WO2023157637A1 - 焼結金属摩擦材及びその製造方法 - Google Patents

焼結金属摩擦材及びその製造方法 Download PDF

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Publication number
WO2023157637A1
WO2023157637A1 PCT/JP2023/003184 JP2023003184W WO2023157637A1 WO 2023157637 A1 WO2023157637 A1 WO 2023157637A1 JP 2023003184 W JP2023003184 W JP 2023003184W WO 2023157637 A1 WO2023157637 A1 WO 2023157637A1
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Prior art keywords
friction material
powder
mass
material composition
nickel powder
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PCT/JP2023/003184
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English (en)
French (fr)
Japanese (ja)
Inventor
真 安田
優介 岡村
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Tokai Carbon Co Ltd
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Tokai Carbon Co Ltd
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Priority to EP23729005.1A priority Critical patent/EP4480607A4/en
Priority to US18/270,024 priority patent/US20250084292A1/en
Priority to JP2023530668A priority patent/JP7642814B2/ja
Publication of WO2023157637A1 publication Critical patent/WO2023157637A1/ja
Anticipated expiration legal-status Critical
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C30/00—Alloys containing less than 50% by weight of each constituent
    • C22C30/04—Alloys containing less than 50% by weight of each constituent containing tin or lead
    • 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
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • 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
    • B22F1/09—Mixtures of metallic powders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0433—Nickel- or cobalt-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C30/00—Alloys containing less than 50% by weight of each constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C30/00—Alloys containing less than 50% by weight of each constituent
    • C22C30/06—Alloys containing less than 50% by weight of each constituent containing zinc
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0207—Using a mixture of pre-alloyed powders or a master alloy
    • C22C33/0228—Using a mixture of pre-alloyed powders or a master alloy comprising other non-metallic compounds or more than 5% of graphite
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02—Composition of linings ; Methods of manufacturing
    • F16D69/027—Compositions based on metals or inorganic oxides
    • 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
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B22F1/062—Fibrous particles
    • 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
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B22F1/065—Spherical particles
    • 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
    • B22F2301/15—Nickel or cobalt
    • 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
    • B22F2301/30—Low melting point metals, i.e. Zn, Pb, Sn, Cd, In, Ga
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/35—Iron
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
    • C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
    • C22C32/0026—Matrix based on Ni, Co, Cr or alloys thereof
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0084—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ carbon or graphite as the main non-metallic constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0261—Matrix based on Fe for ODS steels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/006—Materials; Production methods therefor containing fibres or particles

Definitions

  • the present invention relates to a sintered metal friction material, and more particularly to a sintered metal friction material with a low copper content.
  • Vehicles such as motorcycles and automobiles are provided with friction materials in order to achieve a braking function.
  • the friction material is pressed against a mating material that is integrally attached to the wheel.
  • the wheel is braked by the frictional force generated between the mating material and the friction material, and the braking function is exhibited.
  • a sintered metal friction material is known as such a friction material.
  • a sintered metal friction material is a material obtained by molding and sintering a raw material containing metal (hereinafter referred to as a friction material composition).
  • copper powder has been mainly used as a raw material from the viewpoint of moldability.
  • the friction material contains copper
  • abrasion powder containing copper is generated during use. From the viewpoint of environmental protection, it is required to suppress the generation of abrasion powder containing copper. For example, some states in the United States have enacted laws regulating the use of copper-containing wear particles, which are considered to have an adverse effect on aquatic life.
  • Patent Document 1 Japanese Patent Application Laid-Open No. 2018-111755 describes that as matrix metals, iron powder 20 to 40% by mass, nickel powder 20 to 40% by mass, zinc powder 0.5 to 10% 0.5 to 5% by mass of tin powder, 0.5 to 4% by mass of copper powder, 0.5 to 5% by mass of sintering aid powder, and a friction modifier.
  • a sintered metal friction material is disclosed which is characterized by comprising a composite.
  • copper powder is used from the viewpoint of moldability.
  • the copper powder functions as a binder when the copper powder is mixed with other powder materials and molded. Therefore, the copper powder contributes to the strength of the compact. If the content of copper powder is reduced, the compact becomes brittle, making it difficult to obtain a sintered metal friction material.
  • the metal powder when preparing the friction material composition, is mixed with other materials. If the composition of other components is devised in order to increase the strength of the compact, aggregates may be generated when the metal powder is mixed with other materials, depending on the mixing conditions.
  • sintered metal friction materials are required to be resistant to wear during use.
  • an object of the present invention is to provide a sintered metal friction material with a reduced copper content that is less prone to agglomerates during production, maintains the strength of the molded body, and suppresses wear during use. It is to provide the technology that is possible.
  • a sintered metal friction material that is a sintered material of a friction material composition, wherein the friction material composition contains 42 to 95% by mass of a matrix metal powder, and the matrix metal powder contains: 20 to 40% by mass of iron powder based on the mass of the friction material composition and 20 to 40% by mass of nickel powder based on the mass of the friction material composition, and copper of the friction material composition
  • a sintered metal friction material having a content of 0.5% by mass or less, wherein the nickel powder includes spherical nickel powder and chain-like nickel powder.
  • the sintered metal friction material according to any one of [1] to [4], wherein the friction material composition further contains 0.5 to 5% by mass of tin powder.
  • the friction material composition contains 42 to 95% by mass of matrix metal powder, and the matrix metal powder is 20 to 40% by mass of iron powder based on the mass of the friction material composition, and the friction material.
  • an object of the present invention is to provide a sintered metal friction material with a reduced copper content that is less prone to agglomerates during production, maintains the strength of the molded body, and suppresses wear during use. It is to provide the technology that is possible.
  • the sintered metal friction material according to this embodiment is a sintered body of a friction material composition having a specific composition.
  • the term “friction material” refers to a material that generates friction when it comes into contact with a mating material and realizes a function by the generated friction. The configuration of the friction material composition will be described below.
  • the friction material composition according to the present embodiment has a low copper content. Specifically, the content of copper in the friction material composition is 0.5% by mass or less. More preferably, the friction material composition does not contain copper.
  • copper-free means not containing copper in a substantial sense, and is unavoidably contained in the friction material composition, that is, unintentionally contained in the friction material composition. does not imply that it does not contain copper at the level of impurities found in
  • the copper content can be measured by the method specified in SAE J2975. Specifically, it can be obtained by cutting the sintered metal friction material with a drill, collecting the obtained cutting powder, and performing ICP mass spectrometry.
  • the friction material composition contains 42 to 95% by mass of matrix metal powder.
  • the matrix metal powder is metal powder that forms the matrix metal portion in the sintered metal friction material, which is a sintered body. It can also be said that the matrix metal powder is a metal powder that undergoes a sintering reaction during sintering.
  • the matrix metal powder contains 20 to 40% by mass of iron powder based on the mass of the friction material composition and 20 to 40% by mass of nickel powder based on the mass of the friction material composition.
  • the nickel powder includes spherical nickel powder and chain nickel powder.
  • the nickel powder As the nickel powder, the spherical nickel powder and the linear nickel powder are used in combination. It is possible to maintain the strength of the molded body without causing it to occur.
  • the iron powder one or more selected from reduced iron powder, cast iron powder, etc. can be mentioned, and reduced iron powder is preferable.
  • the melting point of the reduced iron powder is about 300° C. higher than that of the cast iron powder. Therefore, by using the reduced iron powder, it is possible to easily obtain a sintered metal friction material having excellent friction characteristics at high temperatures.
  • the reduced iron powder include those obtained by heat-treating iron ore at a temperature of 600 to 1200° C. in a hydrogen gas or ammonia gas atmosphere.
  • the iron powder preferably has a particle size range of 10 to 500 ⁇ m, more preferably 20 to 300 ⁇ m, even more preferably 40 to 150 ⁇ m.
  • the particle size range of the iron powder means a value measured by a sieving method.
  • the content of the iron powder in the friction material composition is 20 to 40% by mass, preferably 23 to 37% by mass, more preferably 25 to 35% by mass, and 30% by mass. More preferably, it is up to 34% by mass.
  • the content of the iron powder is within such a range, the strength of the friction material can be improved, and a desired amount of other components can be included to exhibit suitable fade resistance.
  • Nickel powder like iron powder, is also used to form part of the matrix metal in the sintered metal friction material.
  • nickel powder As mentioned above, as nickel powder, spherical nickel powder and chain nickel powder are used in combination.
  • Spherical nickel powder refers to nickel powder having a loose bulk specific gravity of 1.0 to 3.0 g/cm 3 .
  • chain nickel powder refers to nickel powder having a loose bulk specific gravity of 0.4 to 0.8 g/cm 3 . That is, by using together two kinds of nickel powders having different loose bulk specific gravities, it is possible to improve the strength of the compact without generating agglomerates during the preparation of the friction material composition.
  • Nickel powder (hereinafter simply referred to as nickel powder refers to both spherical nickel powder and linear nickel powder), for example, those prepared by the atomization (spraying) method, and the carbonyl nickel method One or more selected from those prepared by When these nickel powders are used, the strength of the friction material can be easily improved, the heat resistance is excellent even under high output, and suitable fade resistance can be exhibited while having a higher coefficient of friction. .
  • the particle size of the spherical nickel powder is, for example, 1-200 ⁇ m, preferably 3-100 ⁇ m, more preferably 5-20 ⁇ m.
  • the particle size of the chain nickel powder is, for example, 0.5 to 100 ⁇ m, preferably 1 to 50 ⁇ m, more preferably 3 to 20 ⁇ m.
  • the particle size of said nickel powder means the value ( D50 ) measured by the laser diffraction method.
  • the total content of nickel powder in the friction material composition is 20 to 40% by mass, preferably 23 to 37% by mass, more preferably 25 to 35% by mass.
  • the strength of the friction material can be improved, and a desired amount of other components can be included to exhibit suitable fade resistance.
  • the friction material composition preferably satisfies the following formula (1). (Formula 1) 0.25 ⁇ Ni 2vol / (Ni 1Vol + Ni 2vol ) ⁇ 0.75
  • the ratio “Ni 2vol /(Ni 1Vol +Ni 2vol )” is more preferably 0.50 to 0.75.
  • the friction material composition preferably satisfies the following formula (2) where Fe vol is the volume of the iron powder. (Formula 2) 0.33 ⁇ Fe vol / (Fe vol + Ni 1 Vol + Ni 2 vol ) ⁇ 0.66 The ratio "Fe vol /(Fe vol +Ni 1Vol +Ni 2vol )" is preferably between 0.33 and 0.50.
  • the total content of iron powder and nickel powder in the friction material composition is preferably 40 to 80% by mass, more preferably 46 to 74% by mass, and further preferably 50 to 70% by mass. preferable.
  • the total content of the iron powder and the nickel powder is within the above range, the effect of improving the strength of the friction material and the desired amount of the other components are included, so that the fade resistance can be more easily exhibited.
  • the matrix metal powder may contain other metal powder as necessary.
  • other metal powders include zinc powder, tin powder, and sintering aid powder.
  • the zinc powder is not particularly limited, and examples thereof include those prepared by an atomizing (spraying) method.
  • the zinc powder preferably has a particle size range of 5 to 200 ⁇ m, more preferably 10 to 100 ⁇ m, and even more preferably 20 to 65 ⁇ m.
  • the particle size range of the said zinc powder means the value ( D50 ) measured by the laser diffraction method.
  • the content of zinc powder in the friction material composition is, for example, 0.5 to 10% by mass, preferably 1 to 9% by mass, more preferably 5 to 7% by mass. When the zinc powder content is within the above range, the strength of the friction material is improved, the wear resistance is improved, adhesion to the mating material during friction is easily suppressed, and the desired coefficient of friction is achieved. easier to present.
  • the tin powder preferably has a particle size range of 5 to 200 ⁇ m, more preferably 10 to 100 ⁇ m, even more preferably 20 to 50 ⁇ m.
  • the particle size range of the said tin powder means the value ( D50 ) measured by the laser diffraction method.
  • the content of tin powder in the friction material composition is 0.5 to 5% by mass, preferably 1 to 4% by mass, more preferably 1 to 3% by mass.
  • the strength of the friction material is improved, the wear resistance is improved, adhesion to the mating material during friction is easily suppressed, and the desired coefficient of friction is achieved. easier to present.
  • the sintering aid powder is not particularly limited, and examples thereof include one or more selected from iron boride powder, iron phosphorous powder, yttrium oxide, magnesium oxide, aluminum oxide, hafnium oxide, etc.
  • the iron boride powder preferably has a particle size range of 5 to 200 ⁇ m, more preferably 10 to 100 ⁇ m, and even more preferably 20 to 50 ⁇ m.
  • the phosphorous iron powder preferably has a particle size range of 5 to 200 ⁇ m, more preferably 10 to 100 ⁇ m, even more preferably 10 to 30 ⁇ m.
  • the particle size range of each sintering aid powder means a value (D 50 ) measured by a laser diffraction method.
  • the content of the sintering aid powder in the friction material composition is 0.5 to 5% by mass, preferably 0.5 to 4% by mass, and preferably 0.5 to 3% by mass. more preferred.
  • the content of the sintering aid powder in the friction material composition is within the above range, the sinterability of the iron powder and nickel powder is enhanced, the strength of the friction material is improved, and the torque waveform during friction is flattened. (squeal is easily suppressed), adhesion to the mating member during friction is easily suppressed, and a desired coefficient of friction is easily exhibited.
  • the total content of the matrix metal powder in the friction material composition may be 42 to 95% by mass as described above, preferably 49.5 to 90% by mass, and more preferably 59 to 84% by mass. % by mass. When the total content of the matrix metals is within the above range, the strength of the friction material can be improved and suitable fade resistance can be exhibited.
  • the friction material composition may contain other additives as necessary.
  • Other additives include, for example, friction modifiers.
  • the friction modifier is not particularly limited, and examples thereof include one or more selected from lubricating materials and hard materials.
  • Examples of the lubricating material include one or more selected from graphite powder, coke powder, calcium fluoride powder, barium fluoride powder, boron nitride powder and molybdenum disulfide powder.
  • alumina powder mullite powder, zircon sand powder and silica stone powder can be used.
  • one or more selected from manganese powder, iron oxide powder, Fe--Mo alloy powder, Fe-Si alloy powder, Fe--W alloy powder, mica powder and zeolite powder can be mentioned.
  • the manganese powder and the like mentioned here are not substances that are sintered at the time of sintering, so they are not matrix metal powders.
  • the content of the friction modifier in the friction material composition is preferably 5 to 58% by mass, more preferably 10 to 50.5% by mass, and even more preferably 16 to 41% by mass. .
  • the content of the friction modifier in the friction material composition is within the above range, it has excellent wear resistance and heat resistance even under high output, has a higher coefficient of friction, and even when used repeatedly and deterioration of wear resistance can be suppressed.
  • the friction material composition may optionally contain reinforcing fibers such as carbon fibers, silicon carbide fibers, boron fibers, silica/alumina fibers, glass fibers, aramid fibers, steel fibers, other inorganic fibers, and metal fibers (copper and copper alloys are excluded).
  • reinforcing fibers such as carbon fibers, silicon carbide fibers, boron fibers, silica/alumina fibers, glass fibers, aramid fibers, steel fibers, other inorganic fibers, and metal fibers (copper and copper alloys are excluded).
  • the sintered metal friction material can be produced by using the above-described friction material composition, appropriately molding it by a conventionally known method, and then sintering it.
  • it can be manufactured by mixing each component to prepare a friction material composition, followed by pressure molding to obtain a molded body, and then pressure sintering the molded body.
  • Conventionally known conditions can be adopted for the processing conditions during the molding and pressure sintering.
  • the sintered metal friction material according to this embodiment can be suitably used as clutch materials and brake materials, specifically clutch facing materials, brake lining materials, brake pad materials, and the like.
  • the counterpart material is not particularly limited, but a SUS material is preferable.
  • the friction material composition when a friction material composition lacking copper is used, it is generally difficult to obtain a sintered metal friction material because the molding strength of the compact cannot be maintained.
  • the present embodiment by using two types of nickel together and adopting a specific composition, it is possible to achieve high molding strength despite the lack of copper.
  • Spherical nickel with high fluidity and chain-like nickel for constructing the inter-powder network of the green compact are used in combination.
  • the friction material composition preferably satisfies the following formula (1), where the volume of the spherical nickel powder is Ni 1 vol and the volume of the linear nickel powder is Ni 2 vol .
  • the mating material is a SUS material
  • the use of a friction material composition containing copper tends to reduce the braking force due to the lubricity of copper.
  • a friction material composition with a low copper content is used, moderate adhesive wear due to seizure occurs even if the mating material is a SUS material, A constant frictional force can be obtained from the initial stage of sliding.
  • Table 1 shows the compositions of Examples 1-3 and Comparative Examples 1-7.
  • the unit of the numerical value described in Table 1 is a "mass part.”
  • matrix metal powder copper powder, tin powder, zinc powder, iron powder, phosphorus iron powder, stainless steel powder, spherical nickel powder, chain nickel powder
  • other additives manganesese powder, SiO 2 , mullite, fluorite, Zr sand, graphite, and coke
  • the obtained friction material composition was pressure-molded into a predetermined shape to obtain a molded body.
  • the obtained compact was placed on a copper-plated steel plate and sintered at a temperature of 850° C. in a reducing atmosphere to obtain a sintered metal friction material.
  • the copper powder used had a particle size of 40 ⁇ m. Tin powder having a particle size of 30 ⁇ m was used. Zinc powder having a particle size of 30 ⁇ m was used. Iron powder having a particle size of 80 ⁇ m was used. Phosphorus iron powder having a particle size of 20 ⁇ m was used. The spherical nickel powder used had a particle size of 10 ⁇ m and a loose bulk specific gravity of 1.6 to 2.6 g/cm 3 . Chain nickel powder used had a particle size of 8 ⁇ m and a loose bulk specific gravity of 0.50 to 0.80 g/cm 3 .
  • transverse rupture strength A compact was produced using a mold of 13 mm ⁇ 33 mm, and the transverse rupture strength of the compact (before sintering) was measured by a three-point bending test. The distance between fulcrums was 25 mm.
  • shear strength (shear strength) Using the obtained sintered metal friction material, the shear strength was measured according to JIS D4422.
  • Table 3 shows the presence or absence of aggregates, the bending strength and shear strength measurement results.
  • Table 3 also shows Fevol ratio ( Fevol /( Fevol + Ni1Vol + Ni2vol )), Ni2vol /( Ni1Vol + Ni2vol ), and Cu content.
  • the values of Cu content in Examples 1 to 3 and Comparative Examples 3 to 6 are not 0 wt % because copper is included as an unavoidable impurity.
  • Table 3 regarding the acceptance/rejection of physical properties when the transverse rupture strength was 150 cm 2 or more and the shear strength was 5.0 MPa or more, it was evaluated as " ⁇ ", and the others were evaluated as "X”.
  • Table 4 shows the test results of abrasion resistance.
  • Comparative Examples 1 to 3 when the copper content was reduced, the strength (transverse rupture strength) of the compacts decreased. In particular, in Comparative Example 3 in which only spherical nickel powder was used as the nickel powder, the transverse rupture strength was reduced to 127 (N/cm 2 ). On the other hand, in Comparative Examples 4 and 5, in which chain nickel powder alone was used as the nickel powder, the transverse rupture strength was excellent, or aggregates were generated. In Comparative Example 6, in which the content of the chain-like nickel powder was smaller than that in Comparative Example 4, the problem of aggregates was resolved, but the pad wear amount was as large as 0.69 mm, and the wear property was impaired.

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Publication number Priority date Publication date Assignee Title
WO2018131287A1 (ja) * 2017-01-10 2018-07-19 東海カーボン株式会社 焼結金属摩擦材
WO2018168968A1 (ja) * 2017-03-14 2018-09-20 Jfe精密株式会社 ブレーキ用焼結摩擦材
WO2019003969A1 (ja) * 2017-06-27 2019-01-03 曙ブレーキ工業株式会社 焼結摩擦材及び焼結摩擦材の製造方法
WO2020090725A1 (ja) * 2018-10-31 2020-05-07 曙ブレーキ工業株式会社 焼結摩擦材及び焼結摩擦材の製造方法

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Publication number Priority date Publication date Assignee Title
WO2018131287A1 (ja) * 2017-01-10 2018-07-19 東海カーボン株式会社 焼結金属摩擦材
JP2018111755A (ja) 2017-01-10 2018-07-19 東海カーボン株式会社 焼結金属摩擦材
WO2018168968A1 (ja) * 2017-03-14 2018-09-20 Jfe精密株式会社 ブレーキ用焼結摩擦材
WO2019003969A1 (ja) * 2017-06-27 2019-01-03 曙ブレーキ工業株式会社 焼結摩擦材及び焼結摩擦材の製造方法
WO2020090725A1 (ja) * 2018-10-31 2020-05-07 曙ブレーキ工業株式会社 焼結摩擦材及び焼結摩擦材の製造方法

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