• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    An iron-based alloy powder for powder metallurgy contains 2.0 mass% to 5.0 mass% of Cu, the balance being Fe and incidental impurities. From 1/10 to 8/10 of the Cu is diffusion bonded in powder-form to the surfaces of iron powder that serves as a raw material for the iron-based alloy powder, and the remainder of the Cu is contained in this iron powder as a pre-alloy. The iron-based alloy powder has superior compressibility to conventional Cu pre-alloyed iron-based alloy powders and enables production of a high strength sinter-forged member even when sintered at a lower temperature than conventional iron-based alloy powders containing mixed Cu powder.
    公开号:SE1750785A1
    申请号:SE1750785
    申请日:2015-12-08
    公开日:2017-06-20
    发明作者:Nakamura Naomichi；Sonobe Akio；Kobayashi Akio
    申请人:Jfe Steel Corp；
    IPC主号:
    专利说明:

    [2] [0002] Among powder metallurgical products, sinter-forged products, inparticular, are used as members that are required to have especially highstrength, such as connecting rods for automobile engines.
    [3] [0003] Iron-based alloy powders of an Fe-Cu-C type in which Cu powder andgraphite powder are mixed with pure iron powder are commonly used asprecursor powders for sinter-forged products (PTL l to 4). A machinabilityenhancer such as MnS may also be added to a precursor powder to enhancemachinability (PTL l, 4, and 5).
    [4] [0004] In recent years, there has been demand for even higher strengthmaterials for connecting rod applications due to progress toward morecompact and higher performance engines. Consequently, studies have beenconducted in relation to optimization of the amounts of Cu and C (PTL l, 2,and 5), but the effect of improving strength has been limited.
    [5] [0005] PTL 3 proposes using a pre-alloyed product obtained by pre-alloyingan alloying element, such as Mo, Ni, or Cu, with iron powder. However, notonly are alloying elements expensive, they also form hard structures such asmartensite in an iron-based alloy powder. Consequently, a sintered bodyobtained using an iron-based alloy powder containing some alloying elementssuffers from a problem of poorer machinability.
    [6] [0006] In response to this problem, PTL 4 proposes a technique by which thestrength of a sintered body can be improved while maintaining machinabilityofthe sintered body by only pre-alloying Cu with iron powder.
    [7] [0007] PTL 1: US 6391083 BlPTL 2: US 2006/86204 A1PTL 3: US 3901661 APTL 4: JP 2011-509348 APTL 5: JP 4902280 BPTL 6: JP H10-96001 APTL 7: JP H8-92604 APTL 8: JP 2004-232004 ASUMMARY(Technical Problem)
    [8] [0008] However, the technique described in PTL 4 increases the hardness ofiron-based alloy powder particles and reduces compressibility. Consequently,the strength of a molded body obtained using the iron-based alloy powdertends to be reduced. Moreover, high compression force is required formolding this iron-based alloy powder, which may cause a problem of reducedpress mold life due to the press mold being worn down more readily. Tocombat these problems, a technique has been proposed in which Cu particlesare diffusion bonded to iron powder to ensure compressibility (PTL 6).However, the Cu tends to be ununiformly distributed after sintering and theeffect of improving strength is limited.
    [10] [0010] PTL 4 provides an example of a conventional technique in which Cu ispre-alloyed with a raw material iron powder. However, the aim of thetechnique in PTL 4 is to raise the uniformity of Cu distribution in the rawmaterial iron powder after the pre-alloyed raw material iron powder is mixedwith only graphite powder and sintered. Thus, the technique in PTL 4 does notsuggest optimal allotment of Cu (i.e., a ratio of pre-alloyed Cu and diffusionbonded Cu) for achieving a balance of both compressibility in greencompacting and uniformity of Cu distribution after sinter-forging.
    [11] [0011] The primary features ofthe present disclosure are as follows.1. An iron-based alloy powder for powder metallurgy in which Cu isdiffusion bonded in powder-form to surfaces of raw material iron powderpre-alloyed with Cu, the iron-based alloy powder comprising (consisting of)2.0 mass% to 5.0 mass% of Cu, the balance being Fe and incidentalimpurities, wherein1/10 to 8/10 of the Cu is diffusion bonded to the surfaces of the rawmaterial iron powder and the remainder ofthe Cu is pre-alloyed.
    [12] [0012] 2. A sinter-forged member having the iron-based alloy powderaccording to 1 as a precursor.
    [13] [0013] According to the presently disclosed techniques, Cu is distributedmore uniformly at the surfaces of iron powder, which enables a uniform Cudistribution to be obtained in a sintered member even when the sinteringtemperature is low compared to conventional iron-based alloy powders of anFe-Cu-C type. Consequently, a sinter-forged member having high mechanicalstrength can be produced at low cost.
    [15] [0015] The main feature disclosed herein is that 1/10 to 8/10 of the Cucontained in the iron-based alloy powder is diffusion bonded in powder-formto the surfaces of raw material iron powder that has been subjected topre-alloying, and the remainder of the Cu is contained in the raw material ironpowder as a pre-alloy.
    [16] [0016] If the amount of diffusion bonded Cu is less than 1/10 of the amountof Cu contained in the iron-based alloy powder, an effect of improvingcompressibility of the iron-based alloy powder is reduced. On the other hand,if the amount of diffusion bonded Cu exceeds 8/10 of the amount of Cucontained in the iron-based alloy powder, the uniformity of Cu distribution atthe surfaces of the raw material iron powder that has been subjected topre-alloying is not improved and the effect of improving strength of asinter-forged member is limited.
    [17] [0017] In this disclosure, when Cu is described as being diffusion bonded inpowder-form to the surfaces of the raw material iron powder that has beensubjected to pre-alloying, this means that Cu powder having an averageparticle diameter (d50) of approximately 50 um or less, and preferablyapproximately 20 um or less, is diffusion bonded to the surfaces of the rawmaterial iron powder that has been subjected to pre-alloying. The averageparticle diameter (d50) ofthe Cu powder refers to a particle diameter at whicha value of 50 % is reached when a cumulative particle size distribution ismeasured on a volume basis by laser diffraction-scattering.
    [18] [0018] When the disclosed iron-based alloy powder is embedded in resin andRef. No. PO153451-PCT-ZZ (4/16)polished, and an element distribution in a particle cross-section thereof ismapped by an electron probe microanalyzer (EPMA), the distribution ofpre-alloyed Cu is observed. On the other hand, when the particle surfaces ofthe iron-based alloy powder are mapped by the EPMA, a higher concentrationof Cu is observed at the particle surfaces ofthe iron-based alloy powder thanwithin the particles due to the diffusion bonded Cu powder.
    [19] [0019] Although the uniformity of Cu after sinter-forging can be improvedthrough use of finer Cu powder particles, metallic copper powder having anaverage particle diameter of 20 um or less is expensive. Therefore, it ispreferable to set a lower limit of approximately 10 um for the average particlediameter of the Cu powder when metallic copper powder is used as a rawmaterial. Herein, the powder used as a copper source may be a conventional,commonly known powder used for iron-based alloy powders, such as metalliccopper or copper oxide.
    [20] [0020] The iron powder used herein as a raw material for the iron-based alloypowder (this iron powder is referred to herein as “raw material iron powder”)may be any commonly known powder used for iron-based alloy powders.
    [22] [0022] The following describes the method by which Cu is diffusion bondedin powder-form to the surfaces ofthe raw material iron powder.
    [23] [0023] The following describes a method for producing the disclosediron-based alloy powder.
    [24] [0024] Heat treatment: Heat treatment in which the raw material iron powderis held in a reducing atmosphere for approximately 0.5 hours to 2 hours in atemperature range of 800 °C to 1000 °C may be performed to remove oxygenand carbon from the raw material iron powder.
    [25] [0025] Cu powder mixing: Mixing of the Cu powder with the raw materialiron powder obtained after Cu pre-alloying may be performed by anyconventional, commonly known method (for example, using a V-mixer, adouble-cone mixer, a Henschel Mixer, or a Nauta Mixer). A binder such asmachine oil may be added in the powder mixing to prevent segregation of theRef. No. P01 5345 l -PCT-ZZ (6/16)mixed Cu powder.
    [26] [0026] Diffusion bonding heat treatment: The Cu powder is diffusion bondedto the surfaces of the raw material iron powder obtained after pre-alloying bysubjecting the Cu powder mixture described above to heat treatment in whichthe mixture is held in a reducing atmosphere (for example, hydrogen gas orhydrogen-nitrogen mixed gas) for approximately 0.5 hours to 2 hours in atemperature range of 700 °C to 1000 °C.
    [27] [0027] Grinding and classification: Classification of a specific particle sizecan be performed using a sieve or the like after grinding by any commonlyknown method, such as using a hammer mill.
    [28] [0028] The following describes a production method (sinter-forging method)for a sinter-forged member for which the presently disclosed iron-based alloypowder is used.
    [30] [0030] A lubricant, such as zinc stearate, may be mixed at the same time, orin a separate step, in an amount of 0.3 mass% to 1.0 mass%. Furthermore, asubstance for enhancing machinability, such as MnS, may be mixed inpowder-form in an amount of 0.1 mass% to 0.7 mass%.
    [31] [0031] Next, compression molding is performed using a press mold to obtaina specific shape. The compression molding may be performed by a commonlyknown technique used in sinter-forging.
    [32] [0032] The sintering may be preceded by a degreasing step in which thetemperature is maintained in a range of 400 °C to 700 °C for a specific time toremove the lubricant.
    [33] [0033] Hot forging is performed either consecutively with the sintering,without cooling, or after cooling and subsequent reheating. Commonly knownforging conditions may be used. The forging temperature is preferably 1000°C or higher. The forging temperature is preferably 1200 °C or lower.
    [34] [0034] Production conditions, equipment, methods, and so forth for thesinter-forged member, other than those described above, may be anycommonly known examples thereof.
    [36] [0036] 0 Production and evaluation of sinter-forged memberA mixed powder was obtained by adding 0.6 parts by mass of graphitepowder, 0.8 parts by mass of a lubricant (zinc stearate), and 0.6 parts by massof MnS powder to 100 parts by mass of iron-based alloy powder andRef. No. PO153451-PCT-ZZ (9/16)_10-performing mixing using a double cone mixer.
    [37] [0037] [Table 1]Table 1^0X00009 99.9 090 00::0> .XL0:2:96: mm_o mm:: oww o»:: w»_o o.o mm 90:02:00: :O 220960: o o_: o.m o.m m:0:2:96: mm_o mo: : mmw om: : w»_o o.o mm 90:02:00: :O 220960: o o_: o.m o.m ::0:2:96: om.o woo: mo» om: : m»o o.o mm 90:02:00: :O 220960: o m_: m_: o.m o:0:2:96: owo owo: om» om: : mwo o.o mm 90:02:00: :O 220960: o w_m o.o o.m o0:2:9620 02::00902:90O om.o m oo: owo om: : owo o.o mm 90:02:02: :O 2020960: o »_m m.o o.m 990O o omo: wo» o»:: mmo o.o - - o.m o o o.m w0:2:9620 :690:0990>990O o o»o m»o om: : mmo o.o - - o.m o o o.m »0:2:9620 :690:0990>990O o »wo woo om: : w»o o.o - - o o o.m o.m o0:2:96: m: .o mmo mm o om: : mwo o.o mm 90:02:00: :O 220960: o m.o »_: o.m m0:2:96: om.o omm owo om: : wwo o.o m: 90:02:00: :O :0009004 o o: o: o.m 0:2:96: om.o oww o: o om: : owo o.o mm 90:02:00: :O 220960: o o: o: o.m w0:2:96: owo oww woo om: : :oo o.o mm 90:02:00: :O 220960: o o: w_o o.m 990O o wmw owm om: : om.o o.o - - o.m o o o.m m0:2:9620 02::00902:90O om.o :w wow om: : m oo o.o mm 90:02:02: :O 2020960: o m.o »o o: :99: 90 096 0 9900000000000000000000000002 2000020 2000020 6000 200000020 20000000 0200M00 :00000002200 005 0000002 0W0000W00000w 0002000000000 0290090: :O :00:09902: 9:0~w990900 000900 09:00900:900 20209900 22: 090% _ 0: : 0 990 99090 G0 v _99099_9 0 0 : 0 _02990902fi9:0<:0 099:09< 0:90990f:0 :0:09> w9900999w :0000090:90O 0092:90 90:02:0 O :0 :0 2: _ å: 0 0 0 :: O :6 :L_ _ _ _ _ _ _ 90:02:00: 20: :0006:-9909:: 0:2:0f:0Ref. No. PO153451-PCT-ZZ (11/16)_12-Table 1 (cont°d)ošmmš n.. En mu2m> .xoQñëäß QEEßQEoO ß: .o wm :: mww om: : mm.o o.o mm Eošo: :O äåoboßm: o o. : o.m o.o wmQEESG :ÉQEQEoO o ww: oww om: : wwo o.o - - o o m.w m.w mmoñëmxm: : : .o mv: www om: : mm.o o.o mm Eošo: :O ouboboßm: o m.o o.w m.w mmoñëmxm: omo ow: oow om: : wm.o o.o mm Eošo: :O aåoboßm: o m. : m.m m.w <:moñëmxm: wwo om: : mww om: : mo.o oo mm Eošo: :O ouboboßm: o o.m m.m m.w :moñëmxm: om.o o: :: mmw om: : mßo oo mm Eošo: :O ouboboßm: o m.m o.m m.w omQñëßwo QEEßQEoO ßwo mo: : ma: om: : wßo oo mm Eošo: :O aåoboßm: o o.m oo m .w då:QEESG :ÉQEQEoO o ow: oßw om: : oo.o oo - - o o o.m o.m o:Qñëäß QEEßQEoO wo.o om: wow om: : wo.o oo mm Eošo: :O äåoboßm: o mo w.m o.m w:oñënxm: ß: .o wm:: wow om: : :wo oo m.m Eošo: Bio w:o&:O o mo m.m o.m <ß:oñëmxm: b: .o om: : mww om: : oßo oo mm Eošo: :O ouboboßm: o mo m.m o.m ß:oñëmxm: :o woo: :w om:: oßo oo mm Eošo: :O ouboboßm: mo mo o.m o.m o:oñëmxm: mm.o mb: mww oß: wßo oo m Eošo: :O :vëoë o o: o.m o.m m:oñënxm: mm.o oo: mww oß: wßo oo m.m Eošo: Bio w:o&:O o o: o.m o.m v:oñëmxm: mm.o wo:: :ow omm: wßo oo mm Eošo: :O ouboboßm: o o: o.m o.m m:E: E än. o :o:O oo :šocä :SoH OBHQ/:v QnQ/:o AOL AMEEÉV G må: oíto: oowåowmfi QÉH ooxš: :oñfiä ooæošw -Em omowmwßmvtšow: :O :öosoo :rmsohm mmohm QÉEQQEB Émsoo »o mtmmo Eošo: :O :öosoo coäå: oxo :sficfišm :O :SoH .szâëfiwoø ošêë ëëå :å wëaem Eæåeå æêäöEošo: :ån :V33 .coh:ESV _ 2%:Ref. No. PO153451-PCT-ZZ (12/16)_13-
    [38] [0038] No. 1 in which the added amount of Cu was lower than the disclosedrange had a low yield stress compared to examples conforming with thisdisclosure. Moreover, No. 24 in which the added amount of Cu was higherthan the disclosed range had low compressed density.
    [39] [0039] ConVentional examples in which Cu was only mixed with raw materialiron powder (Nos. 2, 7, and 8) had low yield stress after sinter-forgingcompared to examples conforming with this disclosure in which the addedamount of Cu and other conditions were the same (Nos. 3A, 4, and 5 for No. 2;Nos. 9-11 for No. 7; and No. 12 for No. 8). This is thought to be due to Cu notbeing uniformly distributed at the surfaces of the iron powder.
    [40] [0040] Conventional examples in which Cu was not diffusion bonded to rawmaterial iron powder that had been subjected to pre-alloying (Nos. 6, 19, and23) had low compressed density and poor compressibility compared toexamples conforming with this disclosure in which other conditions were thesame (Nos. 3A, 4, and 5 for No. 6; Nos. 9-11, 16, and 17 for No. 19; and Nos.20-22 and 21A for No. 23). This is thought to be due to excessive pre-alloyingof Cu with the raw material iron powder.
    [41] [0041] Under conditions in which the amount of diffusion bonded Cu waslower than the disclosed range (No. 18), compressed density was low andcompressibility was poor compared to examples conforming with thisdisclosure in which other conditions were the same (Nos. 10, 11, 16, and 17).This is thought to be due to excessive pre-alloying of Cu with the base metalofthe raw material iron powder.
    [42] [0042] Under conditions in which the amount of diffusion bonded Cu washigher than the disclosed range (Nos. 3, 8A, and 19A), yield stress was lowcompared to examples conforming with this disclosure in which otherconditions were the same (Nos. 3A, 4, and 5 for No. 3; Nos. 9-11, 16, and 17for No. 8A; and Nos. 20-22 and 21A for No. 19A). This is thought to be due toCu not being uniformly distributed within the sintered member.
    [43] [0043] Under conditions in which the particle diameter of diffusion bondedCu powder was small (Nos. 4A and 15), yield stress and tensile strength werehigh compared to under conditions in which the particle diameter of the Cupowder was coarser, but other conditions were the same (No. 4 for No 4A andNo. 12 for No. 15). This is thought to be due to Cu being more uniformlyRef. No. PO153451-PCT-ZZ (13/16)_14-distributed at the surfaces ofthe iron powder.
    [44] [0044] No. 14 in which cuprous oxide powder having an average particlediameter of 2.5 um was used as Cu powder for diffusion bonding had evenhigher yield stress and tensile strength than No. 12 in which the particlediameter of the Cu was coarser, but other conditions were the same. On theother hand, No. 14 had yield stress and tensile strength roughly equivalent tothose of No. 13 in which the particle diameter of the Cu was coarser and thesintering temperature was 1250 °C. This shows that by using Cu powderhaving a smaller particle diameter for diffusion bonding, a uniform Cudistribution can be achieved in a sintered member even through a lowersintering temperature, enabling greater expression of the effects of thepresently disclosed techniques.
    [45] [0045] Note that higher yield stress was achieved in examples conformingwith this disclosure with a sintering temperature of 1120 °C (Nos. 10, 11, 16,and 17) than in No. 8 with a sintering temperature of 1170 °C, which is aconventional example in which Cu was mixed with iron powder. This isthought to be due to conformance with the present disclosure enabling a moreuniform Cu distribution to be achieved in a sintered member even when alower sintering temperature is adopted.
    Ref. No. PO153451-PCT-ZZ (14/16)
    权利要求:
    Claims (2)
    [1] 1. An iron-based a11oy powder for powder meta11urgy in which Cu isdiffusion bonded in powder-form to surfaces of raw material iron powderpre-a11oyed with Cu, the iron-based a11oy powder comprising 2.0 mass% to 5.0 mass% of Cu, the balance being Fe and incidentalimpurities, wherein 1/10 to 8/10 of the Cu is diffusion bonded to the surfaces of the raw materia1 iron powder and the remainder ofthe Cu is pre-alloyed.
    [2] 2. A sinter-forged member having the iron-based alloy powder of c1aim 1 as a precursor. Ref. No. PO153451-PCT-ZZ (15/16)
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    JP2014252313|2014-12-12|
    JP2015120565|2015-06-15|
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