Patent Grant
9108246
The present invention relates to a method for mixing a raw material powder for use in powder metallurgy technology.
The present invention also relates to a method for producing a raw material powder for powder metallurgy using the mixing method.
The raw material powder for use in powder metallurgy technology (hereinafter referred to as a raw material powder for powder metallurgy) is produced by mixing an iron powder as a basic component, a metal powder containing an alloy component (hereinafter referred to as an alloying powder), and a binding agent for fixing the alloying powder (or at least some of them) to the surface of the iron powder (hereinafter referred to as a binding agent). Moreover, a raw material powder for powder metallurgy containing, as required, one or two or more members selected from lubricant powders, flow enhancing agents, free-machining agent powders, and lubricant powders for sliding surface is also used.
In the raw material powder for powder metallurgy, it is required that the alloying powder is fixed to the surface of the iron powder through the binding agent and the lubricant powder, the flow enhancing agent, the free-machining agent powder, the lubricant powder for sliding surface, and the like, which are added as required, are uniformly mixed. Then, various mixing methods have been examined.
For example, Japanese Unexamined Patent Application Publication No. 2-47201 (Patent Document 1) discloses a technology for adding an alloying powder, a free-machining agent powder, and a lubricant powder to an iron powder and performing first mixing, adding a binding agent and performing second mixing while increasing the temperature, and performing third mixing while cooling.
However, since the first to third mixing processes are performed by one mixing device according to the technology disclosed in Patent Document 1, the mixing device is exclusively used over a long period of time until the raw material powder for powder metallurgy is obtained by charging raw material powders, such as the iron powder or the alloying powder, and mixing.
Furthermore, according to the technology disclosed in Patent Document 1, it is difficult to adjust the apparent density of the raw material powder for powder metallurgy. More specifically, in order to obtain a raw material powder for powder metallurgy having a high apparent density, it is required to grind the raw material powders, such as the iron powder or the alloying powder by prolonging the mixing time to thereby obtain round shaped particles, which reduces the productivity. In contrast, in order to obtain a raw material powder for powder metallurgy having a low apparent density, the mixing time needs to be shortened, possibly resulting in segregation of the raw material powder.
It is an object of the present invention to provide a method for mixing a raw material powder for powder metallurgy that allows efficient mixing at a low cost with a simple measure and easy adjustment of the apparent density. It is another object of the present invention to provide a method for producing a raw material powder for powder metallurgy having excellent uniformity and productivity irrespective of the apparent density.
The present invention is a method for mixing a raw material powder for powder metallurgy, including: performing first agitation mixing in which a powder mixture obtained by adding, to an iron powder,
an alloying powder,
a binding agent, and
one or two or more members selected from lubricant powders, free-machining agent powders, and lubricant powders for sliding surface, is agitated while increasing the temperature to a temperature TK equal to or higher than the melting point (hereinafter referred to as TM) of the binding agent, the resultant is agitated while maintaining the temperature TK, and the resultant is further agitated while reducing the temperature from the temperature TK; and performing second agitation mixing in which the obtained powder mixture is agitated while further cooling.
In the mixing method of the invention, the first agitation mixing process is preferably performed using a high-speed agitating mixer (e.g., Henschel mixer). The second agitation mixing process is preferably performed using a high-speed agitating mixer or a conical screw mixer (e.g. Nauta mixer). More specifically, although a first agitating mixer for performing the first agitation mixing process and a second agitating mixer for performing the second agitation mixing process are separately provided, the mixer type may be the same or different.
In the first agitation mixing, it is preferable that gentle agitation is performed in a process for increasing the temperature to the temperature TK and in a process for reducing the temperature from the temperature TK and strong agitation be performed in a process for maintaining the temperature TK. Moreover, it is preferable that switching from the first agitation mixing to the second agitation mixing is conducted so that the duration of the first agitation mixing and the duration of the second agitation mixing are equal to each other.
Also, the present invention is a method for producing a raw material powder for powder metallurgy, including mixing the iron powder, the alloying powder, the binding agent, and one or two or more members selected from the lubricant powders, the free-machining agent powders, and the lubricant powders for sliding surface in accordance with the aforementioned mixing method.
1 Iron powder
2 Alloying powder
3 Binding agent
4 Additive powder
5 Powder mixture
6 Raw material powder for powder metallurgy
7 Double layered structure
8 Rotating shaft
9 Rotating impeller
11 First agitating mixer
12 Second agitating mixer
TK Maintained temperature in first agitation mixing
TM Melting point of binding agent
t1 Duration of first agitation mixing
t2 Duration of second agitation mixing
t3 Switching time
tTOTAL Total time of one cycle
(First Agitation Mixing)
First, the first agitation mixing will be described.
As illustrated in
Both the iron powder and the additive powder can be selected from known substances according to the application for use. For example, pure iron powders or alloy steel powders (including diffusion alloyed steel powder and the like) are usable as the iron powder. Examples of other raw materials include the following substances but are not limited thereto.
The melting point TM of the binding agent is preferably adjusted to about 0 to 150° C.
The first agitating mixer 11 is not limited to a specific type, and known devices are used. However, according to the study of the present inventors, a high-speed agitating mixer is preferable, and particularly a Henschel mixer is preferable.
As illustrated in the top of
The first agitating mixer 11 is provided with a heating member to agitate the powders in the first agitating mixer 11 while increasing the temperature. As the heating member, known heating technologies are used. In the first agitation mixing, not only the heating member but a cooling member described later is required. Therefore, it is preferable to select a technology that can obtain a heating function and a cooling function with a simple measure.
For example, when an electric heater is used, the temperature of the powders in the first agitating mixer 11 can be increased. However, since the electric heater is not provided with a cooling function, a cooling member needs to separately dispose (e.g. water-cooling), which complicates the structure of the first agitating mixer 11.
According to the study of the present inventors, it is preferable to form the circumference of the first agitating mixer 11 into a double walled structure as illustrated in
Thus, the powders in the first agitating mixer 11 are agitated while increasing the temperature. Then, the temperature is increased until the temperature reaches the temperature TK equal to or higher than the melting point TM of the binding agent 3, and the powders are further agitated while maintaining the temperature TK. By maintaining the temperature TK, the binding agent 3 melts and, by agitating, the binding agent 3 in a molten state is applied to the surface of the iron powder 1, whereby the alloying powder 2 and the additive powder 4 further adhere to the iron powder. The time for increasing the temperature is not particularly limited, and is preferably adjusted to about 5 to 40 minutes from the viewpoint of productivity and economical efficiency.
Subsequently, the powders in the agitating mixer 11 are agitated while cooling. When the temperature decrease to a temperature equal to or lower than the melting point TM, the binding agent 3 solidifies to thereby fix the alloying powder 2 and the additive powder 4 to the surface of the iron powder 1. The cooling member is as previously described above together with the heating member. The time for cooling is not particularly limited, and is preferably adjusted to 60 minutes or less from the viewpoint of productivity and economical efficiency.
The first agitation mixing is ceased in the cooling process, and the powders in the first agitating mixer 11 are discharged.
(Second Agitation Mixing)
A mixture 5 thus obtained (hereinafter referred to as a powder mixture) of the iron powder 1, the alloying powder 2, the binding agent 3, and the additive powder 4, is charged in a second agitating mixer 12. Furthermore, one or two or more member(s) (second additive powder 13) selected from lubricant powders, flow enhancing agents, free-machining agent powders, and lubricant powders for sliding surface is/are charged, as required, in a second agitating mixer 12. As the flow enhancing agents, lubricant powders, and free-machining agent powders, known substances can be preferably used. As the flow enhancing agents, nanosized oxide powders such as fumed silica, carbon black, etc., are mentioned. As the lubricant powders and the free-machining agent powders, the substances mentioned as the additive powder in the first agitation mixing above can be utilized. However, the lubricant powders and the free-machining agent powders do not need to be the same as those selected in the first agitation mixing.
Next, the second agitation mixing will be described.
The second agitating mixer 12 is not limited to a specific type (therefore, the details are not illustrated in the drawings), and known devices are used. However, according to the study of the present inventors, a high-speed agitating mixer or a conical screw mixer is preferable, and particularly a Henschel mixer or a Nauta mixer is preferable.
The second agitating mixer 12 is provided with a cooling member, and agitates the powder mixture 5 in the second agitating mixer 12 while cooling. Known cooling technologies are used as the cooling member. According to the study of the present inventors, it is preferable to form the circumference of the second agitating mixer 12 into a double walled structure similarly as in the first agitating mixer 11 illustrated in
The powder mixture 5 in the second agitating mixer 12 is cooled to room temperature while agitating (sufficient when the temperature decreases to 80° C. or lower), and discharged from the second agitating mixer 12, thereby obtaining a raw material powder for powder metallurgy 6 having a given apparent density.
The relationship between the time until the iron-powder 1, the alloying powder 2, the binding agent 3, and the additive powder 4 are charged in the first agitating mixer 11, and then the raw material powder for powder metallurgy 6 is discharged from the second agitating mixer 12 (hereinafter referred to as one cycle) as described above and the temperatures during the cycle is illustrated in
(Adjustment of Each Agitation Mixing)
In the invention, the timing (i.e., time allocation of the first agitation mixing and the second agitation mixing) when the switching from the first agitation mixing to the second agitation mixing is conducted is not particularly limited. The time allocation is suitably determined according to properties (i.e., an apparent density, a particle size, etc.) required for the raw material powder for powder metallurgy 6, the facility specification of the first agitating mixer 11 and the second agitating mixer 12, etc. Depending on the timing when the switching from the first agitation mixing to the second agitation mixing is conducted, temperatures may decrease to be equal to or lower than the melting point TM during the second agitation mixing. Also in such a case, the raw material powder for powder metallurgy 6 can be mixed without any trouble.
It is preferable that the duration t1 of the first agitation mixing and the duration t2 of the second agitation mixing be equal to each other (i.e., t1=t2). The total time tTOTAL of one cycle is the total of the duration t1 of the first agitation mixing, the duration t2 of the second agitation mixing, and the switching time t3 from the first agitation mixing to the second agitation mixing (i.e., tTOTAL=t1+t2+t3). Thus, by adjusting the t1 and t2 to be t1=t2, the interval in which the raw material powder for powder metallurgy 6 is discharged from the second agitating mixer 12 is shortened to about ½tTOTAL. As a result, the raw material powder for powder metallurgy 6 is discharged twice during the total time tTOTAL of one cycle. It is a matter of course that even when t1 and t2 are not strictly adjusted to be t1=t2, sufficient effects are obtained when t2 is about t1±20%. Preferably, t2 is about t1±10%.
It is preferable, in the first agitation mixing, that the agitation be performed relatively strongly (hereinafter referred to as strong agitation) while maintaining the temperature TK and the agitation be performed relatively gently (hereinafter referred to as gentle agitation) in the process for increasing the temperature to the temperature TK and in the process for reducing the temperature from the temperature TK. Since the binding agent 3 melts in a state where the temperature TK is maintained, the alloying powder 2 and the additive powder 4 can be uniformly adhered to the surface of the iron powder 1 by performing strong agitation. By performing gentle agitation in the process for increasing the temperature to the temperature TK and the process for reducing the temperature from the temperature TK, excessive grinding of the iron powder 1, the alloying powder 2, and the additive powder 4 can be prevented. By the method, particularly a raw material powder for powder metallurgy that has a low apparent density and is uniformly mixed can be easily mixed and produced. In order to increase the apparent density of the raw material powder for powder metallurgy, strong agitation can be conversely performed at least partially in the agitation during an increase and/or a reduction in the temperature.
Here, in the case of strong agitation, when a 2 L Henschel mixer is taken as an example (blade diameter of 180 mm), agitation equivalent to the rotation number of about 500 rpm or more is preferable. In gentle agitation, more gentle agitation than the agitation equivalent to the rotation number of about 500 rpm or more is preferable.
As a measure for increasing the apparent density of the raw material powder for powder metallurgy, a measure for increasing the tTOTAL is acceptable in addition to the above. Here, since the interval in which the raw material powder for powder metallurgy 6 is discharged from the second agitating mixer 12 is shortened up to ½tTOTAL in the invention, effects of a reduction in productivity can be lessened. Moreover, the time of strong agitation at the temperature TK may be intensively increased.
The first agitating mixer and the second agitating mixer are freely combined, and the combination thereof can be changed according to the application. For example, a device suitable for strong agitation (for high apparent densities) and a device suitable for gentle agitation (for low apparent densities) are prepared for the second agitating mixer, and may be selected when switching from the first agitation mixing.
Moreover, a relatively inexpensive device may be adopted as the second agitating mixer, and one or more second agitating mixers per the first agitating mixer may be disposed. For example, when two second agitating mixers are disposed in series per the first agitating mixer, the interval in which the raw material powder for powder metallurgy 6 is discharged from the second agitating mixer 12 is shortened to about ⅓tTOTAL by adjusting t1 and t2 to be t2=t1×2 (about ±20%, preferably about ±10%). The productivity can be optimized also by using a first agitating mixer and a second agitating mixer that are different in the capacity.
As described above, when the invention is applied, the raw material powder for powder metallurgy can be efficiently mixed at a low cost with a simple measure and the apparent density of the raw material powder for powder metallurgy can also be adjusted.
As illustrated in
When the temperature reached a given maintained temperature TK (Duration of experience: 20 minutes), agitation was further performed while maintaining the temperature TK for 5 minutes. The maintained temperature TK (about 140° C.) is a temperature higher than the melting point TM (about 110 to 130° C.) of the binding agent 3. The rotational speed (130 rpm) of the rotating impeller 9 when agitated at the maintained temperature TK was increased to be higher than the rotational speed (100 rpm) in the temperature increasing process.
Subsequently, the iron powder 1, the alloying powder 2, the binding agent 3, and the additive powder 4 in the first agitating mixer 11 were agitated while cooling by circulating cold water through the double layered structure 7. In the cooling process, the rotational speed of the rotating impeller 9 was reduced to be lower (80 rpm) than that of the agitation at the maintained temperature TK.
The first agitation mixing was ceased in the cooling process (5 minutes later). Then, the obtained powder mixture 5 was discharged from the first agitating mixer 11, and then charged in the second agitating mixer 12. Furthermore, lubricant powder (zinc stearate: 0.4%) as the additive powder was charged in the second agitating mixer 12. As the second agitating mixer 12, a Nauta mixer (capacity: 1000 L, Maximum rotational speeds: rotation of 60 rpm and revolution of 2 rpm) was used, and the circumference thereof was formed into a double walled structure. The powder mixture 5 in the second agitating mixer 12 was agitated (rotation of 60 rpm and revolution of 2 rpm) and mixed while cooling by circulating cold water through the double layered structure. The duration t1 of the first agitation mixing and the duration t2 of the second agitation mixing were adjusted to be t1=t2.
Thus, when the temperature decreased to room temperature, the resultant was discharged from the second agitating mixer 12. The apparent density of the obtained raw material powder for powder metallurgy 6 satisfied a predetermined target range (2.8 to 3.6 Mg/m3).
Raw material powders for powder metallurgy were mixed and produced under the respective conditions illustrated in Table 1. The conditions (e.g. proportion of each processing time of the process for increasing the temperature, the process for maintaining the temperature TK, and the process for cooling) other than the conditions illustrated in Table 1 were the same as in Example 1. In the invention, the apparent density in a wide range can be achieved while suppressing a reduction in productivity. As is understood from the comparison between Experiments Nos. 2-1 and 2-3 and the comparison between Experiments Nos. 2-2 and 2-3, the apparent density can be adjusted or the same raw material powder can be mixed at a higher speed by adjusting the agitation force of the mixers in the first agitation mixing and the second agitation mixing without changing other operation conditions (thus, without applying a load to the whole process).
As a Comparative Example, the whole process of t1 and t2 was performed using one (and the same) Henschel mixer. First, mixing was performed under the conditions of Gentle agitation during increasing the temperature, Strong agitation during maintaining the temperature TK, and Strong agitation during cooling so that the apparent density was “low”. Then, the total processing time was 20 minutes, and thus time sufficient for mixing was not secured, resulting in insufficient mixing of the raw materials. More specifically, when samples were randomly extracted from the obtained raw material powder for powder metallurgy, the concentration of graphite powder varied by ±20% relative to the average content (in the case of the Examples of invention, ±10% or lower). When the apparent density was “medium” or higher, the uniformity was secured, but the interval in which the raw material powder for powder metallurgy was discharged was t1+t2, and thus the productivity was not secured.
According to the present invention, the raw material powder for powder metallurgy can be efficiently mixed at a low cost with a simple measure and the apparent density of the raw material powder for powder metallurgy can also be adjusted.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-213227 | Aug 2007 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2008/064762 | 8/13/2008 | WO | 00 | 4/16/2010 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2009/025274 | 2/26/2009 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4946499 | Sakuranda et al. | Aug 1990 | A |
| 5135566 | Sakuranda et al. | Aug 1992 | A |
| 20010028859 | Ozaki et al. | Oct 2001 | A1 |
| Number | Date | Country |
|---|---|---|
| 0 853 994 | Jul 1998 | EP |
| 0 861 698 | Sep 1998 | EP |
| 0 913 220 | May 1999 | EP |
| 1 364 731 | Nov 2003 | EP |
| A-01-165701 | Jun 1989 | JP |
| A-02-047201 | Feb 1990 | JP |
| A-03-162502 | Jul 1991 | JP |
| Entry |
|---|
| Written Opinion of the International Searching Authority issued in International Application No. PCT/JP2008/064762 on Oct. 14, 2008 (with translation). |
| International Search Report issued in International Application No. PCT/JP2008/064762 on Oct. 14, 2008. |
| May 3, 2013 Extended European Search Report issued in European Application No. 08792542.6. |
| Number | Date | Country | |
|---|---|---|---|
| 20100284239 A1 | Nov 2010 | US |
