WO2019230259A1 - 粉末冶金用粉末混合物およびその製造方法 - Google Patents
粉末冶金用粉末混合物およびその製造方法 Download PDFInfo
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- C—CHEMISTRY; METALLURGY
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- 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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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/102—Metallic powder coated with organic material
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/108—Mixtures obtained by warm mixing
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/16—Metallic particles coated with a non-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
- 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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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/08—Metals
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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
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/40—Carbon, graphite
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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
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/45—Others, including non-metals
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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
- B22F2304/00—Physical aspects of the powder
- B22F2304/10—Micron size particles, i.e. above 1 micrometer up to 500 micrometer
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/08—Metals
- C08K2003/085—Copper
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/08—Metals
- C08K2003/0856—Iron
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/005—Additives being defined by their particle size in general
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present invention relates to a powder mixture for powder metallurgy, and more particularly to a powder mixture for powder metallurgy that can be extracted from a mold with a small force during molding and die galling is suppressed.
- the present invention also relates to a method for producing the powder mixture for powder metallurgy.
- a raw material powder composed mainly of iron-based powder is molded using a mold to form a molded product (a green compact), and the molded product is sintered to produce a sintered part. .
- a lubricant to the raw material powder or to attach a lubricant to the surface of the mold used for the molding.
- the iron-based powder contained in the raw material powder and the mold are in direct contact with each other, resulting in an increased frictional force.
- lubricants are used in powder metallurgy.
- a metal soap such as lithium stearate or zinc stearate
- an amide lubricant such as ethylene bisstearamide
- Patent Document 1 As proposed in Patent Document 1, by using an iron-based powder coated with graphite powder, it is possible to reduce the friction during molding and to reduce the extraction force from the mold. However, it has been found that the technique proposed in Patent Document 1 has the following problems.
- Patent Document 1 a binder is used to adhere the graphite powder to the iron-based powder.
- the binder is also applied to the surface of the graphite powder adhered to the iron-based powder.
- the fluidity of the powder mixture cannot be sufficiently improved.
- the surface of the graphite powder or the copper powder can be prevented from being coated with the binder by coating the fine graphite powder.
- the particle surface is coated with graphite, it can be extracted from the mold with a small force during molding, and mold galling can be suppressed.
- the present invention is based on the above findings, and the gist of the present invention is as follows.
- Ratio [m b / (m r + m g + m Cu + m c ) ⁇ 100] is 0.10 to 0.80 mass%
- Ratio [m g / (m r + m g + m Cu + m c ) ⁇ 100] is 0.6 to 1.0% by mass
- Ratio [m Cu / (m r + m g + m Cu + m c ) ⁇ 100] is 0.1 to 3.0% by mass, The mass of the carbon black relative to
- binder is one or more resins selected from the group consisting of copolymerized polyamide and polyurethane.
- Ratio [m b / (m r + m g + m Cu + m c ) ⁇ 100] is 0.10 to 0.80 mass%
- Ratio [m g / (m r + m g + m Cu + m c ) ⁇ 100] is 0.6 to 1.0% by mass
- Ratio [m Cu / (m r + m g + m Cu + m c ) ⁇ 100] is 0.1 to 3.0% by mass, The mass of the carbon black relative to
- the powder mixture for powder metallurgy according to the present invention has extremely excellent fluidity. Therefore, it can be extracted from the mold with a small force during molding, and continuous molding can be performed without causing mold galling. Therefore, the yield of molded products can be improved and high productivity can be realized.
- the powder mixture for powder metallurgy according to the present invention has little segregation of Cu, a sintered body with high dimensional accuracy can be obtained.
- the powder mixture for powder metallurgy can be produced without using a solvent.
- the powder mixture for powder metallurgy of the present invention contains raw material powder, copper powder, binder, graphite powder, and carbon black as essential components. Hereinafter, each component will be described.
- the raw material powder a powder containing iron-based powder is used.
- the ratio of the iron-based powder in the raw material powder may be 90% by mass or more, but more preferably 95% by mass or more.
- the upper limit of the ratio of the iron-based powder in the raw material powder is not particularly limited, and may be 100% by mass. That is, the raw material powder may be composed only of iron-based powder. However, from the viewpoint of imparting various properties to the finally obtained sintered body, it is preferable to use a mixed powder composed of an iron-based powder and an auxiliary material described later as the raw material powder.
- iron-based powder Any iron-based powder can be used without any particular limitation.
- the iron-based powder include iron powder and alloy steel powder.
- the alloy steel powder include pre-alloyed steel powder (alloyed steel powder) pre-alloyed at the time of melting the alloy element, partially diffused alloyed steel powder alloyed by partially diffusing the alloy element into iron powder.
- One or two or more selected from the group consisting of hybrid steel powder obtained by partially diffusing alloying elements in prealloyed steel powder can be used.
- “iron-based powder” refers to a metal powder having an Fe content of 50 mass% or more.
- the “iron powder” refers to a powder composed of Fe and inevitable impurities, and is generally referred to as “pure iron powder” in this technical field.
- the average particle diameter of the iron-based powder is not particularly limited, but is preferably 70 to 100 ⁇ m.
- the particle size of the iron-based powder is a measured value by dry sieving based on JISJZ 2510: 2004 unless otherwise specified.
- auxiliary material arbitrary things can be used, without being specifically limited.
- auxiliary material it is preferable to use 1 or 2 or more selected from the group which consists of powder for alloys and machinability improvement material powder.
- a metal powder is preferably used as the alloy powder.
- metal powder it is preferable to use 1 or 2 or more selected from the group which consists of metal powders, such as Ni powder and Mo powder, for example.
- the machinability improving material powder include MnS.
- the ratio of the auxiliary material in the raw material powder is 10% by mass or less.
- Binder The surface of the raw material powder is coated with at least a part of a binder. Any binder can be used as long as it can adhere graphite powder, copper powder, and carbon black to the surface of the raw material powder.
- the binder it is preferable to use an organic resin, and it is more preferable to use one or more resins selected from the group consisting of copolymerized polyamide and polyurethane.
- the binder is preferably in the form of powder.
- the average particle size of the binder is less than 5 ⁇ m, the cost for pulverizing to the particle size increases and the raw material cost increases. Therefore, from the viewpoint of cost reduction, it is preferable that the average particle size of the binder is 5 ⁇ m or more.
- the average particle size of the binder exceeds 100 ⁇ m, the time required for uniform mixing with the raw material powder increases, and the productivity decreases. Therefore, from the viewpoint of improving productivity, the average particle size of the binder is preferably 100 ⁇ m or less.
- the surface of the binder coated on the surface of the raw material powder is coated with at least a part of graphite powder.
- the surface of the raw material powder is coated with graphite powder through the binder.
- Average particle diameter of graphite powder less than 5 ⁇ m
- the particle diameter of graphite powder used in powder metallurgy is about 5 to 20 ⁇ m.
- the average particle size of the graphite powder is set to less than 5 ⁇ m.
- the lower limit of the average particle size of graphite powder is not particularly limited.
- the average particle diameter of graphite powder shall be 100 nm or more from an economical viewpoint.
- the addition amount of the graphite powder is the graphite with respect to the total of the mass of the raw material powder (m r ), the mass of the graphite powder (m g ), the mass of the copper powder (m Cu ), and the mass of the carbon black (m c ). It is defined as the ratio of the mass (m g ) of the powder [m g / (m r + m g + m Cu + m c ) ⁇ 100].
- the surface of the binder coated on the surface of the raw material powder is further coated with at least a part of copper powder.
- the surface of the raw material powder is coated with copper powder through the binder.
- Addition amount of copper powder 0.1 to 3.0% by mass
- the addition amount of copper powder shall be 0.1 mass% or more.
- the amount of copper powder added is the mass of the raw material powder (m r ), the mass of the graphite powder (m g ), the mass of the copper powder (m Cu ), and the mass of the carbon black (m c ).
- the specific surface area of the carbon black is not particularly limited, but is preferably 50 m 2 / g or more. Since carbon black having a specific surface area of 50 m 2 / g or more has a small particle diameter, the amount of carbon black added to coat the binder surface can be reduced. As a result, the compressibility of the powder mixture can be further improved.
- the specific surface area is preferably 100 m 2 / g or less. If the specific surface area is 100 m 2 / g or less, it is possible to further suppress the deterioration of mechanical properties due to dimensional fluctuation during sintering. In the present invention, the specific surface area of carbon black can be measured by the BET method (JIS K 6217-2: 2001).
- the average particle size of carbon black is not particularly limited. However, if the average particle size of the carbon black is less than 5 nm, the carbon black may be buried in the irregularities on the surface of the iron-based powder or in the binder present on the surface of the iron-based powder. Carbon black having an average particle size of less than 5 nm may adhere to the binder surface in an aggregated state. Therefore, from the viewpoint of further enhancing the effect of carbon black, it is preferable that the average particle size of carbon black be 5 nm or more. On the other hand, when the average particle diameter of carbon black exceeds 500 nm, the number of carbon black particles decreases, and the effect of adhering carbon black decreases.
- the average particle size of carbon black is preferably 500 nm or less.
- the average particle diameter of carbon black refers to the arithmetic average diameter obtained by observing the carbon black particles with an electron microscope.
- Addition amount of carbon black 0.01 to 0.30 mass%
- the amount of carbon black added is carbon relative to the total of the mass of raw material powder (m r ), the mass of graphite powder (m g ), the mass of copper powder (m Cu ), and the mass of carbon black (m c ). It is a ratio [m c / (m r + m g + m Cu + m c ) ⁇ 100] of the mass (m c ) of black.
- the manufacturing method in one embodiment of the present invention includes a first mixing step, a second mixing step, and a third mixing step.
- the first mixing step the raw material powder, the copper powder, and the binder are mixed at a temperature equal to or higher than the melting point of the binder to obtain a first powder mixture.
- the second mixing step the first powder mixture and graphite powder having an average particle size of less than 5 ⁇ m are mixed at a temperature equal to or higher than the melting point of the binder to obtain a second powder mixture.
- the second powder mixture and carbon black are mixed at a temperature below the melting point of the binder to obtain a powder mixture for powder metallurgy.
- the binder and graphite powder are mixed in advance, the viscosity of the binder increases, and as a result, it becomes difficult to uniformly coat the binder on the surface of the iron-based powder. Therefore, prior to the step of coating the graphite powder, a step of coating the binder on the surface of the iron-based powder and the copper powder is performed. Thereby, copper powder adheres to the surface of iron base powder through a binder. From the above viewpoint, it is preferable to add and mix only the binder with respect to the raw material powder and the copper powder in the first mixing step. In the second mixing step, it is preferable to add and mix only graphite powder without adding a binder to the raw material powder to which the copper powder is adhered by the binder.
- the surface of the iron-based powder is coated with the binder and the graphite powder at the same time, the surface of the graphite powder is also coated with the binder, so that the effect of coating with the graphite powder cannot be obtained sufficiently. Therefore, by coating the graphite powder after coating the binder, it is possible to prevent the surface of the graphite powder from being coated with the binder.
- the powder mixture for powder metallurgy obtained by the method of the present invention the iron-based powder surface is uniformly coated with the graphite powder adhered via the binder.
- the powder mixture for powder metallurgy of this invention is excellent in fluidity
- the mixing means used in the first mixing step, the second mixing step, and the third mixing step is not particularly limited, and any mixer can be used. From the viewpoint of easy heating, it is preferable to use a high-speed bottom stirring mixer, an inclined rotary pan mixer, a rotary mulberry mixer, or a conical planetary screw mixer.
- the mixing temperature at the time of performing the first mixing step and the second mixing step is not less than the melting point (T m ) of the binder to be used.
- T m melting point
- the mixing temperature is preferably T m + 20 ° C. or higher, and preferably T m + 50 ° C. or higher.
- the upper limit of the mixing temperature is not particularly limited. However, if the mixing temperature is excessively increased, adverse effects such as a decrease in production efficiency and oxidation of the iron-based powder occur. Therefore, T m + 100 ° C. or lower is preferable.
- the mixing temperature at the time of implementing the said 3rd mixing process shall be below melting
- Tm melting
- the mixing temperature is preferably T m ⁇ 20 ° C. or lower, more preferably T m ⁇ 50 ° C. or lower.
- the lower limit of the mixing temperature is not particularly limited, but if the mixing temperature is excessively lowered, the production efficiency is lowered. Therefore, it is preferable that the mixing temperature at the time of implementing a 3rd mixing process shall be 60 degreeC or more.
- an additional auxiliary material and a lubrication agent can also be arbitrarily added to the powder mixture for powder metallurgy of this invention.
- additional auxiliary material the thing similar to the auxiliary material contained in the raw material powder mentioned above can be used.
- a lubricant is added after the third mixing step, it is preferable to use a lubricant that is not an organic resin as the lubricant, and the lubricant is selected from the group consisting of fatty acids, fatty acid amides, fatty acid bisamides, and metal soaps. It is more preferable to use one or more lubricants.
- the second powder mixture is cooled to a temperature below the melting point in the high-speed bottom stirring mixer, and then carbon black is further added to the high-speed bottom stirring mixer and mixed at the temperature (first 3 mixing steps). After mixing, the obtained powder mixture for powder metallurgy was discharged from the mixer.
- carbon black commercially available carbon black having an average particle diameter of 25 nm was used.
- graphite powder having an average particle size of 4 ⁇ m was added in the first mixing step.
- heating was performed at room temperature without heating in the first mixing step and the second mixing step. No. In No. 18, since the mixing was performed without heating, the surface of the raw material powder was not covered with the binder and the graphite powder.
- Fluidity 50 g of the obtained powder mixture for powder metallurgy was filled in a container having an orifice diameter of 2.5 mm, and the time from filling to discharging was measured to determine the fluidity (unit: s / 50 g). Other measurement conditions were based on JIS Z 2502: 2012. The fluidity is an index indicating the fluidity of the mixed powder at the time of mold filling, and the smaller the value of the fluidity, the better the fluidity of the mixed powder. In some comparative examples, the powder mixture for powder metallurgy did not flow and was not discharged from the orifice.
- Cu adhesion The Cu adhesion degree defined by the following formula (1) was measured.
- Cu adhesion [%] A / B ⁇ 100
- A Cu amount (mass%) of powder mixture for powder metallurgy sieved to 75 ⁇ m or more and 150 ⁇ m or less
- B Cu amount (mass%) of the powder mixture for powder metallurgy
- the values of A and B are measured using an ICP emission spectrophotometer (Shimadzu: ICPS-8100) after dissolving the obtained powder metallurgy mixture by a method in accordance with JIS G1258 ICP sulfuric acid phosphoric acid decomposition method. did. The measurement was performed under the condition of an integration time of 10 seconds, and an average value of values obtained by three measurements was used.
- the value A can be regarded as the amount of Cu adhering to the raw material powder. Therefore, the Cu adhesion degree represents the ratio of Cu adhering to the raw material powder out of Cu contained in the entire powder metallurgy mixture.
- the Cu adhesion degree can be used as an index of Cu segregation, and the larger the Cu adhesion degree, the better the Cu segregation prevention of the powder mixture.
- the powder mixture for powder metallurgy was pressure molded using a mold to obtain a molded body having a diameter of 11.3 mm and a height of 11 mm.
- the molding pressure in the pressure molding was 686 MPa.
- the force (pulling output) required when the molded body was extracted from the mold and the green density (average of the molded body) of the obtained molded body were measured. In some comparative examples, galling occurred, and the molded body could not be extracted from the mold.
- the powder mixture for powder metallurgy that satisfies the conditions of the present invention is extremely excellent in fluidity, can be extracted from a compacting mold with a small force, and is a mold during molding. The galling was also suppressed. Moreover, it turned out that Cu adhesion degree is also favorable.
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Abstract
Description
前記原料粉末が、該原料粉末の90質量%以上の鉄基粉末を含有し、
前記黒鉛粉の平均粒径が5μm未満であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記バインダの質量(mb)の比率[mb/(mr+mg+mCu+mc)×100]が、0.10~0.80質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記黒鉛粉の質量(mg)の比率[mg/(mr+mg+mCu+mc)×100]が、0.6~1.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記銅粉の質量(mCu)の比率[mCu/(mr+mg+mCu+mc)×100]が、0.1~3.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記カーボンブラックの質量(mc)の比率[mc/(mr+mg+mCu+mc)×100]が、0.01~0.30質量%であり、
前記原料粉末の表面が、前記バインダの少なくとも一部で被覆されており、
前記バインダの表面が、前記黒鉛粉の少なくとも一部、前記銅粉の少なくとも一部、および前記カーボンブラックの少なくとも一部で被覆されている、粉末冶金用粉末混合物。
前記第1の粉末混合物と平均粒径が5μm未満の黒鉛粉とを、前記バインダの融点以上の温度で混合して第2の粉末混合物とする第2混合工程と、
前記第2の粉末混合物とカーボンブラックとを、前記バインダの融点以下の温度で混合して粉末冶金用粉末混合物とする第3混合工程とを有し、
前記原料粉末が、該原料粉末の90質量%以上の鉄基粉末を含有し、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記バインダの質量(mb)の比率[mb/(mr+mg+mCu+mc)×100]が、0.10~0.80質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記黒鉛粉の質量(mg)の比率[mg/(mr+mg+mCu+mc)×100]が、0.6~1.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記銅粉の質量(mCu)の比率[mCu/(mr+mg+mCu+mc)×100]が、0.1~3.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記カーボンブラックの質量(mc)の比率[mc/(mr+mg+mCu+mc)×100]が、0.01~0.30質量%である、
粉末冶金用粉末混合物の製造方法。
上記原料粉末としては、鉄基粉末を含有する粉末を使用する。原料粉末中における鉄基粉末の比率は、90質量%以上であればよいが、95質量%以上とすることがより好ましい。一方、原料粉末中における鉄基粉末の比率の上限は特に限定されず、100質量%とすることもできる。すなわち、前記原料粉末は、鉄基粉末のみからなるものであってもよい。しかし、最終的に得られる焼結体に様々な特性を付与するという観点からは、鉄基粉末と後述する副原料とからなる混合粉末を前記原料粉末として用いることが好ましい。
上記鉄基粉末としては、特に限定されることなく、任意のものを用いることができる。前記鉄基粉末の例としては、鉄粉や合金鋼粉が挙げられる。前記合金鋼粉としては、例えば、合金元素を溶製時に予め合金化した予合金鋼粉(完全合金化鋼粉)、鉄粉に合金元素を部分拡散させて合金化した部分拡散合金化鋼粉、予合金化鋼粉にさらに合金元素を部分拡散させたハイブリッド鋼粉からなる群より選択される1または2以上を用いることができる。なお、ここで「鉄基粉末」とは、Fe含有量が50質量%以上である金属粉末を指す。また、「鉄粉」とは、Feおよび不可避不純物からなる粉末を指し、本技術分野においては一般的に「純鉄粉」と称される。
上記副原料としては、特に限定されることなく任意のものを用いることができる。前記副原料としては、合金用粉末および切削性改善材粉からなる群より選択される1または2以上を用いることが好ましい。前記合金用粉末としては、金属粉末を用いることが好ましい。前記金属粉末としては、例えば、Ni粉、Mo粉などの金属粉末からなる群より選択される1または2以上を用いることが好ましい。また、前記切削性改善材粉としては、例えば、MnSなどが挙げられる。原料粉末における前記副原料の比率は、10質量%以下とする。
前記原料粉末の表面は、バインダの少なくとも一部で被覆される。前記バインダとしては、原料粉末の表面に黒鉛粉、銅粉、およびカーボンブラックを付着させることができるものであれば、任意のものを用いることができる。前記バインダとしては、有機樹脂を用いることが好ましく、共重合ポリアミドおよびポリウレタンからなる群より選択される1または2以上の樹脂を用いることがより好ましい。
前記バインダの添加量が0.10質量%未満であると、原料粉末の表面をバインダで十分に被覆することができない。そのため、バインダの添加量を0.10質量%以上とする。一方、バインダの添加量が0.80質量%を超えると バインダが黒鉛粉の表面も被覆してしまい、流動性が低下する。そのため、バインダの添加量を0.80質量%以下とする。なお、ここでバインダの添加量は、原料粉末の質量(mr)と黒鉛粉の質量(mg)と銅粉の質量(mCu)とカーボンブラックの質量(mc)の合計に対するバインダの質量(mb)の比率[mb/(mr+mg+mCu+mc)×100]と定義する。
前記原料粉末の表面に被覆された前記バインダの表面は、黒鉛粉の少なくとも一部で被覆される。言い換えると、原料粉末の表面には、バインダを介して黒鉛粉が被覆される。バインダを介して鉄基粉末の表面を黒鉛粉で被覆することによって、鉄基粉末表面の潤滑性が向上する。また、黒鉛粉が介在することによって、鉄基粉末と金型との直接接触が回避されるため、金型表面に鉄基粉末が付着、堆積することがなく、その結果、型かじりが防止される。
一般的に粉末冶金で用いられる黒鉛粉の粒径は5~20μm程度である。しかし、黒鉛粉の平均粒径が5μm以上であると、黒鉛粉の粒子数が少なくなるため黒鉛粉を鉄基粉末の表面に十分に被覆することが難しい。本発明では、鉄基粉末を含む原料粉末の表面に黒鉛粉を十分に被覆するために、黒鉛粉の平均粒径を5μm未満とする。一方、黒鉛粉の平均粒径は小さければ小さいほどよいため、黒鉛粉の平均粒径の下限は特に限定されない。しかし、過度に粒径が小さくいと、粉砕に必要なエネルギーが増大し、経済的に不利になる。そのため、経済性の観点からは、黒鉛粉の平均粒径を100nm以上とすることが好ましい。
黒鉛の添加量が0.6質量%未満であると、鉄基粉末の最表面を黒鉛粉で十分に被覆することができない。そのため、黒鉛粉による被覆の効果を十分に得るためには、黒鉛粉の添加量を0.6質量%以上とする必要がある。一方、黒鉛粉は最終的に焼結時の浸炭に消費され、焼結体の強度などの特性を高めるが、黒鉛粉の添加量が1.0質量%を超えると、かえって焼結体の特性が低下する。そのため、黒鉛粉の添加量は1.0質量%以下とする。なお、ここで黒鉛粉の添加量は、原料粉末の質量(mr)と黒鉛粉の質量(mg)と銅粉の質量(mCu)とカーボンブラックの質量(mc)の合計に対する黒鉛粉の質量(mg)の比率[mg/(mr+mg+mCu+mc)×100]と定義する。
上記原料粉末の表面に被覆された前記バインダの表面は、さらに、銅粉の少なくとも一部で被覆される。言い換えると、原料粉末の表面には、バインダを介して銅粉が被覆される。銅粉を添加することにより、焼結体の機械的性質が向上する。また、銅粉をバインダ表面に付着させることにより、輸送中や充填、成形工程中における銅粉の偏析が抑制され、焼結後の寸法精度を安定させることができる。
銅粉の添加効果を得るために、銅粉の添加量を0.1質量%以上とする。一方、銅粉の添加量が3.0質量%を超えるとCu膨張が大きくなり寸法精度が安定しない。また、Cu膨張による密度低下のため、焼結体の強度および靭性が低下する。そのため、銅粉の添加量を3.0質量%以下とする。なお、ここで、銅粉の添加量は、原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記銅粉の質量(mCu)の比率[mCu/(mr+mg+mCu+mc)×100]と定義する。
上記原料粉末の表面に被覆された前記バインダの表面は、カーボンブラックの少なくとも一部で被覆される。言い換えると、原料粉末の表面には、バインダを介してカーボンブラックが被覆される。鉄基粉末の表面を黒鉛粉で被覆し、さらにカーボンブラックで被覆することによって、鉄基粉末表面に露出するバインダがさらに減少し、バインダとバインダとの直接接触が回避されるため、流動性が改善される。前記カーボンブラックとしては、特に限定されることなく任意のものを用いることができる。
カーボンブラックの添加量が少なすぎると、カーボンブラックによるバインダ表面の被覆率が不足し、流動性改善の効果が得られない。また、添加量が多すぎると成形時の抜出力(ejection force)が高くなることがある。そのため、カーボンブラックの添加量は、0.01~0.30質量%とする。ここで、カーボンブラックの添加量とは、原料粉末の質量(mr)と黒鉛粉の質量(mg)と銅粉の質量(mCu)とカーボンブラックの質量(mc)の合計に対するカーボンブラックの質量(mc)の比率[mc/(mr+mg+mCu+mc)×100]である。
次に、上記粉末冶金用粉末混合物の製造方法について説明する。本発明の一実施形態における製造方法は、第1混合工程、第2混合工程、および第3混合工程を含む。前記第1混合工程では、原料粉末、銅粉、およびバインダが、前記バインダの融点以上の温度で混合されて、第1の粉末混合物が得られる。前記第2混合工程では、前記第1の粉末混合物と平均粒径が5μm未満の黒鉛粉とが、前記バインダの融点以上の温度で混合されて、第2の粉末混合物が得られる。前記第3混合工程では、前記第2の粉末混合物とカーボンブラックとが、前記バインダの融点以下の温度で混合されて、粉末冶金用粉末混合物が得られる。
得られた粉末冶金用粉末混合物50gを、オリフィス径:2.5mmの容器に充填し、充填してから排出するまでの時間を測定して、流動度(単位:s/50g)を求めた。なお、その他の測定条件は、JIS Z 2502:2012に準拠した。流動度は、金型充填時の混合粉の流動性を示す指標であり、流動度の値が小さいほど混合粉の流動性が優れていることを意味する。なお、一部の比較例では粉末冶金用粉末混合物が流れず、オリフィスから排出されなかった。
下記(1)式で定義されるCu付着度を測定した。
Cu付着度[%]=A/B×100 ・・・(1)
A:75μm以上150μm以下に篩った粉末冶金用粉末混合物のCu量(質量%)
B:粉末冶金用粉末混合物のCu量(質量%)
前記AおよびBの値は、得られた粉末冶金用混合物をJIS G1258 ICP硫酸リン酸分解法に準拠した方法で溶解した後、ICP発光分光装置(島津製:ICPS-8100)を使用して測定した。測定は積分時間10秒の条件で行い、3回の測定で得られた値の平均値を使用した。
加圧成形では、上記粉末冶金用粉末混合物を、金型を用いて加圧成形し、径:11.3mm、高さ:11mmの成形体を得た。前記加圧成形における成形圧力は686MPaとした。前記成形体を金型から抜き出すときに必要な力(抜出力)と、得られた成形体の圧粉密度(成形体の平均)とを測定した。なお、一部の比較例では型かじりが発生して、成形体を金型から抜出すことができなかった。
・銅粉の添加量(*1):銅粉の質量/(鉄基粉末の質量+黒鉛粉の質量+Cu粉の質量+カーボンブラックの質量)×100(質量%)
・黒鉛粉の添加量(*2):黒鉛粉の質量/(鉄基粉末の質量+黒鉛粉の質量+Cu粉の質量+カーボンブラックの質量)×100(質量%)
・バインダの添加量(*3):バインダの質量/(鉄基粉末の質量+黒鉛粉の質量+Cu粉の質量+カーボンブラックの質量)×100(質量%)
・カーボンブラックの添加量(*4):カーボンブラックの質量/(鉄基粉末の質量+黒鉛粉の質量+Cu粉の質量+カーボンブラックの質量)×100(質量%)
Claims (6)
- 原料粉末、銅粉、バインダ、黒鉛粉、およびカーボンブラックを含む粉末冶金用粉末混合物であって、
前記原料粉末が、該原料粉末の90質量%以上の鉄基粉末を含有し、
前記黒鉛粉の平均粒径が5μm未満であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記バインダの質量(mb)の比率[mb/(mr+mg+mCu+mc)×100]が、0.10~0.80質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記黒鉛粉の質量(mg)の比率[mg/(mr+mg+mCu+mc)×100]が、0.6~1.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記銅粉の質量(mCu)の比率[mCu/(mr+mg+mCu+mc)×100]が、0.1~3.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記カーボンブラックの質量(mc)の比率[mc/(mr+mg+mCu+mc)×100]が、0.01~0.30質量%であり、
前記原料粉末の表面が、前記バインダの少なくとも一部で被覆されており、
前記バインダの表面が、前記黒鉛粉の少なくとも一部、前記銅粉の少なくとも一部、および前記カーボンブラックの少なくとも一部で被覆されている、粉末冶金用粉末混合物。 - 前記バインダが、共重合ポリアミドおよびポリウレタンからなる群より選択される1または2以上の樹脂である、請求項1に記載の粉末冶金用粉末混合物。
- 前記銅粉の平均粒径が10μm未満である、請求項1または2に記載の粉末冶金用粉末混合物。
- 原料粉末と銅粉とバインダとを、前記バインダの融点以上の温度で混合して、第1の粉末混合物とする第1混合工程と、
前記第1の粉末混合物と平均粒径が5μm未満の黒鉛粉とを、前記バインダの融点以上の温度で混合して第2の粉末混合物とする第2混合工程と、
前記第2の粉末混合物とカーボンブラックとを、前記バインダの融点以下の温度で混合して粉末冶金用粉末混合物とする第3混合工程とを有し、
前記原料粉末が、該原料粉末の90質量%以上の鉄基粉末を含有し、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記バインダの質量(mb)の比率[mb/(mr+mg+mCu+mc)×100]が、0.10~0.80質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記黒鉛粉の質量(mg)の比率[mg/(mr+mg+mCu+mc)×100]が、0.6~1.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記銅粉の質量(mCu)の比率[mCu/(mr+mg+mCu+mc)×100]が、0.1~3.0質量%であり、
前記原料粉末の質量(mr)と前記黒鉛粉の質量(mg)と前記銅粉の質量(mCu)と前記カーボンブラックの質量(mc)の合計に対する前記カーボンブラックの質量(mc)の比率[mc/(mr+mg+mCu+mc)×100]が、0.01~0.30質量%である、
粉末冶金用粉末混合物の製造方法。 - 前記バインダが、共重合ポリアミドおよびポリウレタンからなる群より選択される1または2以上の樹脂である、請求項4に記載の粉末冶金用粉末混合物の製造方法。
- 前記銅粉の平均粒径が10μm未満である、請求項4または5に記載の粉末冶金用粉末混合物の製造方法。
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KR20210003231A (ko) | 2021-01-11 |
CN112166001B (zh) | 2023-07-14 |
JPWO2019230259A1 (ja) | 2020-07-09 |
EP3804880A4 (en) | 2021-08-04 |
US20210197258A1 (en) | 2021-07-01 |
US11946119B2 (en) | 2024-04-02 |
CN112166001A (zh) | 2021-01-01 |
JP6760504B2 (ja) | 2020-09-23 |
EP3804880A1 (en) | 2021-04-14 |
KR102364527B1 (ko) | 2022-02-17 |
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