CN101484611B - 金属构件的表面硬化方法和使用其表面硬化方法制造的活塞、汽缸盖、汽缸体及其制造方法 - Google Patents

金属构件的表面硬化方法和使用其表面硬化方法制造的活塞、汽缸盖、汽缸体及其制造方法 Download PDF

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CN101484611B
CN101484611B CN2007800238200A CN200780023820A CN101484611B CN 101484611 B CN101484611 B CN 101484611B CN 2007800238200 A CN2007800238200 A CN 2007800238200A CN 200780023820 A CN200780023820 A CN 200780023820A CN 101484611 B CN101484611 B CN 101484611B
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piston
alloy layer
cast iron
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mother metal
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荻野知也
金井保博
冈正德
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Yanmar Power Technology Co Ltd
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Abstract

在发动机部件的表面涂布耐磨性优异的合金层，使部件寿命提高的表面硬化方法，和采用该方法使耐磨性提高的活塞等的制造方法中，通过将金属粉末、粘合剂和溶剂混合，将该混合物均匀地涂布在金属母材表面形成涂膜，使该涂膜干燥，照射激光或电子束使之烧结和扩散，在上述金属母材表面生成合金层的同时，使该合金层与金属母材结合。

Description

金属构件的表面硬化方法和使用其表面硬化方法制造的活塞、汽缸盖、汽缸体及其制造方法
技术领域
本发明涉及发动机或驱动部件等的输送机械领域或机械结构领域等需要耐磨性的部件使用的金属构件的表面硬化方法及其制造方法。
技术背景
近年，随着原油的重质化、轻质油的需求增加、石油加工方法的变化等，低质油的燃料性质恶化，由于燃料中含有的硬质粒子或硫含量、燃料残渣物等内燃机的部件处于容易磨损的环境。
为了适应上述状况，例如作为主要用于使柴油机使用的一体型FCD(球墨铸铁)制活塞的环形槽部的耐磨性提高的技术，使用激光对环形槽部进行淬火的这样的激光淬火技术(例如，参照专利文献1)、高频淬火技术(例如，参照专利文献2)和镀铬处理技术等成为公知技术而广泛地使用。
专利文献1：特开昭61-149424号公报
专利文献2：特开平7-119831号公报
然而，采用激光淬火技术或高频淬火技术实施淬火的部分的硬度只有600Hv～800Hv左右。并且，淬火部分的组织不是完全均匀的，混合存在着马氏体、贝氏体、残留奥氏体等的组织，硬度的偏差也大。
另外，第一道密封环槽容易传导发动机燃烧温度，变成约150℃以上时淬火组织被回火，硬度约降低100Hv～200Hv左右。
此外，活塞的材质是容易腐蚀的铸铁的场合，燃烧气体中含有的硫等对环形槽部发生腐蚀。
由于上述理由，通过长时间使用活塞环槽部磨损、尤其是内燃机用的活塞环槽，由于磨损其上下间隙增大时，由于抽吸作用而使润滑油上升过多，因此润滑油消耗量变大。所以达到一定的磨损量时必须更换活塞，从而产生维修费用。
另外，激光淬火在淬火深度达到约300μm以上时，由于发生许多微细龟裂，因此淬火不能够太深。而高频淬火虽然淬火深度可达到约800μm左右，但热处理变形大，需要磨削等后加工。
另外，镀铬处理中的表面硬化，镀敷部分的硬度为800Hv～1000Hv左右，虽然耐磨性优异，但成本非常高。并且镀敷处理液含有六价铬，因此若考虑对环境的影响不是优选的方法。
发明内容
发明要解决的课题
因此本发明是鉴于上述状况而完成的发明，要解决的课题是提供在发动机部件的表面涂布耐磨性优异的合金层，使部件寿命提高的表面硬化方法，和采用该方法使耐磨性提高的活塞等的制造方法。
解决课题的方法
本发明的金属构件的表面硬化方法，是将含有金属粉末、粘合剂和溶剂的混合物均匀地涂布在金属母材表面上形成涂膜，通过使该涂膜干燥照射激光或电子束使之烧结和扩散，在上述金属母材表面生成合金层的同时，将该合金层与上述金属母材进行结合的方法。
本发明的金属构件的表面硬化方法，是通过在上述涂膜上被覆石墨促进上述金属粉末的烧结和扩散的方法。
本发明的金属构件的表面硬化方法，是上述金属母材为铸铁母材的方法。
本发明的活塞的制造方法，是对内燃机用活塞的环形槽部使用权利要求1～3的任何一项所述的金属构件的表面硬化方法的制造方法。
本发明的汽缸盖的制造方法，是对内燃机用汽缸盖的阀座部使用权利要求1～3的任何一项所述的金属构件的表面硬化方法的制造方法。
本发明的汽缸体的制造方法，是对内燃机用汽缸体的衬里表面部使用权利要求1～3的任何一项所述的金属构件的表面硬化方法的制造方法。
本发明的活塞，是对内燃机用活塞的环形槽部使用权利要求1～3的任何一项所述的金属构件的表面硬化方法的活塞。
本发明的汽缸盖，是对内燃机用汽缸盖的阀座使用权利要求1～3的任何一项所述的金属构件的表面硬化方法的汽缸盖。
本发明的汽缸体，是对内燃机用汽缸体的衬里表面部使用权利要求1～3的任何一项所述的金属构件的表面硬化方法的汽缸体。
发明效果
作为本发明的效果，通过在金属构件的制造中使用本发明的表面硬化方法，即通过在金属母材表面均匀地涂布含有金属粉末、粘合剂和溶剂的混合物形成涂膜，使该涂膜干燥照射激光或电子束使之烧结和扩散，在上述金属母材表面生成合金层的同时，将该合金层与金属母材结合的方法，使MoC或VC这样的MC型碳化物微细且均匀地分散在例如内燃机用FCD制活塞的环形槽表面部，可容易地形成具有1000～3000Hv左右硬度的高硬度合金层。由此能够防止碳等的燃烧残渣物导致的腐蚀性磨损。
另外，钢铁材料的场合，在150℃以上时引起由回火导致的硬度降低，但如上述那样的特殊碳化物是高熔点的，即使是高温下也难以凝聚粗大化。因此，防止环形槽表面的硬度随发动机运转时活塞环槽部的温度上升而降低。
此外，通过在表面形成比钢铁材料有耐腐蚀性的陶瓷类合金，能够防止硫等导致的腐蚀。
另外，现有技术的高频淬火，淬火后必须回火和磨削。
而本发明在对环形槽进行切削加工后，通过在其表面形成100μm～300μm的均匀的合金层，省去回火，可以没有后加工，因此能够降低制造成本。
附图说明
图1是表示本发明的一实施例涉及的制造工序。
图2是相同的一部分剖面的活塞使用的模型图。
图3是图2的主要部分放大剖面图。
图4是示意地表示采用本发明方法制造的铸铁制汽缸盖一例的主要部分剖面图。
图5是图4的Z部分扩大图。
图6是表示汽缸体的衬里表面部分的图。
符号说明
1-活塞、3、4-环形槽部分、8-激光、10-激光吸收剂、15-汽缸盖、19-阀座、20、21、22-合金层、25-汽缸体、26-衬里表面部。
实施发明的最佳方式
以下，对发明的实施方式进行说明。
图1是表示本发明的一实施例涉及的制造工序的图，图2是相同的一部分剖面的活塞使用的模型图，图3是图2的主要部分放大剖面图，图4是示意地表示采用本发明方法制造的铸铁制汽缸盖一例的主要部分剖面图，图5是图4的Z部分放大图，图6是表示汽缸体的衬里表面部分的图。
实施例1
利用图1、图2和图3对内燃机用铸铁制活塞制造使用本发明的金属构件的表面硬化方法的工序进行说明。
<铸造·机械加工工序>
向铸型中流入铸铁熔液铸造FCD(球墨铸铁)制活塞1后，对活塞环槽部进行切削加工，形成环形槽部3、4。
<配合·涂布工序>
首先，对数种金属粉末称取规定量进行配合。接着，使用球磨机等将合金粉末混合使上述金属粉末均等地分散。向该合金粉末中加入规定量的溶剂进一步进行混合，使合金粉末与溶剂均匀地分散。然后向其中添加粘合剂充分地进行搅拌使整体成为均匀的混合物。
接着，使用喷射用喷嘴(未图示)在上述环形槽部3、4涂布如上述制得的合金粉末、树脂与溶剂混合的混合物。进行涂布时，以一定速度使活塞1旋转，形成均匀的粉末合金层(厚度：200～400μm)。形成该粉末合金层后，在常温下放置使溶剂充分地干燥。
作为上述金属粉末，例如优选使用Cr、V、W、Mo、Ti等生成非常硬的碳化物(MC系碳化物)的金属，而作为形成其他的硬质合金的金属，也可以使用氧化铝、TiN、TiO2、CrN、氧化锆、SiC、TiC等形成粉末合金层。另外树脂优选使用在常温下能够固化的邻苯二甲酸树脂系、醇酸树脂系的树脂，但不限定于这些树脂。
另外，作为溶剂可使用稀释剂、甲苯、二甲苯或甲醇、乙醇、丙醇等的醇类，考虑干燥速度或安全性适当进行选择即可。
再者，作为实施例虽然举出了如上述向金属粉末与溶剂的混合物中后添加粘合剂的工序作为一个例子，但也可以成为在溶剂与粘合剂的混合物中添加金属粉末进行配合的工序。
另外，为了得到本发明的效果，作为粉末合金层的厚度优选为200～400μm左右，但不限定于此。
再者，金属粉末不仅可以混合多种也可以只使用单一的金属粉末。另外，为了促进溶剂干燥也可以将被涂布物放入干燥炉等中缩短干燥时间。
<涂布吸收剂工序>
使用喷射用喷嘴在上述粉末合金层的上面按照激光波长涂布激光吸收剂10使之成为5μm～15μm左右的膜厚。在进行涂布时以一定速度使活塞1旋转以成为均匀的被膜。形成该被膜后，在常温下放置使溶剂充分干燥。
本实施例中，作为激光吸收剂10使用由稀释剂等的溶剂稀释石墨粉末的吸收剂在粉末合金层上形成石墨被膜，但不特别限定于此，也可以将氧化铁为主要成分的涂布剂等作为吸收剂进行涂布。
另外，上述稀释溶剂可以使用稀释剂、甲苯、二甲苯或甲醇、乙醇、丙醇等的醇类，考虑干燥速度或安全性适当地进行选择即可。
<合金化工序>
如图2和图3所示按照适当的输出功率和扫描速度对环形槽部3、4照射激光或电子束，使粉末合金层烧结或熔融，在环形槽部3、4上形成150μm～350μm左右膜厚的合金层20。
另外，作为激光，可举出CO2激光或YAG激光、半导体激光等。还可以使用能量高于激光的电子束等。
这样，通过前工序的激光吸收剂(石墨被膜)10的涂布，激光8在粉末合金层上被高效率地吸收、粉末合金层被加热，由于在粉末合金层内以及该粉末合金层与活塞等金属母材(铸铁母材)的界面部促进烧结和熔融、向母材的扩散，因此在金属母材表面生成牢固而具有耐磨性的合金层的同时，能够将该合金层与金属母材(铸铁母材)进行结合。
再者，本实施例中作为金属母材使用FCD(球墨铸铁)制的构件，但不特别限定于此也可以是铝合金等。
<精加工>
通过以上的工序制造的活塞1的环形槽3、4，根据需要进行合金层20的表面的磨削加工。
通过这样的工序能够制造环形槽部3、4具有合金层的活塞。
以下，对制造活塞1的具体的一个例子进行说明。
首先，秤取Mo(钼)粉末添加到作为溶剂的甲苯中，使用球磨机进行混合。接着添加规定量的邻苯二甲酸树脂，进行搅拌使整体成为均匀的混合物。
接着，一边使FCD制活塞沿周围方向旋转，一边使用喷射用喷嘴在环形槽部3的凹部均匀地涂布上述混合物使膜厚成为300μm左右形成粉末合金层。形成该粉末合金层后，在常温下放置使溶剂充分地干燥。
接着，使用喷射用喷嘴在上述粉末合金层上涂布激光吸收剂10(石墨与稀释剂的混合物)使之成为10μm左右的膜厚。进行涂布时使活塞以一定速度沿圆周方向旋转，以成为均匀的被膜。形成该被膜后，在常温下放置使溶剂充分地干燥。
然后，如图2和图3所示使用CO2激光器对环形槽部3照射激光8，例如在环形槽部3的上侧面形成合金层20的场合，利用聚光透镜5将激光8聚光后，利用反射镜6形成的入射角α，一边对上述上侧面进行照射，一边使该活塞1旋转使槽整个圆周形成合金层20。接着，在环形槽部3的下侧面形成合金层20的场合，可使活塞1上下倒置照射激光8，但也可以使激光8的入射角α变化进行照射。
在此，本实施例中，尤其是在环形槽部3的两侧面形成合金层20时，如图2所示，使激光8具有入射角α，而且利用涂布有与该槽的粉末合金层上涂布的激光吸收剂10同样的石墨的遮蔽板9遮住角部12进行照射，因此不需要剥离该角部12的激光吸收剂10而调整其厚度，能够只在磨损区域11形成合金层20，能够不使该角部12熔融、而防止熔融导致的龟裂等的缺陷进行构成。
这样，制得在环形槽3的磨损区域11形成了合金层20的活塞。
<耐磨性评价方法>
在与上述的工序同样的制作条件下，使球墨铸铁制试片(30×100(mm))上形成合金层20，使用维氏硬度计测定表面的硬度，进行耐磨性评价。如上述那样使用Mo(钼)形成合金层20的试片，维氏硬度为2000Hv左右。与作为母材的球墨铸铁(维氏硬度300Hv～350Hv)进行比较确认得到6倍左右的高硬度的合金层20。
<合金层的分析方法>
作为对上述试片使用EDX(能量分散型荧光X射线分析装置)分析合金层20与作为铸铁母材的试片的界面部分的结果，确认成梯度地分布着Mo(钼)。即确认合金层20与铸铁母材结合。另外，使用X射线衍射装置也确认Mo与C结合生成高硬度且高熔点的作为陶瓷合金一例的MoC(钼碳化物)。
通过在金属构件的制造中使用本发明的表面硬化方法，即通过将金属粉末、粘合剂和溶剂混合，将该混合物均匀地涂布在金属母材表面上形成涂膜(粉末合金层)，使该涂膜干燥后照射激光8或电子束使之烧结和熔融、扩散，在上述金属母材表面生成合金层20的同时，将该合金层20与金属母材结合，例如使MoC或VC这样的MC型碳化物微细且均匀地分散在FCD制活塞的环形槽表面部，能够容易地形成具有1000～3000Hv左右硬度的高硬度的合金层。由此能够大幅度地提高耐磨性或耐热性，防止碳等的燃烧残渣物导致的腐蚀性磨损。
另外，即使是使用昂贵的金属合金的场合，由于只是必要的部位使用因此使用量极少经济性好。
另外，钢铁材料的场合在150℃以上时引起回火导致的硬度降低，但如上述的MoC等的特殊碳化物为高熔点即使是高温下也难以凝聚粗大化。为此，防止随发动机运转时活塞环槽部3、4温度上升而环形槽表面的硬度降低。
此外，通过在表面形成如上述比钢铁材料更具有耐腐蚀性的陶瓷系的合金能够防止硫等导致的腐蚀。
另外，现有技术的高频淬火，淬火后必须回火和磨削。
而本发明对环形槽部3切削加工后，通过在其表面均匀地形成100-～300μm的合金层20，省去回火，可以没有后加工，因此能够降低制造成本。
实施例2
以下，利用图4、图5对内燃机用铸铁制汽缸盖使用本发明的金属构件的表面硬化方法的例子进行说明。
除了使用V(钒)与C的混合粉末作为金属粉末以外，在与实施例1同样的制造条件下，制得汽缸盖15。
如图5所示，在铸铁制汽缸盖15中，通过阀杆18沿上下方向滑动自如地支撑吸气阀16和排气阀17。在作为汽缸盖15的滑动部的阀座部19上，按照本发明的制造方法形成150μm～350μm的膜厚的合金层21。在该合金层21与作为铸铁母材的汽缸盖15的界面部分成梯度地分布着V，并且确认生成VC(钒碳化物)。已知VC为与实施例1的MoC同样地为高硬度且具有耐磨性、耐热性的陶瓷合金(维氏硬度：2500Hv～2800Hv左右)，在滑动部的耐磨性提高方面非常有效。即通过如上述金属粉末被激光8加热熔融，在合金层21内和合金层21与作为母材的汽缸盖15的界面部分促进烧结和扩散，能够制造在阀座部19的表面具有有耐磨性的合金层21的阀座一体型汽缸盖15。
若采用由以上的工序制造的铸铁制汽缸盖15，则能够使阀座部19与铸铁母材(汽缸盖11)成为一体结构，因此能够使作为铸铁母材的汽缸盖11与合金层21的边界部的结合强度提高。即与以往的阀座嵌合方式的铸铁汽缸盖进行比较，能够提高结合强度。
实施例3
以下，利用图6对内燃机用铸铁制汽缸体的衬里表面部使用本发明的金属构件的表面硬化方法的例子进行说明。
除了使用W(钨)与C的混合粉末作为金属粉末以外，在与实施例1同样的制造条件下制得汽缸体25。
按照本发明的制造方法在如图6所示成为铸铁制汽缸体25的滑动部的衬里表面部26上形成150μm～350μm膜厚的合金层22。在该合金层22与作为铸铁母材的汽缸体25的衬里表面部26的界面部分成梯度地分布着W，并且确认生成WC(钨碳化物)。已知WC与实施例1的MoC或实施例2的VC同样为高硬度且具有耐磨性·耐热性的陶瓷合金(维氏硬度：2600～2800Hv左右)，在耐磨性提高方面非常有效。即通过如上述金属粉末被激光8加热熔融，在合金层22内和合金层22与作为母材的汽缸体25的衬里表面部26的界面部分促进烧结和扩散，能够制造衬里表面部31具有有耐磨性的合金层22的铸铁制汽缸体25。
再者，本实施例中虽然对内燃机用金属构件形成具有耐磨性及耐热性的合金层的方法进行了说明，但也可以在除此以外的用途中在需要耐磨性的构件表面部同样地形成合金层提高耐磨性。
产业上的利用可能性
本发明不限于内燃机用金属构件的用途，可以广泛地在需要耐磨性的构件表面部使用。

Claims (2)

1.一种金属构件的表面硬化方法，其特征在于，将包含含有碳粉末的钨粉末、粘合剂和溶剂的混合物均匀地涂布在铸铁母材表面上形成涂膜，通过使该涂膜干燥，照射激光或电子束使之烧结和扩散，在上述铸铁母材表面生成合金层的同时，将该合金层与上述铸铁母材进行结合，通过在上述涂膜上被覆由溶剂稀释石墨粉末而得到的吸收剂，促进上述钨粉末的烧结以及向上述铸铁母材的扩散。
2.一种活塞的制造方法，其特征在于，对内燃机用活塞的环形槽部使用权利要求1所述的金属构件的表面硬化方法。
CN2007800238200A 2006-05-16 2007-03-12 金属构件的表面硬化方法和使用其表面硬化方法制造的活塞、汽缸盖、汽缸体及其制造方法 Expired - Fee Related CN101484611B (zh)

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