WO2020071224A1 - 金属管の製造方法及び洗浄方法 - Google Patents
金属管の製造方法及び洗浄方法Info
- Publication number
- WO2020071224A1 WO2020071224A1 PCT/JP2019/037792 JP2019037792W WO2020071224A1 WO 2020071224 A1 WO2020071224 A1 WO 2020071224A1 JP 2019037792 W JP2019037792 W JP 2019037792W WO 2020071224 A1 WO2020071224 A1 WO 2020071224A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- cleaning
- ultrasonic
- metal tube
- tank
- liquid
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C43/00—Devices for cleaning metal products combined with or specially adapted for use with machines or apparatus provided for in this subclass
- B21C43/02—Devices for cleaning metal products combined with or specially adapted for use with machines or apparatus provided for in this subclass combined with or specially adapted for use in connection with drawing or winding machines or apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/04—Cleaning involving contact with liquid
- B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
- B08B3/12—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B9/00—Cleaning hollow articles by methods or apparatus specially adapted thereto
- B08B9/02—Cleaning pipes or tubes or systems of pipes or tubes
- B08B9/023—Cleaning the external surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B9/00—Cleaning hollow articles by methods or apparatus specially adapted thereto
- B08B9/02—Cleaning pipes or tubes or systems of pipes or tubes
- B08B9/027—Cleaning the internal surfaces; Removal of blockages
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/82—After-treatment
- C23C22/83—Chemical after-treatment
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
- C23G1/14—Cleaning or pickling metallic material with solutions or molten salts with alkaline solutions
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G3/00—Apparatus for cleaning or pickling metallic material
- C23G3/04—Apparatus for cleaning or pickling metallic material for cleaning pipes
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G5/00—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B2209/00—Details of machines or methods for cleaning hollow articles
- B08B2209/005—Use of ultrasonics or cavitation, e.g. as primary or secondary action
Definitions
- the present disclosure relates to a method for manufacturing and cleaning a metal tube.
- the present disclosure particularly relates to a method for cleaning a metal tube formed by performing cold drawing on a tube on which a chemical conversion film and a lubricating film are formed.
- a chemical conversion film such as a phosphate film, an oxalate film, or a chromate film is formed on the surface of the tube.
- a lubricating film is formed on the chemical conversion film with a higher fatty acid salt (soap) or the like.
- the chemical conversion coating prevents direct contact between the base tube and the drawing tool to improve seizure resistance, and also enhances the adhesion between the base tube and the lubricating film to improve lubricity.
- Patent Document 1 discloses a method of pickling a metal tube by irradiating an ultrasonic wave to an end of the metal tube while rubbing a plurality of metal tubes in an acid solution.
- scales are removed by a friction reducing action by rubbing and a dissolving action by an acid solution in portions of the metal tube that are rubbed with each other.
- the scale is removed by the ultrasonic wave promoting the dissolving action of the acid solution.
- Patent Document 2 discloses a method of descaling a hot-rolled steel sheet using both ultrasonic waves and microbubbles. According to Patent Literature 2, by supplying the microbubbles to the portion of the hot-rolled steel sheet to which the ultrasonic wave is applied, cavitation is reliably generated and the descaling effect can be reliably obtained.
- Patent Document 3 discloses a cleaning device using both ultrasonic waves and microbubbles.
- the cleaning liquid in the cleaning tank is irradiated with ultrasonic waves from an ultrasonic generator.
- a circulation path is connected to the cleaning tank.
- the cleaning liquid in the cleaning tank is introduced into the deaerator through the circulation path.
- the deaerator separates dissolved air from the cleaning liquid to generate microbubbles.
- the microbubbles are supplied to the cleaning tank via the circulation path, and reduce the dissolved air concentration of the cleaning liquid.
- Patent Literature 3 by setting the dissolved air concentration of the cleaning liquid to a specified value or less, the sound pressure of ultrasonic waves does not decrease, and efficient and good cleaning can be performed.
- metal pipes after cold drawing have been subjected to degreasing and pickling. That is, first, the lubricating film is removed from the metal tube by the degreasing treatment, and then the chemical conversion film is removed from the metal tube by the pickling treatment.
- a metal tube is subjected to a degreasing treatment with a high-temperature alkaline degreasing solution at a temperature of 70 ° C. or higher, and then is subjected to an acid washing treatment.
- the metal soap component in the lubricating film forms a complex, and the other soap components dissolve.
- the present disclosure has an object to realize both energy saving (low cost) and good cleaning performance in cleaning a metal pipe having a chemical conversion film and a lubricating film formed on the surface.
- the method for manufacturing a metal tube according to the present disclosure includes a preparation step of preparing a metal tube, a lubrication step of forming a chemical conversion film on the surface of the tube, and forming a lubricating film on the chemical conversion film, A cold drawing process of applying a cold drawing process to the raw tube on which the lubricating film is formed to form a metal tube of a predetermined size, and a cleaning process of cleaning the metal tube to remove the chemical conversion film and the lubricating film, Is provided.
- the cleaning step is a step of immersing the metal tube in an alkali degreasing solution that is not heated at a high temperature in an alkaline cleaning tank, and irradiating ultrasonic waves into the cleaning liquid in the ultrasonic cleaning tank and generating fine bubbles in the cleaning liquid. Immersing the metal tube after immersion in the alkaline degreasing solution in the cleaning solution.
- FIG. 1 is a flowchart of the method for manufacturing a metal tube according to the embodiment.
- FIG. 2 is a side view of the alkali cleaning apparatus used in the alkali cleaning step in the manufacturing method according to the embodiment.
- FIG. 3 is a sectional view taken along the line III-III of the alkaline cleaning apparatus shown in FIG.
- FIG. 4 is a plan view of an ultrasonic cleaning device used in an ultrasonic cleaning step in the manufacturing method according to the embodiment.
- FIG. 5 is a sectional view taken along line VV of the ultrasonic cleaning apparatus shown in FIG.
- FIG. 6 is a diagram illustrating a discharge mechanism that can be employed in the ultrasonic cleaning apparatus shown in FIG. FIG.
- FIG. 7 is a diagram illustrating another discharge mechanism that can be employed in the ultrasonic cleaning apparatus shown in FIG.
- FIG. 8A is a diagram schematically illustrating the surface of a metal tube after cold drawing.
- FIG. 8B is a diagram schematically illustrating the surface of the metal tube after the alkali cleaning step.
- FIG. 8C is a diagram schematically illustrating the surface of the metal tube during the ultrasonic cleaning step.
- FIG. 9 is a graph showing a change in the amount of carbon adhering to the inner surface of the metal tube in Example, Comparative Example 1, and Comparative Example 2.
- FIG. 10 is a scanning electron microscope image of the inner surface of each metal tube cleaned by the cleaning method of Example and Comparative Example 1.
- the method of manufacturing a metal tube according to the embodiment includes a preparation step of preparing a metal pipe, a lubrication step of forming a chemical conversion film on the surface of the pipe, and forming a lubricating film on the chemical conversion film; A cold drawing process of applying a cold drawing process to the raw tube on which the lubricating film is formed to form a metal tube of a predetermined size, and a cleaning process of cleaning the metal tube to remove the chemical conversion film and the lubricating film, Is provided.
- the cleaning step is a step of immersing the metal tube in an alkali degreasing solution that is not heated at a high temperature in an alkaline cleaning tank, and irradiating ultrasonic waves into the cleaning liquid in the ultrasonic cleaning tank and generating fine bubbles in the cleaning liquid. Immersing the metal tube after immersion in the alkaline degreasing solution in the cleaning solution.
- the raw tube is formed into a metal tube of a predetermined size by cold drawing. I do.
- the metal tube obtained by the cold drawing is washed (alkali degreasing) by the following method. That is, the metal tube is first immersed in an alkali degreasing solution that has not been heated to a high temperature.
- the alkali degreasing solution that is not heated at a high temperature in the present disclosure is typically an alkali degreasing solution that does not perform an active heating process using a heater (for example, a steam heater or an electric heater) on the alkali degreasing solution.
- a heater for example, a steam heater or an electric heater
- the temperature of the alkali degreasing solution is lower than 20 ° C., the alkali degreasing solution is heated so that the temperature becomes about 20 to 40 ° C.
- the temperature of the alkaline degreasing solution may drop to less than 20 ° C.
- aggressive heat treatment is performed so that the liquid temperature becomes about 20 to 40 ° C.
- energy for heating the alkaline degreasing solution is used.
- the energy consumption can be reduced.
- the temperature of the alkaline degreaser may be affected by the heat of reaction during the cleaning process or by circulating the alkaline degreaser in the cleaning device, and the alkaline degreaser is heated by these effects. This is not included in the positive heat treatment described above.
- the manufacturing method according to the embodiment it is not necessary to heat the alkali degreasing solution to a high temperature of 70 ° C. or higher when removing each film from the metal tube as in the related art. Therefore, both energy saving (low cost) and good cleanability can be realized.
- the dissolved oxygen concentration of the cleaning liquid is preferably 5.2 mg / L or less.
- the method for cleaning a metal tube is a method for cleaning a metal tube formed by performing cold drawing on a raw tube having a chemical conversion film and a lubricating film formed on the surface.
- the cleaning method includes a step of immersing the metal tube in an alkali degreasing solution that is not heated at a high temperature in an alkaline cleaning tank, and irradiating ultrasonic waves into the cleaning liquid in the ultrasonic cleaning tank and generating fine bubbles in the cleaning liquid. While immersing the metal tube in the cleaning liquid after immersion in the alkaline degreasing liquid.
- the concentration of dissolved oxygen in the cleaning liquid is preferably 5.2 mg / L or less.
- FIG. 1 is a flowchart of the method for manufacturing a metal tube according to the present embodiment.
- the method for manufacturing a metal tube includes a preparation step S1, a lubrication step S2, a cold drawing step S3, and a cleaning step S4.
- the lubrication step S2 includes a chemical conversion film formation step S21 and a lubrication film formation step S22.
- the cleaning step S4 is an alkaline degreasing step of the metal tube on which the chemical conversion film and the lubricating film are formed, and includes an alkali cleaning step S41 and an ultrasonic cleaning step S42.
- the alkali cleaning device used in the alkali cleaning step S41 and the ultrasonic cleaning device used in the ultrasonic cleaning step S42 will be described.
- FIG. 2 is a side view schematically showing the alkaline cleaning apparatus 10 used in the alkaline cleaning step S41.
- FIG. 3 is a sectional view taken along the line III-III of the alkaline cleaning apparatus 10 shown in FIG.
- the alkaline cleaning device 10 includes an alkaline cleaning tank 11, a storage tank 12, and a circulation pipe 13.
- the alkaline cleaning tank 11 has a tank body 111 and a lid 112.
- the tank main body 111 has an opening on its upper surface.
- the lid 112 is configured to cover the opening of the tank body 111.
- the tank main body 111 is configured to be able to accommodate the metal pipe P. In alkali cleaning, a plurality of metal tubes P are usually accommodated in the tank body 111 at the same time.
- An alkali degreasing liquid is supplied to the tank body 111.
- the alkali degreasing solution is a known alkali solution used in a general alkali degreasing treatment, and includes, for example, an aqueous solution of sodium hydroxide (NaOH), an aqueous solution of sodium silicate (Na 2 SiO 3 ), and sodium carbonate (Na 2 CO 3). A) aqueous solution and the like. Additives such as a surfactant and a chelating agent can be appropriately added to the alkali degreasing solution.
- the tank main body 111 has, for example, a rectangular shape in plan view.
- the tank main body 111 has a bottom surface 111a and a peripheral wall 111b extending upward from the periphery of the bottom surface 111a.
- the bottom surface 111a is an inclined surface that descends from one end 111c side in the longitudinal direction of the tank body 111 toward the other end 111d.
- the depth of the tank body 111 increases from the end 111c to the end 111d.
- a plurality of support members 113 may be provided in the tank main body 111.
- the plurality of support members 113 are arranged at intervals along the longitudinal direction of the tank main body 111.
- the support member 113 supports the metal tube P so that the metal tube P does not directly contact the bottom surface 111a.
- Each support member 113 is formed, for example, in a substantially U-shape.
- the storage tank 12 is arranged below the alkaline cleaning tank 11.
- the storage tank 12 is formed, for example, in a hollow rectangular parallelepiped shape.
- the storage tank 12 stores an alkaline degreasing liquid.
- the storage tank 12 communicates with the tank body 111 via the circulation pipe 13.
- the storage tank 12 communicates with the tank body 111 through the communication port 14.
- the communication port 14 is configured to be openable and closable.
- the circulation pipe 13 connects the tank body 111 and the storage tank 12 in the vicinity of the end 111c of the tank body 111 of the alkaline washing tank 11.
- the circulation pipe 13 is configured so that the alkaline degreasing solution in the storage tank 12 can be supplied to the tank body 111.
- the circulation pipe 13 is provided with a pump 131 (FIG. 3) for sending the alkaline degreasing liquid from the storage tank 12 to the tank main body 111.
- FIG. 4 is a plan view of the ultrasonic cleaning device 20 used in the ultrasonic cleaning step S42.
- FIG. 5 is a sectional view taken along line VV of the ultrasonic cleaning apparatus 20 shown in FIG.
- the ultrasonic cleaning device 20 includes an ultrasonic cleaning tank 21, a supply mechanism 22, a plurality of discharge mechanisms 23, a plurality of ultrasonic irradiation mechanisms 24, and a plurality of fine bubble generation mechanisms 25. , Is provided.
- the ultrasonic cleaning device 20 further includes a plurality of buffer members 26.
- the ultrasonic cleaning tank 21 is configured to accommodate the metal pipe P.
- a cleaning liquid for cleaning the metal pipe P is stored.
- the type of the cleaning liquid is not particularly limited, and may be appropriately selected from known cleaning liquids.
- the cleaning liquid is, for example, water (tap water, industrial water).
- the ultrasonic cleaning tank 21 has, for example, a rectangular shape in plan view.
- the upper surface of the ultrasonic cleaning tank 21 is open.
- the bottom surface of the ultrasonic cleaning tank 21 is an inclined surface that descends from one end in the longitudinal direction toward the other end.
- the depth of the ultrasonic cleaning tank 21 increases from one end in the longitudinal direction toward the other end.
- the material of the ultrasonic cleaning tank 21 is not particularly limited.
- Examples of the material of the ultrasonic cleaning tank 21 include a metal material such as stainless steel, a plastic resin such as fiber reinforced plastic (FRP) and polypropylene (PP), and an acid-resistant brick.
- the above-described alkali cleaning tank 11 and storage tank 12 (FIG. 2) can also be formed of the same material as the ultrasonic cleaning tank 21.
- the supply mechanism 22 supplies the cleaning liquid to the ultrasonic cleaning tank 21.
- the supply mechanism 22 has at least one supply pipe 221.
- the supply mechanism 22 has a plurality of supply pipes 221.
- the cleaning liquid is supplied to the ultrasonic cleaning tank 21 via each supply pipe 221.
- the plurality of supply pipes 221 are arranged at intervals. Therefore, the cleaning liquid is dispersed and supplied to the ultrasonic cleaning tank 21.
- the intervals between the supply pipes 221 be substantially uniform from the viewpoint of uniformly supplying a new cleaning liquid.
- the supply pipes 221 are provided along one of the pair of longitudinal side walls of the ultrasonic cleaning tank 21.
- the position and number of the supply pipes 221 are not particularly limited.
- One or more supply pipes 221 may be provided on both side walls in the longitudinal direction of the ultrasonic cleaning tank 21.
- one or more supply pipes 221 may be provided on the short side wall of the ultrasonic cleaning tank 21 in addition to or instead of the longitudinal side wall of the ultrasonic cleaning tank 21.
- Each discharge mechanism 23 discharges the cleaning liquid from the ultrasonic cleaning tank 21 when the amount of the cleaning liquid in the ultrasonic cleaning tank 21 exceeds a predetermined amount.
- the plurality of discharge mechanisms 23 are arranged at intervals. Therefore, the cleaning liquid is dispersed and discharged from the ultrasonic cleaning tank 21.
- the intervals between the discharge mechanisms 23 are substantially equal. Note that the number of discharge mechanisms 23 may be one.
- the plurality of discharge mechanisms 23 are provided along a side wall opposite to the supply pipe 221 among a pair of longitudinal side walls of the ultrasonic cleaning tank 21.
- the position and the number of the discharge mechanisms 23 are not particularly limited.
- the discharge mechanism 23 may be provided on the side wall on the supply pipe 221 side.
- one or more discharge mechanisms 23 may be provided on the lateral side wall of the ultrasonic cleaning tank 21.
- FIG. 6 illustrates a discharge mechanism 23A that can be employed in the ultrasonic cleaning device 20.
- the discharge mechanism 23A includes a discharge port 231 and a discharge pipe 232.
- the discharge port 231 is an opening formed on the side wall of the ultrasonic cleaning tank 21.
- the discharge pipe 232 is provided outside the ultrasonic cleaning tank 21 and is connected to the discharge port 231.
- the cleaning liquid is discharged from the ultrasonic cleaning tank 21 through the discharge port 231 and the discharge pipe 232.
- the reference liquid level S of the cleaning liquid in the ultrasonic cleaning tank 21 is set.
- the cleaning liquid is supplied to the ultrasonic cleaning tank 21 until the liquid level reaches the reference liquid level S.
- the position of the lower end of the discharge port 231 in the depth direction of the ultrasonic cleaning tank 21 substantially coincides with the position of the reference liquid level S.
- the discharge mechanism 23A discharges the cleaning liquid from the ultrasonic cleaning tank 21 when the amount of the cleaning liquid in the ultrasonic cleaning tank 21 exceeds the liquid amount (predetermined amount) corresponding to the reference liquid level S. .
- FIG. 7 illustrates another discharge mechanism 23 ⁇ / b> B that can be employed in the ultrasonic cleaning device 20.
- the discharge mechanism 23B includes a discharge port 233, a discharge pipe 234, a discharge pump 235, and a liquid level detecting unit (not shown).
- a liquid level detecting unit a commercially available liquid level sensor or the like can be used.
- the discharge port 233 is an opening formed on the side wall of the ultrasonic cleaning tank 21.
- the discharge port 233 is provided at an arbitrary height lower than the reference liquid level S on the side wall of the ultrasonic cleaning tank 21.
- the discharge pipe 234 is provided outside the ultrasonic cleaning tank 21 and is connected to the discharge port 233. The cleaning liquid is discharged from the ultrasonic cleaning tank 21 through the discharge port 233 and the discharge pipe 234.
- the discharge pump 235 is provided in the middle of the discharge pipe 234.
- the discharge pump 235 sucks the cleaning liquid exceeding the reference liquid level S from the ultrasonic cleaning tank 21. Is controlled as follows. For example, when the liquid level of the cleaning liquid exceeds the reference liquid level S, the discharge pump 235 is driven in accordance with a signal from the liquid level detecting means disposed in the ultrasonic cleaning tank 21 to increase the level of the cleaning liquid.
- the control of the discharge pump 235 is stopped.
- the discharge mechanism 23B similarly to the discharge mechanism 23A (FIG. 6), the discharge mechanism 23B also discharges the cleaning liquid from the ultrasonic cleaning tank 21 when the amount of the cleaning liquid in the ultrasonic cleaning tank 21 exceeds a predetermined amount.
- the ultrasonic irradiation mechanism 24 irradiates the cleaning liquid in the ultrasonic cleaning tank 21 with ultrasonic waves.
- the ultrasonic irradiation mechanism 24 a known ultrasonic transducer generally used in ultrasonic cleaning can be used.
- the frequency of the ultrasonic wave emitted by the ultrasonic wave irradiation mechanism 24 is preferably 20 kHz to 200 kHz.
- the frequency of the ultrasonic wave is more preferably from 20 kHz to 150 kHz, and still more preferably from 25 kHz to 100 kHz.
- the ultrasonic irradiation mechanism 24 preferably has a frequency sweep function.
- the frequency sweeping function is a function of irradiating the cleaning liquid with ultrasonic waves while sweeping the frequency in a range of ⁇ 0.1 kHz to ⁇ 10 kHz around a selected specific frequency.
- the frequency resonance diameter described later fluctuates, and microbubbles contributing to cavitation cleaning can be increased.
- the ultrasonic wave transmits through the irradiation object.
- the frequency of the ultrasonic wave By changing the frequency of the ultrasonic wave by the frequency sweep function, it is possible to satisfy the condition that the wavelength of the ultrasonic wave is 1 / of the wavelength corresponding to the thickness of the metal tube P at various positions of the metal tube P. it can. For this reason, at various positions of the metal tube P, the ultrasonic waves can be transmitted from the outside to the inside of the metal tube P.
- At least one ultrasonic irradiation mechanism 24 is provided on the inner surface of each side wall of the ultrasonic cleaning tank 21.
- the position and number of the ultrasonic irradiation mechanism 24 are not particularly limited.
- One or more ultrasonic irradiation mechanisms 24 may be installed on the bottom surface of the ultrasonic cleaning tank 21.
- the fine bubble generating mechanism 25 generates fine bubbles by converting dissolved gas in the cleaning liquid in the ultrasonic cleaning tank 21 into bubbles.
- the fine bubble generation mechanism 25 is disposed outside the ultrasonic cleaning tank 21.
- a plurality of fine bubble generating mechanisms 25 are arranged along one longitudinal side wall of the ultrasonic cleaning tank 21.
- the position and number of the fine bubble generating mechanism 25 are not particularly limited.
- Each fine bubble generation mechanism 25 has pipings 251 and 252 and a fine bubble generation device 253.
- the pipes 251 and 252 connect the ultrasonic cleaning tank 21 and the fine bubble generator 253.
- the cleaning liquid from the ultrasonic cleaning tank 21 is introduced into the fine bubble generator 253 via the pipe 251.
- the fine bubble generator 253 generates fine bubbles by using dissolved gas in the cleaning liquid.
- the fine bubbles are returned to the ultrasonic cleaning tank 21 via the pipe 252 together with the cleaning liquid.
- the fine bubble generator 253 can be appropriately selected from known fine bubble generators.
- a known fine bubble generator for example, fine bubbles are generated by shearing bubbles, passing bubbles through micropores, depressurizing liquid (pressure change), dissolving gas under pressure, ultrasonic waves, electrolysis, or chemical reaction. What causes them to be known. It is preferable that the fine bubble generation device 253 is such that the bubble diameter and the concentration of the fine bubbles can be easily controlled.
- a known fine bubble generator that generates fine bubbles by causing a change in the pressure of the liquid in the liquid circulation path can be employed.
- the fine bubbles are fine bubbles having an average bubble diameter of 100 ⁇ m or less.
- fine bubbles having an average cell diameter of ⁇ m are sometimes referred to as microbubbles
- fine bubbles having an average cell diameter of nm are sometimes referred to as nanobubbles.
- the average bubble diameter is the diameter at which the number of samples is the largest in the number distribution related to the diameter of the fine bubbles.
- the average bubble diameter of the fine bubbles in the cleaning liquid is preferably 0.01 ⁇ m or more from the viewpoint of preventing the fine bubble generation mechanism 25 from being enlarged and facilitating the control of the bubble diameter.
- the average bubble diameter of the fine bubbles is preferably 100 ⁇ m or less from the viewpoint of increasing the floating speed of the fine bubbles and preventing the propagation of the ultrasonic wave to the metal tube P. More preferably, the fine bubbles are microbubbles having an average bubble diameter of 1 ⁇ m to 50 ⁇ m.
- the fine bubble generating mechanism 25 preferably generates fine bubbles in the cleaning liquid such that the ratio of the number of fine bubbles having a bubble diameter equal to or less than the frequency resonance diameter to the total number of fine bubbles is 70% or more. Considering the presence of bubbles that expand immediately after the generation of fine bubbles, the above ratio is more preferably 80% or more and 98% or less. Thereby, the propagation efficiency of the ultrasonic wave in the cleaning liquid can be improved.
- the concentration of fine bubbles in the cleaning liquid improves the propagation of ultrasonic waves, from the viewpoint of ensuring the number of nuclei of ultrasonic cavitation is preferably 10 3 cells / mL or more.
- the concentration of fine bubbles to be generated in the cleaning liquid, in order to prevent the size and number increase of the fine-bubble generating mechanism 25 is preferably 10 6 cells / mL or less.
- the average bubble diameter and concentration of fine bubbles can be measured by a known device such as a liquid particle counter or a bubble diameter distribution measuring device.
- the buffer member 26 is arranged in the ultrasonic cleaning tank 21.
- the plurality of buffer members 26 are arranged in the longitudinal direction of the ultrasonic cleaning tank 21.
- the buffer member 26 has a substantially U-shape.
- the metal pipe P in the ultrasonic cleaning tank 21 is placed on the buffer member 26.
- the inner surface of the buffer member 26 is located inside the ultrasonic irradiation tank 24 in the ultrasonic cleaning tank 21. Therefore, the metal tube P does not come into contact with the ultrasonic irradiation mechanism 24, and the ultrasonic irradiation mechanism 24 is protected from the metal tube P.
- the alkali cleaning device 10 (FIG. 2) and the ultrasonic cleaning device 20 (FIG. 4) are used for cleaning the metal tube P in manufacturing the metal tube P.
- a method for manufacturing the metal tube P will be described. Referring to FIG. 1 again, the method for manufacturing the metal pipe P includes a preparation step S1, a lubrication step S2, a cold drawing step S3, and a cleaning step S4.
- preparation process In the preparation step S1, a raw tube manufactured by hot working is prepared. One end of the raw tube is subjected to a mouth drawing process for a cold drawing step S3 described later. That is, a process such as tapping or drawing is applied to one end of the raw tube so as to be thinner than other portions.
- the raw tube prepared in the preparing step S1 is, for example, a raw tube made of stainless steel or a raw tube made of a Ni-based alloy.
- the raw pipe made of stainless steel is a steel pipe containing 10.5% or more of Cr.
- the raw pipe it is preferable that it has the following chemical composition. In mass%, C: 0.01 to 0.13%, Si: 0.75% or less, Mn: 2% or less, P: 0.045% or less, S: 0.030% or less, Ni: 7 to 14 % And Cr: 16 to 20%, with the main balance being Fe (typically, the balance is Fe and impurities).
- the chemical composition is such that Nb: 0.2 to 1.1%, Ti: 0.1 to 0.6%, Mo: 0.1 to 3%, Cu: 2.5 to 3.5%, any one or more of them may be contained. Further, instead of part of the remaining Fe, B may contain 0.001 to 0.1% by mass and N may contain 0.02 to 0.12% by mass%.
- the pipe made of a Ni-based alloy is a pipe made of an alloy having the highest Ni content in each component in the alloy.
- the raw pipe is a Ni-based alloy pipe, for example, it has the following chemical composition. In mass%, C: 0.05% or less, Si: 0.5% or less, Mn: 1% or less, P: 0.030% or less, S: 0.030% or less, Cr: 19.5 to 24. 0%, Mo: 2.5 to 4.0%, Ti: 1.2% or less, and Fe: 22% or more, and the main balance is Ni (typically, the balance is Ni and impurities Is).
- the chemical composition contains one or more of Cu: 0.5% or less, Nb: 4.5% or less, and Al: 2.0% or less by mass% instead of a part of the remaining Ni. Is also good.
- the lubrication step S2 is performed after the preparation step S1 and before the cold drawing step S3.
- the lubrication step S2 includes a chemical conversion film formation step S21 and a lubrication film formation step S22.
- a chemical conversion film is formed on the surface of the raw tube.
- the scale generated during hot working or the like is removed from the tube by a known pickling process, and then the tube is immersed in a chemical conversion solution for a predetermined time. Thereby, a chemical conversion film is formed on the surface of the raw tube.
- the chemical conversion treatment liquid used in the chemical conversion film forming step S21 is not particularly limited, but is, for example, an oxalate treatment liquid.
- an oxalate film mainly composed of iron (II) oxalate is formed on the surface of the raw tube.
- the element tube is subjected to water washing and neutralization, and the lubricating film forming step S22 is performed.
- a lubricating film is formed on the chemical conversion film formed on the base tube in the chemical conversion film forming step S21.
- the tube on which the chemical conversion film is formed is immersed in the lubricating solution for a predetermined time. Thereafter, the tube is taken out of the lubricating solution and dried sufficiently. Thereby, a lubricating film is formed on the chemical conversion film.
- the lubricating solution reacts with the chemical conversion film to form a metal soap. That is, the lubricating film includes a metal soap layer on the chemical conversion film and a soap layer on the metal soap layer.
- the chemical conversion film is an oxalate film and the lubricating treatment liquid is sodium stearate
- the main component of the metal soap layer is iron stearate and the main component of the soap layer is sodium stearate.
- a cold drawing process S3 After forming a chemical conversion film and a lubricating film on the base tube by the lubrication process S2, a cold drawing process S3 is performed.
- the raw tube is formed into a metal tube having a predetermined size by performing a known cold drawing process on the raw tube. For example, the end of the raw tube subjected to the mouth drawing process is passed through a die (not shown) and gripped by a gripper (not shown), and the gripper is moved to pull out the raw tube from the die. Thereby, the outer diameter of the raw tube is finished to a predetermined outer diameter.
- pulling is performed with the mandrel inserted into the raw tube.
- the metal tube having a predetermined size obtained through the cold drawing step S3 is washed in a washing step S4 to remove the chemical conversion film and the lubricating film.
- the cleaning step S4 includes an alkali cleaning step S41 and an ultrasonic cleaning step S42.
- the alkali cleaning step S ⁇ b> 41 is a step of dipping the metal pipe P in the alkali cleaning device 11 in the alkaline cleaning tank 11 in the alkali cleaning apparatus 10.
- the metal pipe P is disposed in the tank main body 111.
- a plurality of metal pipes P are arranged in the tank main body 111, but one metal pipe P may be arranged in the tank main body 111.
- the metal pipe P is arranged in the alkaline cleaning tank 11 by a crane or the like.
- the metal tube P is placed on the support member 113. Thereby, a gap is generated between the metal pipe P and the bottom surface 111a of the tank main body 111.
- the alkali degreasing liquid has not been supplied to the tank main body 111.
- the upper surface of the tank main body 111 is covered with the lid 112.
- the alkaline degreasing solution in the storage tank 12 is supplied to the alkaline cleaning tank 11 through the circulation pipe 13.
- the alkaline degreasing solution in the storage tank 12 is sent to the upper alkaline washing tank 11 by driving the pump 131.
- the alkaline degreaser flows into the tank body 111 from the end 111c side and flows to the end 111d side.
- the alkali degreasing solution passes through the inside of the metal tube P, between the metal tube P and the bottom surface 111a, between the metal tube P and the peripheral wall 111b, and the like.
- the communication port 14 near the downstream end 111d is in a closed state. Therefore, the alkaline degreasing liquid is stored in the tank main body 111.
- an alkali degreasing solution not heated at a high temperature is stored. For this reason, an alkaline degreasing solution that is not heated to a high temperature is supplied to the tank body 111.
- the alkali degreasing solution that is not heated to a high temperature is typically subjected to an aggressive heat treatment using a heater (for example, a steam heater or an electric heater) on the alkali degreasing solution as described above. Refers to an alkaline degreasing solution having a temperature corresponding to the ambient temperature of the alkaline cleaning device 10.
- the temperature of the alkaline degreasing solution is set to approximately 20 ° C. to 40 ° C.
- the alkaline degreasing solution can be heated.
- the temperature of the alkali degreasing solution is usually 20 ° C. or higher due to the heat generated by the pump 131 that sends the alkali degreasing solution from the storage tank 12 to the alkali cleaning tank 11.
- the temperature of the alkaline degreasing solution may exceed 40 ° C.
- the tank body 111 (the alkali cleaning tank 11) is typically supplied with an alkali degreasing liquid at a temperature corresponding to the ambient temperature of the alkali cleaning apparatus 10 (that is, an alkali degreasing liquid that has not been subjected to heat treatment). And stored. However, when the temperature of the alkaline degreasing solution falls below 20 ° C., the alkaline degreasing solution heated to 40 ° C. or lower is supplied to the tank body 111 (alkali cleaning tank 11) and stored.
- the supply of the alkali degreasing liquid to the tank body 111 is stopped.
- the metal pipe P is held for a predetermined time in an alkali degreasing solution that is not heated at a high temperature and is filled in the alkali cleaning tank 11.
- the time for holding the metal tube P may be appropriately determined, and is, for example, 1 to 5 minutes.
- the communication port 14 is opened, and the alkaline degreaser is discharged from the tank body 111 to the storage tank 12.
- the alkaline degreasing liquid flows from the end 111c side toward the end 111d side.
- the alkaline degreasing liquid passes through and around the metal pipe P. All the alkaline degreasing solution in the tank body 111 is collected in the storage tank 12.
- the supply of the alkaline degreasing solution from the storage tank 12 to the alkaline cleaning tank 11, the holding of the metal pipe P in the alkaline degreasing liquid, and the discharge of the alkaline degreasing liquid from the alkaline cleaning tank 11 to the storage tank 12 are defined as one cycle.
- the cycle is performed a predetermined number of times. Although the cleaning performance is improved as the number of times the cycle is performed increases, it is preferable to determine the number of times of performance in consideration of the balance between the cleaning performance and the operability.
- the number of times the cycle is performed can be, for example, 2 to 5 times.
- the required time per cycle depends on the capacity of the alkaline cleaning tank 11 and the like, but can be, for example, about 5 to 15 minutes.
- the lid 112 is removed from the tank body 111, and the metal pipe P is pulled up from the tank body 111 using a crane or the like. Thereby, the alkali cleaning step S41 ends.
- the alkaline cleaning step S41 it is preferable to generate a flow of the alkaline degreasing solution in the alkaline cleaning tank 11.
- the alkali cleaning of the metal tube P can be performed by the physical action of the flow of the alkali degreasing solution.
- a flow of the alkali degreasing solution is generated in the alkali cleaning tank 11 during the supply and discharge of the alkali degreasing solution.
- the flow of the alkali degreasing solution is temporarily stopped when the alkali degreasing solution is filled in the alkali cleaning bath 11, but the alkali degreasing solution may be continuously flown in the alkali cleaning bath 11.
- the alkali cleaning step S41 can be performed without causing the flow of the alkaline degreasing liquid in the alkali cleaning tank 11 and keeping the alkali degreasing liquid stationary at all times.
- an ultrasonic cleaning step S42 is performed.
- the ultrasonic cleaning step S42 is a step of immersing the metal pipe P immersed in the alkaline degreaser in the cleaning liquid to which ultrasonic waves and fine bubbles have been applied.
- an ultrasonic cleaning apparatus 20 FIG. 4 that is different from the alkaline cleaning apparatus 10 (FIG. 2) used in the alkali cleaning step S41 is used. That is, after the alkali cleaning step S41 is completed, the metal tube P is carried from the alkali cleaning device 10 to the ultrasonic cleaning device 20.
- the metal pipe P after the alkali cleaning step S41 may be washed with water before the ultrasonic cleaning step S42. Thereby, the alkaline degreasing liquid adhering to the metal pipe P can be washed away.
- the cleaning liquid is stored in the ultrasonic cleaning tank 21 prior to the ultrasonic cleaning of the metal pipe P.
- the cleaning liquid is supplied to the ultrasonic cleaning tank 21 by the supply mechanism 22.
- the cleaning liquid may be supplied to the ultrasonic cleaning tank 21 by means other than the supply mechanism 22.
- the cleaning liquid supplied to the ultrasonic cleaning tank 21 preferably has a dissolved oxygen concentration of about 7 mg / L to 11 mg / L.
- the cleaning liquid is typically water (tap water or industrial water).
- the dissolved oxygen concentration of the washing liquid is 7 mg / L to 11 mg / L. More preferably, the cleaning liquid supplied to the ultrasonic cleaning tank 21 has a dissolved oxygen concentration of about 8 mg / L to 10 mg / L.
- the cleaning liquid is water having a water temperature of 15 to 25 ° C. (tap water or industrial water)
- the dissolved oxygen concentration of the cleaning liquid is 8 mg / L to 10 mg / L.
- the dissolved oxygen concentration is an index of the amount of dissolved gas in the cleaning liquid.
- the metal pipe P transported from the alkali cleaning device 10 (FIGS. 2 and 3) to the ultrasonic cleaning device 20 is immersed in the cleaning liquid stored in the ultrasonic cleaning tank 21 for a predetermined time.
- the metal pipe P can be immersed in the cleaning liquid in the ultrasonic cleaning tank 21 using a crane or the like.
- a plurality of metal tubes P are immersed in the cleaning solution at the same time, but the metal tubes P may be immersed one by one in the cleaning solution.
- a new cleaning liquid is continuously supplied to the ultrasonic cleaning tank 21 by the supply mechanism 22.
- This cleaning liquid is typically water (tap water or industrial water).
- the discharge mechanism 23 the cleaning liquid exceeding the reference liquid level S is continuously discharged from the ultrasonic cleaning tank 21. Thereby, it is possible to suppress a decrease in the cleaning power due to excessive contamination of the cleaning liquid in the ultrasonic cleaning tank 21.
- the amount (per unit time) of the cleaning liquid supplied from the supply mechanism 22 to the ultrasonic cleaning tank 21 can be determined in consideration of the amount of cleaning liquid stored in the ultrasonic cleaning tank 21 and the degree of contamination of the cleaning liquid.
- the cleaning liquid discharged from the ultrasonic cleaning tank 21 by the discharge mechanism 23 is discarded after a predetermined drainage treatment.
- the cleaning liquid is irradiated with ultrasonic waves by the ultrasonic irradiation mechanism 24, and fine bubbles are supplied by the fine bubble generation mechanism 25.
- the dissolved bubble concentration in the cleaning liquid is reduced by the fine bubble generation mechanism 25 forming bubbles in the dissolved gas in the cleaning liquid.
- the fine bubble generation mechanism 25 reduces the dissolved oxygen concentration of the cleaning liquid in the ultrasonic cleaning tank 21 to 5.2 mg / L or less.
- the fine bubble generation mechanism 25 lowers the dissolved oxygen concentration of the cleaning solution in the ultrasonic cleaning tank 21 to preferably 4.5 mg / L or less, more preferably 4.2 mg / L or less.
- the supply mechanism 22 supplies a cleaning liquid having a dissolved oxygen concentration of about 7 mg / L to 11 mg / L, preferably about 8 mg / L to 10 mg / L to the ultrasonic cleaning tank 21.
- the cleaning liquid passes through the fine bubble generator 253 of the fine bubble generation mechanism 25, the dissolved gas in the cleaning liquid is turned into fine bubbles, and the concentration of dissolved oxygen in the cleaning liquid decreases.
- the dissolved oxygen concentration of the cleaning liquid in the ultrasonic cleaning tank 21 is 5.2 mg / L or less, more preferably 4.5 mg / L. L or less, more preferably 4.2 mg / L or less. This makes it possible to ensure good cleaning properties in a wide range of sound pressure of ultrasonic waves. Under such a dissolved oxygen concentration, the sound pressure of the ultrasonic wave is preferably 120 mV or more in order to ensure good cleanability.
- the dissolved oxygen concentration of the cleaning liquid in the ultrasonic cleaning tank 21 is usually 2.0 mg / L or more. However, the lower limit of the dissolved oxygen concentration of the cleaning liquid in the ultrasonic cleaning tank 21 does not need to be particularly controlled or controlled.
- the dissolved oxygen concentration [mg / L] is a value measured by a commercially available dissolved oxygen concentration meter (LAQUA @ OM-71, manufactured by Horiba, Ltd.).
- the sound pressure [mV] is measured in an average measurement value for 5 seconds using a commercially available ultrasonic sound pressure meter (Sound pressure level monitor # 19001D manufactured by Kaijo Co., Ltd.). (Vibration transmission rod) was placed in water 100 mm from the surface of the cleaning liquid and measured.
- the ultrasonic cleaning step S42 After holding the metal pipe P in the cleaning liquid in the ultrasonic cleaning tank 21 for a while, pull up the metal pipe P from the ultrasonic cleaning tank 21.
- the arrangement of the metal pipe P in the ultrasonic cleaning tank 21, the holding of the metal pipe P in the cleaning liquid, and the lifting of the metal pipe P from the ultrasonic cleaning tank 21 are defined as one cycle.
- the cycle is performed a predetermined number of times.
- the holding time of the metal tube P in the cycle and the number of times the cycle is performed can be determined so that the total immersion time of the metal tube P in the cleaning liquid is equal to or longer than a predetermined time.
- the total immersion time of the metal tube P may be appropriately set according to the amount of the film adhering to the metal tube P or the like.
- the total immersion time of the metal tube P is, for example, 30 seconds or more, and more preferably 1 minute or more.
- the metal pipe P is immersed in the cleaning liquid for the total immersion time set in advance or more, the metal pipe P is collected from the ultrasonic cleaning tank 21 using a crane or the like. At this time, it is preferable that the metal tube P is pulled up while being tilted. This can prevent the cleaning liquid from remaining inside the metal pipe P.
- the ultrasonic cleaning step S42 is completed.
- the ultrasonic cleaning tank 21 ultrasonic waves and fine bubbles are continuously applied to the cleaning liquid to supply and discharge the cleaning liquid. For this reason, ultrasonic cleaning of another metal pipe P can be performed subsequently.
- the cleaning liquid in the ultrasonic cleaning tank 21 is brought into the ultrasonic cleaning tank 21 by bringing the metal pipe P into the ultrasonic cleaning tank 21 with an alkaline degreaser or water containing no fine bubbles. May increase the dissolved oxygen concentration.
- the dissolved oxygen concentration of the cleaning liquid increases, it is preferable to stop the ultrasonic cleaning of the metal pipe P until the fine bubble generation mechanism 25 sufficiently reduces the dissolved oxygen concentration.
- the dissolved oxygen concentration of the cleaning solution becomes 5.2 mg / L or less, 4.5 mg / L or less, or 4.2 mg / L or less, ultrasonic cleaning of the metal tube P after the alkali cleaning step S41 is restarted. Good.
- the metal pipe P is disposed in the ultrasonic cleaning tank 21.
- the cleaning liquid can be stored in the ultrasonic cleaning tank 21.
- the metal tube P after cold drawing is immersed in an alkali degreasing solution not heated at a high temperature, and then immersed in a cleaning solution to which ultrasonic waves and fine bubbles are applied.
- a cleaning solution to which ultrasonic waves and fine bubbles are applied.
- FIG. 8A is a diagram schematically illustrating the surface of the metal pipe P after cold drawing.
- FIG. 8B is a diagram schematically illustrating the surface of the metal tube P after the alkali cleaning step S41.
- FIG. 8C is a diagram schematically illustrating the surface of the metal tube P during the ultrasonic cleaning step S42.
- a chemical conversion coating 31 is formed on the surface of the metal pipe P after the cold drawing.
- a lubricating film 32 is formed on the chemical conversion film 31.
- the lubricating film 32 includes a metal soap layer 321 and a soap layer 322.
- an iron (II) oxalate coating is 1 to 100 ⁇ m, preferably 5 to 40 ⁇ m.
- the total thickness is 10 to 1000 ⁇ m, preferably 50 to 200 ⁇ m.
- the chemical conversion coating 31 has cracks. This is presumably because the chemical conversion coating 31 has a very low ductility, so that the chemical conversion coating 31 breaks without extending during cold drawing.
- the lubricating film 32 extends due to the heat generated during the cold drawing, and covers the chemical conversion film 31 in which cracks have occurred.
- the metal tube P after cold drawing is immersed in an alkali degreasing solution not heated at a high temperature
- the lubricating film 32 covering the chemical conversion film 31 is partially removed.
- part of the metal soap layer 321 reacts with the alkali degreasing solution to form a complex
- part of the soap layer 322 dissolves in the alkali degreasing solution.
- the metal pipe P is in a state where a part of the lubricating film 32 is missing.
- the lubricating film 32 separates from the metal pipe P starting from the chipped portion as shown in FIG. 8C.
- the chemical conversion film 31 also peels off from the metal pipe P starting from cracks generated during cold drawing.
- the chemical conversion film 31 and the lubricating film 32 are peeled off from the metal tube P by a physical action such as ultrasonic cavitation.
- the chemical conversion film 31 and the lubricating film can be formed from the metal tube P after cold drawing without using a high-temperature alkaline degreasing solution. 32 can be removed. Therefore, energy saving (low cost) and good cleanability can be realized.
- the chemical conversion film 31 Since the chemical conversion film 31 is bonded to the material of the metal pipe P by a chemical bond, it has conventionally been necessary to remove the chemical coating 31 from the metal pipe P by pickling. That is, after removing the lubricating film 32 from the metal tube P with a high-temperature alkaline degreasing solution, it was necessary to wash the metal tube P with acid to remove the chemical conversion film 31.
- the chemical conversion film 31 can be removed in addition to the lubricating film 32 only by alkali cleaning and ultrasonic cleaning. Therefore, the pickling process for removing the chemical conversion film 31 becomes unnecessary, and the cleaning process of the metal pipe P can be simplified.
- the ultrasonic cleaning step S42 fine bubbles are generated in the cleaning liquid in the ultrasonic cleaning step S42.
- the ultrasonic waves in the cleaning liquid can be scattered and propagated three-dimensionally. For this reason, the cleanability of the metal pipe P is improved.
- the dissolved gas concentration in the cleaning liquid is 5.2 mg / L or less, more preferably 4.5 mg / L or less, further preferably 4 mg / L or less, by dissolving the dissolved gas in the cleaning liquid into fine bubbles. 0.2 mg / L or less. Therefore, good ultrasonic cleaning properties can be ensured in a wide sound pressure range.
- the pickling treatment for removing the chemical conversion film 31, but this does not exclude the pickling treatment, and the pickling treatment is performed after the ultrasonic cleaning. You may.
- the cleaned metal tube P is lifted from the ultrasonic cleaning tank 21, there is a possibility that debris floating in the ultrasonic cleaning tank 21 (a part of the film removed by cleaning) adheres to the metal tube P.
- an acid washing treatment may be performed in order to remove stains re-adhering to the surface of the metal tube. Even in this case, it is possible to remove stains on the surface of the metal tube by pickling in a shorter time than before.
- a cleaning test of the metal tube P after cold drawing was performed using the alkali cleaning device 10 shown in FIG. 2 and the ultrasonic cleaning device 20 shown in FIG. Carried out. That is, in the alkali cleaning device 10, after performing an alkali cleaning process using an alkali degreasing solution not heated at a high temperature, the ultrasonic cleaning device 20 performed an ultrasonic cleaning process using a cleaning solution to which ultrasonic waves and fine bubbles were applied.
- the temperature of the alkaline degreasing solution used in the alkaline cleaning step was a temperature corresponding to the ambient temperature of the alkaline cleaning device 10, and was specifically about 25 ° C.
- the metal pipe P was washed with water after the alkali cleaning step and before the ultrasonic cleaning step.
- Comparative Example 1 As Comparative Example 1, the metal tube P after the cold drawing was subjected to an alkali cleaning step using a high-temperature alkali degreasing solution. After the high-temperature alkali cleaning step, the metal tube P was washed with water. Also in Comparative Example 1, the same alkaline cleaning apparatus 10 as in the example was used. In Comparative Example 1, the ultrasonic cleaning step after the alkali cleaning treatment was not performed.
- Comparative Example 2 As Comparative Example 2, the metal pipe P after the cold drawing was subjected to a cleaning step (ultrasonic cleaning step) using a cleaning liquid provided with ultrasonic waves and fine bubbles. In Comparative Example 2, the alkali cleaning step before the ultrasonic cleaning step was not performed.
- an iron (II) oxalate film is formed as a chemical conversion film 31 having a thickness of 10 ⁇ m, and a metal soap (iron stearate) layer 321 and a soap (sodium stearate) are formed on the iron oxalate film as a lubricating film 32.
- the layer 322 was formed to 100 ⁇ m in total. Table 1 shows other test conditions.
- the 10-minute flow cycle includes the supply of the alkaline degreasing solution to the alkaline cleaning tank 11, the holding of the metal tube P in the alkaline degreasing liquid, and the discharge of the alkaline degreasing liquid from the alkaline cleaning tank 11. It means that the cycle was performed over 10 minutes. In Example and Comparative Example 1, the flow cycle of 10 minutes was repeated three times in the alkali cleaning step.
- FIG. 9 is a graph showing the change in the amount of carbon (C) [mg / m 2 ] attached to the inner surface of the metal tube P for the example, comparative example 1, and comparative example 2.
- the amount of carbon was measured using a commercially available measuring device (manufactured by LECO Japan GK, type-specific carbon / hydrogen / water analyzer RC612).
- Comparative Example 1 the amount of carbon is reduced by performing alkali cleaning using a high-temperature alkaline degreasing solution. This indicates that most of the lubricating film could be removed by alkali washing with a high-temperature alkali degreasing solution. However, it is considered that the chemical conversion film has not been removed, and that a part of the lubricating film remains as described later. For this reason, it is necessary to pickle the metal tube P after high-temperature alkali cleaning to remove the remaining soap components and the chemical conversion film.
- the amount of carbon is slightly reduced from that before the cleaning by performing the alkali cleaning using the alkali degreasing solution at about 25 ° C. This is because the lubricating film covering the chemical conversion film was partially removed as described with reference to FIG. 8B.
- the amount of carbon in the example at the stage when the alkali cleaning with the alkali degreasing solution at about 25 ° C. is completed is larger than the carbon amount after the high-temperature alkali cleaning in Comparative Example 1. This is considered to be because the lubricating film can be only partially removed by alkali cleaning using an alkali degreasing solution at about 25 ° C.
- the carbon amount is significantly reduced (to about several tens mg / m 2 ) as compared with the case of Comparative Example 1.
- Comparative Example 1 since it is considered that most of the lubricating film has been removed, even if the alkali cleaning is performed with an alkaline degreasing solution at a low temperature of about 25 ° C., the metal pipe is subjected to ultrasonic cleaning after that. It is understood from P that not only the lubricating film but also the chemical conversion film can be removed. In the case of the example, unlike the comparative example 1, the subsequent pickling treatment can be omitted. Note that an acid washing treatment may be performed to more reliably remove the chemical conversion film.
- FIG. 10 is a scanning electron microscope (SEM) image of the inner surface of each metal tube P cleaned by the cleaning method of Example and Comparative Example 1.
- SEM scanning electron microscope
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Abstract
Description
図2は、アルカリ洗浄工程S41で使用されるアルカリ洗浄装置10を模式的に示す側面図である。図3は、図2に示すアルカリ洗浄装置10のIII-III断面図である。
アルカリ洗浄槽11は、槽本体111と、蓋112と、を有する。槽本体111は、その上面に開口を有する。蓋112は、槽本体111の開口を覆うことができるように構成されている。
貯留タンク12は、アルカリ洗浄槽11の下方に配置されている。貯留タンク12は、例えば、中空の直方体状に形成される。貯留タンク12には、アルカリ脱脂液が貯留される。槽本体111の端部111cの近傍において、貯留タンク12は、循環配管13を介して槽本体111と連通する。槽本体111の端部111dの近傍において、貯留タンク12は、連通口14によって槽本体111と連通する。連通口14は、開閉可能に構成されている。
循環配管13は、アルカリ洗浄槽11の槽本体111の端部111cの近傍において、槽本体111と貯留タンク12とを接続する。循環配管13は、貯留タンク12内のアルカリ脱脂液を槽本体111に供給可能なように構成されている。例えば、循環配管13には、アルカリ脱脂液を貯留タンク12から槽本体111に送るためのポンプ131(図3)が設けられている。
図4は、超音波洗浄工程S42で使用される超音波洗浄装置20の平面図である。図5は、図4に示す超音波洗浄装置20のV-V断面図である。
超音波洗浄槽21は、金属管Pを収容可能に構成されている。超音波洗浄に際し、超音波洗浄槽21内には、通常、複数の金属管Pが同時に収容される。超音波洗浄槽21には、金属管Pを洗浄するための洗浄液が貯留される。洗浄液の種類は、特に限定されるものではなく、公知の洗浄液から適宜選択して採用することができる。洗浄液は、例えば水(水道水、工業用水)である。
供給機構22は、超音波洗浄槽21に洗浄液を供給する。供給機構22は、少なくとも1つの供給管221を有する。本実施形態では、供給機構22は、複数の供給管221を有する。洗浄液は、各供給管221を介して超音波洗浄槽21に供給される。複数の供給管221は、間隔を空けて配置されている。このため、洗浄液は、超音波洗浄槽21に対して分散して供給される。3つ以上の供給管221が存在する場合、新たな洗浄液の均一供給の観点から、供給管221の間隔は、概ね均等であることが好ましい。
各排出機構23は、超音波洗浄槽21内の洗浄液の量が所定量を超えたときに、超音波洗浄槽21から洗浄液を排出する。複数の排出機構23は、間隔を空けて配置されている。このため、洗浄液は、超音波洗浄槽21から分散して排出される。3つ以上の排出機構23が存在する場合、排出機構23の間隔は、概ね均等であることが好ましい。なお、排出機構23は1つでもよい。
図4に戻り、超音波照射機構24は、超音波洗浄槽21内の洗浄液中に超音波を照射する。超音波照射機構24としては、超音波洗浄において一般に採用されている、公知の超音波振動子を用いることができる。
ファインバブル発生機構25は、超音波洗浄槽21内の洗浄液中の溶存気体を気泡化してファインバブルを発生させる。ファインバブル発生機構25は、超音波洗浄槽21の外側に配置されている。超音波洗浄槽21の長手方向の一側壁に沿って、複数のファインバブル発生機構25が配置されている。ただし、ファインバブル発生機構25の位置及び数は、特に限定されるものではない。
緩衝部材26は、超音波洗浄槽21内に配置されている。複数の緩衝部材26は、超音波洗浄槽21の長手方向に並んでいる。
アルカリ洗浄装置10(図2)及び超音波洗浄装置20(図4)は、金属管Pの製造において、金属管Pを洗浄する際に用いられる。以下、金属管Pの製造方法について説明する。図1を再度参照して、金属管Pの製造方法は、準備工程S1と、潤滑工程S2と、冷間引抜工程S3と、洗浄工程S4と、を備える。
準備工程S1では、熱間加工によって製造された素管を準備する。素管の一端部には、後述の冷間引抜工程S3のため、口絞り加工が施される。すなわち、素管の一端部には、他の部分と比較して細くなるように叩き又は絞り等の加工が施される。
オーステナイト系ステンレス鋼管やNi基合金管の素管は、優れた強度を有する反面、冷間引抜加工時の加工負荷(摩擦力)も大きい。そのため、準備工程S1の後、冷間引抜工程S3の前に、潤滑工程S2を実施する。この潤滑工程S2は、化成皮膜形成工程S21及び潤滑皮膜形成工程S22を含んでいる。
化成皮膜形成工程S21では、素管の表面上に化成皮膜を形成する。化成皮膜形成工程S21では、熱間加工時等に生成されたスケールを公知の酸洗処理によって素管から除去した後、この素管を化成処理液に所定時間浸漬する。これにより、素管の表面上に化成皮膜が形成される。
化成皮膜形成工程S21の後、素管に水洗及び中和処理を施し、潤滑皮膜形成工程S22を実施する。潤滑皮膜形成工程S22では、化成皮膜形成工程S21で素管に形成した化成皮膜上に潤滑皮膜を形成する。潤滑皮膜形成工程S22では、化成皮膜が形成された素管を潤滑処理液に所定時間浸漬する。その後、素管を潤滑処理液から取り出し、十分に乾燥させる。これにより、化成皮膜上に潤滑皮膜が形成される。
潤滑工程S2によって素管に化成皮膜及び潤滑皮膜を形成した後、冷間引抜工程S3を実施する。冷間引抜工程S3では、素管に対して公知の冷間引抜加工を施すことにより、素管を所定の寸法の金属管に成形する。例えば、口絞り加工が施された素管の端部をダイス(図示略)に通してグリッパ(図示略)で把持し、グリッパを移動させてダイスから素管を引き抜く。これにより、素管の外径が所定の外径に仕上げられる。素管の肉厚を調整する場合には、素管にマンドレルを挿入した状態で引抜きが実施される。
冷間引抜工程S3を経て得られた所定寸法の金属管は、化成皮膜及び潤滑皮膜を除去するため、洗浄工程S4で洗浄される。洗浄工程S4は、アルカリ洗浄工程S41と、超音波洗浄工程S42、とを含む。
図2及び図3を再度参照して、アルカリ洗浄工程S41は、アルカリ洗浄装置10において、アルカリ洗浄槽11内のアルカリ脱脂液に金属管Pを浸漬する工程である。アルカリ洗浄工程S41では、まず、槽本体111内に金属管Pを配置する。通常、複数の金属管Pを槽本体111内に配置するが、1つの金属管Pを槽本体111内に配置してもよい。金属管Pは、クレーン等によってアルカリ洗浄槽11内に配置される。具体的には、金属管Pは、支持部材113上に載置される。これにより、金属管Pと槽本体111の底面111aとの間に隙間が生じる。
アルカリ洗浄工程S41が実施された後、超音波洗浄工程S42が実施される。超音波洗浄工程S42は、超音波及びファインバブルが付与された洗浄液に、アルカリ脱脂液に浸漬した後の金属管Pを浸漬する工程である。超音波洗浄工程S42では、アルカリ洗浄工程S41で使用したアルカリ洗浄装置10(図2)とは別の装置である超音波洗浄装置20(図4)が使用される。すなわち、アルカリ洗浄工程S41が終了した後、金属管Pは、アルカリ洗浄装置10から超音波洗浄装置20へと運ばれる。アルカリ洗浄工程S41後の金属管Pは、超音波洗浄工程S42の前に水洗されてもよい。これにより、金属管Pに付着したアルカリ脱脂液を洗い流すことができる。
本実施形態では、冷間引抜加工後の金属管Pを高温加熱されていないアルカリ脱脂液に浸漬した後、超音波及びファインバブルが付与された洗浄液に浸漬する。これにより、高温のアルカリ脱脂液を使用しなくても、金属管Pに形成された化成皮膜及び潤滑皮膜を除去することができる。
本開示による金属管の洗浄効果を確認するため、図2に示すアルカリ洗浄装置10と、図4に示す超音波洗浄装置20を使用して、冷間引抜加工後の金属管Pの洗浄試験を実施した。すなわち、アルカリ洗浄装置10において、高温加熱されていないアルカリ脱脂液によるアルカリ洗浄工程を実施した後、超音波洗浄装置20において、超音波及びファインバブルを付与した洗浄液による超音波洗浄工程を実施した。本実施例において、アルカリ洗浄工程で用いたアルカリ脱脂液の温度は、アルカリ洗浄装置10の周辺温度に応じた温度で、具体的には約25℃であった。本実施例では、アルカリ洗浄工程を実施した後、超音波洗浄工程を実施する前に、金属管Pの水洗を行った。
比較例1として、冷間引抜加工後の金属管Pに対し、高温のアルカリ脱脂液によるアルカリ洗浄工程を実施した。高温アルカリ洗浄工程の後、金属管Pの水洗を行った。比較例1でも、実施例と同様のアルカリ洗浄装置10を使用した。比較例1では、アルカリ洗浄処理後の超音波洗浄工程を実施しなかった。
比較例2として、冷間引抜加工後の金属管Pに対し、超音波及びファインバブルを付与した洗浄液による洗浄工程(超音波洗浄工程)を実施した。比較例2では、超音波洗浄工程前のアルカリ洗浄工程を実施しなかった。
実施例、比較例1、及び比較例2では、それぞれ20本の金属管Pを使用した。金属管Pの化学組成は、質量%で、C:0.08%、Si:0.2%、Mn:0.8%、Cu:3.0%、Ni:8.8%、Cr:18.5%、Nb:0.5%、残部:Fe及び不純物である。金属管Pの寸法は、外径:50.8mm、厚さ:7.2mm、長さ:8000mmである。金属管Pの表面には化成皮膜31としてシュウ酸鉄(II)皮膜を10μm、そのシュウ酸鉄(II)皮膜上に潤滑皮膜32として金属石鹸(ステアリン酸鉄)層321と石鹸(ステアリン酸ナトリウム)層322とを合わせて100μm形成した。その他の試験条件を表1に示す。
実施例、比較例1、及び比較例2のそれぞれについて、金属管Pの洗浄性を評価した。図9は、実施例、比較例1、及び比較例2について、金属管Pの内面に付着している炭素(C)量[mg/m2]の変化を示すグラフである。炭素量は、市販の測定装置(LECOジャパン合同会社製、形態別炭素・水素/水分分析装置RC612型)を使用して測定した。
11:アルカリ洗浄槽
20:超音波洗浄装置
21:超音波洗浄槽
P:金属管
Claims (4)
- 金属管の製造方法であって、
金属の素管を準備する準備工程と、
前記素管の表面上に化成皮膜を形成し、前記化成皮膜上に潤滑皮膜を形成する潤滑工程と、
前記化成皮膜及び前記潤滑皮膜が形成された前記素管に冷間引抜加工を施して、所定の寸法の金属管に成形する冷間引抜工程と、
前記金属管を洗浄して前記化成皮膜及び前記潤滑皮膜を除去する洗浄工程と、
を備え、
前記洗浄工程は、
アルカリ洗浄槽内の高温加熱されていないアルカリ脱脂液に前記金属管を浸漬する工程と、
超音波洗浄槽内の洗浄液中に超音波を照射するとともに前記洗浄液中にファインバブルを発生させながら、前記アルカリ脱脂液に浸漬した後の前記金属管を前記洗浄液に浸漬する工程と、
を含む、製造方法。 - 請求項1に記載の製造方法であって、
前記金属管を前記洗浄液に浸漬している間、前記洗浄液の溶存酸素濃度は、5.2mg/L以下である、製造方法。 - 化成皮膜及び潤滑皮膜が表面に形成された素管に冷間引抜加工を施すことによって成形された金属管の洗浄方法であって、
アルカリ洗浄槽内の高温加熱されていないアルカリ脱脂液に前記金属管を浸漬する工程と、
超音波洗浄槽内の洗浄液中に超音波を照射するとともに前記洗浄液中にファインバブルを発生させながら、前記アルカリ脱脂液に浸漬した後の前記金属管を前記洗浄液に浸漬する工程と、
を備える、洗浄方法。 - 請求項3に記載の洗浄方法であって、
前記金属管を前記洗浄液に浸漬している間、前記洗浄液の溶存酸素濃度は、5.2mg/L以下である、洗浄方法。
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JP7469657B2 (ja) | 2020-07-28 | 2024-04-17 | 株式会社不二越 | 鋼製被処理物の表面処理システムおよびそれを用いた表面処理方法 |
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