object is to provide an iron-based alloy powder for powder metallurgy that can produce a sintered forged member having high strength even if it is tied.
- Another object of the present invention is to provide a sintered forged member using the iron-based alloy powder.
- high strength means that when the amount of Cu is the same, the strength of the member after sintering and forging becomes higher than the strength of the member after conventional sintering and forging.
- Patent Document 4 As a prior art in which Cu is pre-alloyed to the raw iron powder, there is the aforementioned Patent Document 4.
- this technique is for improving the uniformity of Cu distribution in the raw iron powder after the pre-alloyed raw iron powder is mixed with only the graphite powder and sintered. Therefore, this technique suggests the optimal Cu distribution (ratio of prealloyed Cu to diffusion-adhered Cu) to achieve both compressibility during compacting and uniformity of Cu distribution after sintering forging. is not.
- the gist configuration of the present invention is as follows. 1.
- a sintered forged member using the iron-based alloy powder according to 1 as a raw material 1.
- the Cu distribution on the surface of the iron powder becomes more uniform, and therefore the Cu distribution in the sintered member even at a lower sintering temperature than the conventional Fe—Cu—C-based iron-based alloy powder. Becomes uniform. For this reason, a sintered forged member with high mechanical strength can be manufactured at low cost.
- the amount of Cu contained in the iron-based alloy powder is in the range of 2.0 to 5.0% by mass. If the amount of Cu contained in the iron-based alloy powder is less than 2.0% by mass, the effect of improving the strength of the sintered forged member due to the addition of Cu will not be sufficient. On the other hand, even if the amount of Cu contained in the iron-based alloy powder exceeds 5.0% by mass, the strength of the sintered forged member is not so improved as compared with the case of adding 5.0% by mass of Cu. For this reason, the upper limit of the amount of Cu contained in the iron-based alloy powder is 5.0 mass%. The balance of the iron-based alloy powder other than Cu is Fe and inevitable impurities.
- the present invention diffuses and adheres 1/10 to 8/10 of the amount of Cu contained in the iron-based alloy powder to the surface of the prealloyed raw iron powder in the form of powder, and the remaining Cu is the raw material.
- the most important feature is pre-alloying in the iron powder.
- the amount of Cu to be diffused and deposited is less than 1/10 of the amount of Cu contained in the iron-based alloy powder, the effect of improving the compressibility of the iron-based alloy powder is reduced.
- the amount of Cu to be diffused and deposited exceeds 8/10 of the amount of Cu contained in the iron-based alloy powder, the uniformity of Cu distribution on the surface of the pre-alloyed raw iron powder is not improved, The effect of improving the strength of the forged member is limited.
- the average particle diameter (d50) of Cu powder said here means the particle size from which an integrated particle size distribution is measured on a volume basis by the laser diffraction / scattering method, and the value becomes 50%.
- the iron-based alloy powder of the present invention When the iron-based alloy powder of the present invention is embedded in a resin and then polished and the elemental distribution of the particle cross section is mapped by EPMA, the distribution of prealloyed Cu is observed. On the other hand, when the particle surface of the iron-based alloy powder is mapped by EPMA, it is observed that the particle surface of the iron-based alloy powder is more concentrated in Cu than the inside of the particle due to the diffusion-attached Cu powder.
- the uniformity of Cu after sintering forge improves, so that Cu powder particle is fine, the metal copper powder whose average particle diameter is 20 micrometers or less has high cost. Therefore, it is preferable that the lower limit of the average particle diameter of the Cu powder when using metal copper powder as a raw material is about 10 ⁇ m.
- the powder applicable as the copper source in the present invention conventionally known powders used for iron-based alloy powders such as metallic copper and copper oxide can be applied.
- the copper oxide powder exemplified in Patent Document 7 has a particle size of 20 ⁇ m or less and is relatively low in cost, it can be suitably applied.
- the iron powder used as a raw material of the iron-based alloy powder used in the present invention can be any powder as long as it is a known one used for iron-based alloy powder.
- the amount of impurities in the raw iron powder in the present invention is as follows: C is 0.01% by mass or less, O is 0.15% by mass or less, Si is 0.05% by mass or less, Mn is 0.12% by mass or less, P Is 0.015 mass% or less, S is 0.015 mass% or less, Cr is 0.03 mass% or less, N is 0.01 mass% or less, and other elements are suppressed to 0.01 mass% or less. Is desirable.
- the particle size of the raw iron powder is arbitrary, but it can be produced industrially at low cost in the range of 30 to 150 ⁇ m on average (D50) in the water atomization method. Therefore, the particle size of the raw iron powder is preferably in the range of 30 to 150 ⁇ m on average (D50) when using the water atomization method.
- the average particle diameter (D50) of raw material iron powder said here is measured with the dry-type sieving method of JISZ2510. The average particle size is obtained by calculating a mass-based integrated particle size distribution from the particle size distribution measured by the sieving method, and obtaining the particle size at which the value is 50% by interpolation.
- the diffusion adhesion method used in the present invention may follow a conventional method for diffusion adhesion of Cu powder on the surface of iron powder or the like, but it is preferable to use a diffusion adhesion heat treatment described later.
- the copper oxide powder is reduced by performing diffusion adhesion heat treatment in a reducing atmosphere, and the metal Cu powder adheres to the surface of the pre-alloyed raw iron powder.
- the iron-base alloy powder according to the invention is obtained.
- the manufacturing method of the iron-base alloy powder according to this invention is demonstrated.
- the raw material iron in which Cu is prealloyed by any conventionally known method water atomizing method, gas atomizing method, electrolytic method, etc.
- any conventionally known method water atomizing method, gas atomizing method, electrolytic method, etc.
- Use powder since it becomes possible to manufacture at low cost by applying the water atomization method, it is preferable to apply the water atomization method to the production of the raw iron powder in which Cu is pre-alloyed.
- Heat treatment for the purpose of removing oxygen and carbon contained in the raw iron powder, it is possible to perform a heat treatment in a reducing atmosphere at a temperature range of 800 to 1000 ° C. for about 0.5 to 2 hours. .
- Cu powder mixing The raw material iron powder after Cu pre-alloying and Cu powder are mixed using any conventionally known method (V-type mixer, double cone type mixer, Henschel mixer, Nauter mixer, etc.). When mixing the powder, a binder such as machine oil may be added to prevent segregation of the mixed Cu copper powder.
- V-type mixer double cone type mixer
- Henschel mixer Henschel mixer
- Nauter mixer Nauter mixer
- Diffusion adhesion heat treatment The Cu powder mixture is heated in a reducing atmosphere (hydrogen gas, hydrogen nitrogen mixed gas, etc.) in a temperature range of 700 to 1000 ° C. for about 0.5 to 2 hours. The powder diffuses and adheres to the surface of the raw iron powder after pre-alloying. When the above-described heat treatment for removing oxygen and carbon is omitted, carbon and oxygen contained in the raw iron powder are removed in this step.
- a reducing atmosphere hydrogen gas, hydrogen nitrogen mixed gas, etc.
- any conventionally known method can be used as the diffusion adhesion method in the present invention.
- the method described in Patent Document 6 or the method described in Patent Document 8 are also suitable. Can be used for
- the powder can be pulverized by a known method such as a hammer mill and then classified into a predetermined particle size by a sieve or the like.
- the average particle diameter (D50) of the iron-based alloy powder is preferably about 30 to 150 ⁇ m, like the raw iron powder, from the viewpoint of ease of handling.
- the average particle diameter (D50) of the iron-based alloy powder referred to here can be measured and determined by the same method as the average particle diameter of the raw iron powder.
- a predetermined amount (for example, 0.3 to 0.8% by mass) of carbon is mixed with the above-described iron-based alloy powder in the form of graphite powder (the mixing method may be any known means). Any known graphite powder such as natural graphite, artificial graphite, or carbon black can be used.
- a lubricant such as zinc stearate may be mixed in the range of 0.3 to 1.0% by mass.
- a substance that improves machinability such as MnS, can be mixed in the range of 0.1 to 0.7 mass% in the form of powder.
- compression molding is performed into a predetermined shape using a mold.
- Such compression molding may be performed using a known technique used in sintering forging.
- sintering is performed in an inert or reducing atmosphere.
- the sintering temperature is preferably in the range of 1120 to 1250 ° C.
- a degreasing step for holding for a certain time in a temperature range of 400 to 700 ° C. may be added.
- the present invention after sintering, it is continuously cooled without being cooled, or once cooled, then reheated and hot forged.
- the forging conditions may be known ones, but the forging temperature is preferably in the range of 1000 to 1200 ° C.
- Cu was added to the l.
- the raw steel powder in which Cu was pre-alloyed was manufactured by using the water atomization method for the molten steel added with 0 to 6.0% by mass. Some raw iron powders were not prealloyed with Cu.
- the impurity content of the raw iron powder was Si ⁇ 0.05 mass%, Mn ⁇ 0.15 mass%, P ⁇ 0.025 mass%, and S ⁇ 0.025 mass%.
- electrolytic copper powder having an average particle size of 25 ⁇ m was added as a Cu source for diffusion adhesion to the raw iron powder pre-alloyed with Cu and the raw iron powder not pre-alloyed with Cu, and a V-type mixer was used.
- a Cu source for diffusion adhesion an atomized copper powder (No. 4A) having an average particle diameter of 15 ⁇ m, an atomized copper powder (No. 15) having an average particle diameter of 5 ⁇ m, or a cuprous oxide powder having an average particle diameter of 2.5 ⁇ m ( No. 14 and No. 17A) were used.
- No. No. 16 further mixed a predetermined amount of Cu powder into the iron-base alloy steel powder of the present invention. Further, these powders were subjected to the following diffusion adhesion heat treatment and pulverization. Diffusion adhesion heat treatment: Heat treatment was performed in a hydrogen atmosphere at a temperature of 920 ° C.
- Iron-based alloy powder 100 parts by mass, graphite powder: 0.6 parts by mass, lubricant (zinc stearate): 0.8 parts by mass, and MnS powder: 0. 6 parts by mass was added and mixed using a double cone type mixer to obtain a mixed powder.
- This mixed powder was compression-molded into a rectangular parallelepiped shape of 10 mm ⁇ 10 mm ⁇ 55 mm with a predetermined pressure.
- the compression density after compression molding is also shown in Table 1. Subsequently, it sintered for 20 minutes by the sintering temperature described in Table 1 by RX atmosphere.
- test piece which becomes a member density: 7.8 Mg / m ⁇ 3 > or more.
- a tensile test piece having a length of 50 mm ⁇ diameter: 3 mm was cut out, and the yield stress and the maximum stress before breaking (tensile strength) were measured. The measurement results are further shown in Table 1.
- No. 1 has a lower yield stress than the inventive examples.
- the green density was low.
- the condition (No. 18) in which the Cu diffusion adhesion amount is lower than the range of the present invention has a low compression density and poor compressibility compared to the invention examples (No. 10 to 11 and 16 to 17) in which the other conditions are the same. . It is thought that this is because Cu is excessively pre-alloyed on the raw material iron powder.
- the conditions (No. 3, No. 8A, and No. 19A) in which the Cu diffusion adhesion amount is higher than the range of the present invention are the same as those of the invention example in which the other conditions are the same (No. 3 is No. 3A and 4 to 5).
- No. 8A has lower yield stress than No. 9 to 11 and 16 to 17
- No. 19A has lower yield stress than No. 20 to 22 and No. 21A. This is considered to be caused by non-uniformity of Cu distribution in the sintered member.
- the level (No. 4A and No. 15) in which the particle size of the Cu powder diffused and adhered is small compared to the level (No. 4 and No. 12) in which the particle size of the Cu powder is coarse and the other conditions are the same. Further, the yield stress and tensile strength are higher. This is considered because Cu distribution on the iron powder surface is more uniform.
- No. 14 has a coarse Cu powder particle size and the other conditions are the same. Yield stress and tensile strength are higher than 12. On the other hand, no. Yield stress and tensile strength almost equal to 13 are shown. This indicates that the smaller the particle size of the Cu powder to be diffused and adhered, the more uniform the Cu distribution in the sintered member even at a lower sintering temperature, and the more remarkable the effects of the present invention.
- the sintering temperature is 1170 ° C.
- the invention examples (Nos. 10 to 11 and 16 to 17) having a sintering temperature of 1120 ° C. have a higher yield stress than that of No. 8 in accordance with the present invention. It is thought that this is because the Cu distribution in the binding member is more uniform.
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Abstract
Description
また、焼結体の強度向上の方策としては、焼結温度を高温とすることも考えられるが、大量のエネルギーを消費するために、焼結温度は低温化することが望まれている。
また、本発明は、その鉄基合金粉末を用いた焼結鍛造部材を提供することを目的とする。
なお、本発明で高強度とは、Cu量が同等の場合に、焼結鍛造した後の部材強度が従来の焼結鍛造した後の部材強度よりも高くなることを意味する。
1.Cuを予合金化した原料鉄粉の表面にCuを粉末の形で拡散付着させた鉄基合金粉末であって、Cuを2.0~5.0質量%含有し、残部がFeおよび不可避的不純物からなり、
上記Cuの1/10~8/10は上記原料鉄粉の表面に拡散付着し、かつ残りのCuは予合金化している粉末冶金用鉄基合金粉末。
本発明において、鉄基合金粉末に含まれるCu量は2.0~5.0質量%の範囲とする。
鉄基合金粉末に含まれるCu量が2.0質量%に満たないと、Cu添加による焼結鍛造部材の強度向上効果が十分ではなくなる。一方、鉄基合金粉末に含まれるCu量が5.0質量%を超えても、5.0質量%のCu添加の場合に比べて、焼結鍛造部材の強度はさほど向上しない。このため、鉄基合金粉末に含まれるCu量の上限は5.0質量%とする。
なお、上記Cu以外の鉄基合金粉末の残部はFeおよび不可避的不純物である。
さらに、特許文献7に例示される酸化銅粉は、20μm以下の粒径であっても比較的低コストであるため、好適に適用することができる。
なお、本発明における原料鉄粉の不純物量は、Cが0.01質量%以下、Oが0.15質量%以下、Siが0.05質量%以下、Mnが0.12質量%以下、Pが0.015質量%以下、Sが0.015質量%以下、Crが0.03質量%以下、Nが0.01質量%以下およびその他の元素が0.01質量%以下に抑制されることが望ましい。
なお、ここで言う原料鉄粉の平均粒径(D50)とは、JIS Z 2510に記載の乾式ふるい分け法で測定したものである。そして、平均粒径は、かかるふるい分け法で測定した粒度分布から質量基準の積算粒度分布を算出し、その値が50%となる粒径を内挿法で求めたものである。
本発明に用いられる拡散付着方法は、鉄粉等の表面にCu粉末を拡散付着させるための常法に従えば良いが、後述する拡散付着熱処理を用いることが好ましい。なお、Cu粉末として酸化銅粉を用いた場合には、還元雰囲気で拡散付着熱処理を行うことによって酸化銅粉が還元され、予合金化された原料鉄粉の表面に金属Cu粉が付着した本発明に従う鉄基合金粉末となる。
前記した原料鉄粉に対し、前記した成分範囲のCuを予合金化したのち、従来公知の任意の方法(水アトマイズ法、ガスアトマイズ法または電解法など)で、Cuが予合金化された原料鉄粉とする。なお、水アトマイズ法を適用することによって低コストで製造することが可能となるので、Cuが予合金化された原料鉄粉の製造には、水アトマイズ法を適用することが好ましい。
なお、前記した事前の酸素や炭素を除去する熱処理を省略した場合には、この工程で原料鉄粉に含まれる炭素や酸素が除去される。
また、本発明における拡散付着の方法は、従来公知の任意の方法を用いることが可能であるが、例えば特許文献6に記載された方法や、特許文献8に記載された方法であっても好適に使用することができる。
本発明において、鉄基合金粉末の平均粒径(D50)は、取り扱いの容易性等から、原料鉄粉と同様に30~150μm程度とするのが好ましい。なお、ここで言う鉄基合金粉末の平均粒径(D50)は、原料鉄粉の平均粒径と同様の方法で測定し、求めることができる。
前述した鉄基合金粉末に、所定量(例えば、0.3~0.8質量%)の炭素を、黒鉛粉の形態で混合(混合法は公知の任意の手段が適用可能)する。
なお、黒鉛粉は天然黒鉛や人造黒鉛、カーボンブラックなど、従来公知のものがいずれも適用可能である。
さらに、不活性または還元性の雰囲気で焼結する。焼結温度は1120~1250℃の範囲が好ましい。なお、焼結温度は、高温ほどCu分布が均一となって好ましいが、高コストとなるため、本発明では、1120~1250℃の範囲が好ましい。より好ましくは、1120~1180℃の範囲である。
表1に示すように、Cuをl.0~6.0質量%添加した溶鋼を、水アトマイズ法を用いて、Cuが予合金化された原料鉄粉を製造した。なお、一部の原料鉄粉は、Cuの予合金化を行わなかった。また、原料鉄粉の不純物含有量は、いずれも、Si≦0.05質量%、Mn≦0.15質量%、P≦0.025質量%およびS≦0.025質量%であった。
ついで、Cuを予合金化した原料鉄粉およびCuを予合金化しなかった原料鉄粉に、平均粒径:25μmの電解銅粉を拡散付着用のCu源として添加し、V型混合機を用いて15分間混合した。なお、一部の条件では、かようなCuの添加を行わなかった。拡散付着用のCu源としては、平均粒径15μmのアトマイズ銅粉(No.4A)、平均粒径5μmのアトマイズ銅粉(No.15)、あるいは平均粒径2.5μmの亜酸化銅粉(No.14、およびNo.17A)を用いた。また、No.16は、本発明の鉄基合金鋼粉に所定量のCu粉をさらに混合した。
さらに、これらの粉末に対し、以下の拡散付着熱処理および粉砕を施した。
拡散付着熱処理:水素雰囲気中、温度:920℃で、30分間熱処理して、表1に示した成分の鉄基合金粉末を製造した。
粉砕:ケーキ状に固化した熱処理体を、ハンマーミルを用いて粉砕し、目開きが180μmの節で分級して、篩下を製品とした。粉砕後の製品のC量およびO量は、いずれの条件でも、C≦0.01質量%、O≦0.25質量%であった。なお、亜酸化銅をCu粉として添加したNo.14およびNo.17Aは、この処理によって亜酸化銅が金属銅に還元されていることを確認した。
鉄基合金粉末:100質量部に対して、黒鉛粉:0.6質量部、潤滑剤(ステアリン酸亜鉛):0.8質量部、およびMnS粉末:0.6質量部を添加して、ダブルコーン型混合機を用いて混合し、混合粉を得た。
この混合粉を、10mm×10mm×55mmの直方体形状に、所定の圧力で、圧縮成形した。圧縮成形後の圧縮密度を表1に併記する。
ついで、RX雰囲気で、表1に記載した焼結温度で20分間焼結した。
さらに、室温まで一旦冷却した後、1120℃まで加熱して鍛造し、部材密度:7.8Mg/m3以上となる試験片を作製した。
この試験片から、長さ:50mm×直径:3mmの引張試験片を切り出して、降伏応力および破断前最大応力(引張強さ)を測定した。
測定結果をさらに表1に併記する。
Claims (2)
- Cuを予合金化した原料鉄粉の表面に、Cuを粉末の形で拡散付着させた鉄基合金粉末であって、Cuを2.0~5.0質量%含有し、残部がFeおよび不可避的不純物からなり、
上記Cuの1/10~8/10は上記原料鉄粉の表面に拡散付着し、かつ残りのCuは予合金化している粉末冶金用鉄基合金粉末。 - 請求項1に記載の鉄基合金粉末を原料とする焼結鍛造部材。
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WO2020241087A1 (ja) * | 2019-05-24 | 2020-12-03 | Jfeスチール株式会社 | 鉄基合金焼結体及び粉末冶金用鉄基混合粉 |
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