The present invention relates to a brass-based copper alloy for a plain bearing and a plain bearing.
A copper alloy in which crystallized Mn-Si compound particles are dispersed in a sliding surface is known (see Patent Literature 1). In Patent Literature 1, the average interparticle distance among the crystallized Mn-Si compound particles is defined within the range of 20 to 80 μm, thereby making it possible to bring a surface of the copper alloy matrix in a uniformly active state and to form a sulfide film at an early stage. This sulfide film enhances the seizure resistance.
Patent Literature 1: Japanese Unexamined Patent Application Publication No. 2011-179600
However, with the progress of the wear of the matrix, hard crystallized Mn-Si compounds protrude, so that the load from a counter shaft concentrates on the crystallized Mn-Si compounds. Therefore, seizure would be easily and disadvantageously caused by the frictional heat generated at the crystallized Mn-Si compounds. Further, even if the average interparticle distance among the crystallized Mn-Si compound particles is managed within the range of 20 to 80 μm, a region with an increased interparticle distance, i.e., a region where the crystallized Mn-Si compounds are present sparsely can be created. In the region where the crystallized Mn-Si compounds are present sparsely in this manner, the load would disadvantageously concentrate on a small number of the crystallized Mn-Si compounds, thereby easily causing seizure.
The present invention has been made in light of the aforementioned problems, and an object thereof is to provide a copper alloy for a bearing and a bearing, which can prevent seizure in Mn-Si primary crystals.
In order to attain the aforementioned object, the copper alloy for a bearing and the bearing according to the present invention contain: 25 wt % or more and 48 wt % or less of Zn, 1 wt % or more and 7 wt % or less of Mn, 0.5 wt % or more and 3 wt % or less of Si, and 1 wt % or more and 10 wt % or less of Bi, the balance consisting of inevitable impurities and Cu, and are characterized in that, in a sliding surface on which a counter material slides, the proportion of triangles having an area of 5000 μm2 or more and including no Bi particle with a circle equivalent diameter of 10 μm or more, among triangles having the closest three Mn-Si primary crystals as apices, is 20% or less.
In the copper alloy for a bearing configured in the above manner, Bi which has been supplied from the Bi particles covers the sliding surface, thereby making it possible to improve the seizure resistance. Here, a region where triangles having Mn-Si primary crystals as apices and also having an area of 5000 μm2 or more are formed, i.e., a region where Mn-Si primary crystals are present sparsely, can be formed. It is noted that, assuming an equilateral triangle having an area of 5000 μm2 or more, the length of one side of the equilateral triangle, i.e., the distance between the Mn-Si primary crystals, is 107.45 μm. In the region where the Mn-Si primary crystals are present sparsely in this manner, the load would concentrate on the Mn-Si primary crystals that are difficult to wear, and seizure easily occurs. However, if the proportion of triangles having an area of 5000 μm2 or more and including no Bi particle with a circle equivalent diameter of 10 μm or more is at most 20% or less, Bi can be configured to cover the Mn-Si primary crystals even though the region where the Mn-Si primary crystals are present sparsely exists. Hence, the frictional resistance in the Mn-Si primary crystals can be reduced. Accordingly, it is possible to reduce the frictional heat in the Mn-Si primary crystals and to prevent seizure.
The incorporation of 25.0 wt % or more of Zn can enhance the strength of the Cu-Zn matrix and suppress sulfurization corrosion caused by the S component in a lubricant oil. In the region where the Mn-Si primary crystals are present sparsely, sulfurization corrosion due to the S component is easily caused by the frictional heat in the Mn-Si primary crystals. However, since the region where the Mn-Si primary crystals are present sparsely can be covered with Bi, the sulfurization corrosion due to the S component can be suppressed. It is noted that 35.0 wt % or more of Zn is incorporated so that the Mn-Si primary crystal particles can grow up to such a size as to obtain more excellent wear resistance. Also, the Zn content is suppressed to 48.0 wt % or less, thereby making it possible to prevent deposition of a large amount of the γ phase in a Cu-Zn matrix and embrittlement of the Cu-Zn matrix.
The incorporation of 1.0 wt % or more of Mn and 0.5 wt % or more of Si can lead to deposition of the Mn-Si primary crystal particles in an amount enough to improve the wear resistance. On the other hand, the Mn content is suppressed to 7.0 wt % or less, and the Si content is suppressed to 3.0 wt % or less, thereby making it possible to prevent reduction in toughness due to excessive deposition of the Mn-Si primary crystals. It is noted that the copper alloy of the present invention can contain inevitable impurities.
An embodiment of the present invention will now be described in the following order.
Hereinafter, a copper alloy for a bearing which constitutes the radial bearing 1 will be described. The copper alloy for a bearing contains 40.0 wt % of Zn, 4.0 wt % of Mn, 1.4 wt % of Si and 3.9 wt % of Bi, the balance consisting of Cu and inevitable impurities. The inevitable impurities include Mg, Ni, Ti, B, Pb, Cr and the like, and are impurities mixed during refining or scrapping. The entire content of the inevitable impurities is 1.0 wt % or less. The masses of the respective elements in the copper alloy for a bearing were measured by using an ICP emission spectrophotometer (ICPS-8100 manufactured by Shimadzu Corporation).
Hereinafter, an explanation will be given about the analysis results of photomicrographs of a sliding surface of a radial bearing 1 and the analysis technique.
The image of the photomicrograph of the sliding surface shown in
Next, the geometrical center of gravity was obtained for the respective images of the particles of the Mn-Si primary crystals 4 having a circle equivalent diameter of 3 μm or more, and triangles having the closest centers of gravity as apices (hereinafter, referred to as “unit triangles”) were formed.
Then, the brightness and contrast of the analysis image were controlled so that images of the Bi particles 3 were white and so that images other than those of the Bi particles 3 were black.
Then, the number of triangles having an area of 5000 μm2 or more and including no image of the Bi particle 3 having a circle equivalent diameter of 10 μm or more (hereinafter referred to as “Bi-absent triangles”), among the unit triangles, was measured. The phrase “no image of the Bi particle 3 in the unit triangles” means that even a part of the image of the Bi particle 3 having a circle equivalent diameter of 10 μm or more is absent in the unit triangles. Further, the proportion of the Bi-absent triangles was calculated by dividing the number of the Bi-absent triangles by the total number of the unit triangles. In this embodiment, the proportion of the Bi-absent triangles was 20%. Here, the phrase “Bi-absent triangles” means a region where the Mn-Si primary crystals 4 are present sparsely and the Bi particles 3 having a large particle size are absent. Accordingly, a small proportion of the Bi-absent triangles means that there are few regions where the Mn-Si primary crystals 4 are present sparsely and that there is a high possibility that the Bi particles 3 may be present in the regions where the Mn-Si primary crystals 4 are present sparsely.
In order to evaluate the wear resistance of the copper alloy for a bearing constituting the radial bearing 1, a wear test was conducted.
Further, the specific wear quantity K was calculated based on the following Equation (1).
L represents a sliding distance, which is the surface length of the counter material A having slid on the test piece T in the wear test. The sliding distance L is a value (bxc) obtained by multiplying the test time c by the relative moving speed b. V represents the volume (wear volume) of the test piece T having worn in the wear test. As indicated in Equation (1), the specific wear quantity K means the volume of the test piece T having worn per unit sliding distance (1 mm) when the unit load (1 N) has been applied onto the test piece T. It is meant that, the smaller the specific wear quantity K is, the higher the wear resistance is.
Next, the wear volume V will be explained.
[Equation 2]
V=(S1−S2)×a (2)
The sectoral area S1 can be calculated based on the following Equation (3).
On the other hand, the triangular area S2 can be calculated based on the following Equation (5) from the figural symmetry.
When measured in the above manner, the specific wear quantity K of the copper alloy for a bearing constituting the radial bearing 1 of this embodiment was 1.95×10−10 mm2/N, which is a favorable result.
In order to evaluate the seizure resistance of the copper alloy for a bearing constituting the radial bearing 1, a seizure test was conducted.
Frictional force is generated between the counter material A and the test pieces T, and the beam parts E rotate horizontally by the frictional force. Therefore, frictional force which horizontally rotates the beam parts E is applied to the load cell Y, and the magnitude of the load measured by the load cell Y means the magnitude of the frictional force between the test pieces T and the counter material A. Therefore, when the load applied to the load cell Y had arrived at a predetermined threshold value or more, it was determined that the frictional force between the test pieces T and the counter material A was abnormally large so that seizure occurred.
The magnitude of the static load applied between the test pieces T by the hydraulic cylinder W was gradually increased (2 MPa/5 min.) to measure the seizure load as the static load when seizure occurred between the test pieces T and the counter material A. Further, the seizure surface pressure was measured by dividing the seizure load by the contact area between the test pieces T and the counter material A.
When measured in the above manner, the seizure surface pressure of the copper alloy for a bearing constituting the radial bearing 1 of this embodiment was 23 MPa, which is a favorable result. It is meant that the greater the seizure surface pressure is, the higher the seizure resistance is.
As explained above, the proportion of the Bi-absent triangles in the sliding surface of the radial bearing 1 was 20% in this embodiment, and it could be confirmed that there were few regions where the Mn-Si primary crystals 4 were present sparsely, and that there was a high possibility that the Bi particles 3 might be present also in the regions where the Mn-Si primary crystals 4 were present sparsely. Therefore, even if there are regions where the Mn-Si primary crystals 4 are present sparsely, Bi can be configured to cover the Mn-Si primary crystals 4 and the frictional resistance in the Mn-Si primary crystals 4 can be reduced. Accordingly, it could be confirmed that the frictional heat in the Mn-Si primary crystals 4 could be reduced, leading to realization of good seizure surface pressure of 23 MPa.
In the present embodiment, the radial bearing 1 is produced by carrying out the following steps: (a) melting, (b) continuous casting, (c) cutting and (d) mechanical processing in turn. Hereinafter, the respective steps will be explained.
a. Melting
Firstly, raw materials were weighed and provided so as to enable the formation of a copper alloy for a bearing containing 40.0 wt % of Zn, 4.0 wt % of Mn, 1.4 wt % of Si and 3.9 wt % of Bi, the balance consisting of Cu and inevitable impurities. In the present embodiment, a Cu ingot, a Zn ingot, a Cu-Mn ingot, and a Cu-Si ingot, respectively, were weighed and provided. The raw materials should be provided in masses according to the target mechanical properties of the radial bearing 1. The target mechanical properties of the radial bearing 1 are determined, for example, according to the mechanical properties of the counter shaft 2. Next, the provided raw materials are heated up to 1200° C. by a high-frequency induction furnace. Thus, the respective ingots melt. Thereafter, bubbles of Ar gas are dispersed and jetted to remove hydrogen gas and inclusions.
b. Continuous Casting
Next, the molten materials for the copper alloy for a bearing were injected into a mold, and the copper alloy for a bearing is continuously pulled out through an opening of the mold in the casting direction and cooled, as it is, to room temperature, thereby forming a continuously cast bar of the copper alloy for a bearing. For example, casting is carried out at 1060° C. by means of a mold formed of carbon, and the copper alloy for a bearing is pulled out at a pulling-out speed of 90 mm/min, thereby forming a continuously cast bar. It is considered that, in the solidification process in continuous casting from the molten state, the Mn-Si primary crystals 4 are crystallized out first; that the Cu-Zn matrix 5 is crystallized out next; and that a eutectic of Mn-Si and Cu-Zn is solidified at the end. It is noted that the diameter of the continuously cast bar of the copper alloy for a bearing is made larger by the machining quantity in the mechanical processing than the outer diameter of the radial bearing 1.
c. Cutting
Then, the continuously cast bar of the copper alloy for a bearing is cut for each thickness of the radial bearing 1 (thickness in the length direction of the counter shaft 2).
d. Mechanical Processing
Finally, the continuously cast bar of the copper alloy for a bearing after cutting is subjected to machine work or press work, thereby completing the radial bearing 1. Here, machine work is carried out so as to form a through hole having an inner diameter which is larger by a predetermined quantity than the outer diameter of the counter shaft 2 and so that the outer diameter size of the radial bearing 1 coincides with a designed value.
Table 1 indicates the experimental results of a plurality of Examples 1 to 3. It is noted that Example 3 is identical with the first embodiment. The values for the wear quantitative ratio in Table 1 are obtained by dividing the specific wear quantities K of Examples 1 to 3 by the specific wear quantity K of Example 3.
For Examples 1 to 3 each having material formulation which was similar to the material formulation of the first embodiment except the Bi content, the distribution states and shapes of the Bi particles 3 and Mn-Si primary crystals 4 were controlled by controlling the Bi content and also controlling the retention time and cooling speed in continuous casting. Specifically, the Bi content of Example 1 was defined as 1.5 wt %; the Bi content of Example 2 was defined as 4.3 wt %; and the Bi content of Example 3 was defined as 3.9 wt %. As indicated in Table 1, the best seizure surface pressure was obtained in Example 3 involving the largest average area of the unit triangles. It is predicted that, the larger the average area among the unit triangles is, the more the regions where the Mn-Si primary crystals 4 are present sparsely exist, so that seizure is easily caused by the frictional heat in the Mn-Si primary crystals 4. However, it has been understood that even when the average area among the unit triangles is large, sufficient seizure resistance is obtained by increasing the Bi content to some degree to ensure the density of the Bi particles 3 while suppressing the proportion of the Bi-absent triangles to 20% or less and by increasing the average circle equivalent diameter among the Bi particles 3.
The above embodiment has illustrated an example of the radial bearing 1 formed of the copper alloy of the present invention, but other sliding members may be formed of the copper alloy of the present invention. For example, gear bushes for transmission, piston pin bushes and boss bushes may be formed of the copper alloy of the present invention. Also, the copper alloy for a bearing of the present invention may be produced by any other production method than continuous casting.
Number | Date | Country | Kind |
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2014-233488 | Nov 2014 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2015/081471 | 11/9/2015 | WO | 00 |