Patent Application
20200047296
The present invention relates to a method of manufacturing a pipe for supplying fuel to an engine in a gasoline direct-injection engine system or diesel engine system, and for example, to a method of manufacturing a high-quality steel fuel-conveying pipe that is excellent in corrosion resistance by removing a fine crack, wrinkle flaw, or the like occurring on an inner surface in drawing process or the like, and performing an inner surface treatment.
In fuel-conveying pipes for use in the gasoline direct-injection engine system or diesel engine system, products acquired by subjecting a stainless-steel-based material to various plastic workings (such as pipe-end forming and bending) and binding (such as brazing) as specifications with various performances such as pressure resistance, airtightness, and corrosion resistance have been most adapted.
Furthermore, in recent years, a fuel-conveying pipe which adopts steel-based pipe such as low carbon steel that is inexpensive more than the stainless-steel-based pipe has been suggested in the gasoline direct-injection engine system (refer to PTL 1). The steel fuel-conveying pipe is subjected to an inner surface treatment and/or outer surface treatment for excellent resistance to corrosive fuel to achieve high resistance particularly to corrosive fuel. Examples are a steel pipe in which a Ni-plated layer is formed on the inner surface of the steel pipe and an anti-rust film layer composed of a Zn-plated layer or a Zn-based alloy-plated layer is further formed on the Ni-plated layer and a steel pipe in which a Zn-plated layer or a Zn-based alloy-plated layer is formed on the outer surface of the steel pipe.
However, the above-described steel fuel-conveying pipes have problems as follows.
That is, for example, when a drawn pipe material is used for the steel fuel-conveying pipe, an initial flaw (such as a fine crack or wrinkle flaw) occurring at the time of drawing is present on the inner peripheral surface of the pipe. Also, in the case of a welded pipe, an initial flaw (such as a weld defect part) occurring due to poor weld or the like is present on the inner peripheral surface of the pipe. If the inner surface treatment (for example, Ni plating) is performed in a state in which any of these defects on the pipe's inner peripheral surface, in particular, a fine crack, wrinkle flaw, or weld defect part, is present, a problem arises in which the plating solution does not penetrate into the inside of that fine crack, wrinkle flaw, or weld defect part, the portion of the fine crack, wrinkle flaw, or weld defect part is completely not subjected to the surface treatment to become a defect and, in particular, resistance to corrosive fuel cannot be acquired, thereby forcing corrosion and rust to occur.
PTL 1: Japanese Patent Application Laid-Open No. 2012-26357
The present invention was made in view of the problems of the conventional technology, and is to suggest a method of manufacturing a high-quality steel fuel-conveying pipe that does not have an initial flaw (such as a fine crack, wrinkle flaw, or weld defect part) occurring on the inner peripheral surface of the pipe and is highly resistant to corrosive fuel, in steel pipes for supplying fuel to an engine in a gasoline direct-injection engine system or diesel engine system.
The method of manufacturing a steel fuel-conveying pipe according to the present invention relating to a method of manufacturing a steel fuel-conveying pipe having an anti-rust film layer on an inner peripheral surface of a steel pipe material. The method is characterized by screening and classifying the pipe material as one having an initial flaw (such as a fine crack, wrinkle flaw, or weld defect part) exceeding a preset threshold or one having the initial flaw not exceeding the preset threshold on the inner peripheral surface of the pipe material, removing the initial flaw on the inner peripheral surface of the pipe material having the initial flaw not exceeding the threshold by mechanical cutting, and subjecting the inner peripheral surface of the pipe material to a surface treatment (for example, Ni plating). Note that the pipe material exceeding the threshold is processed as a defective piece. To determine this threshold, a possible maximum flaw depth may be calculated by using a statistical scheme and the resulting maximum flaw depth may be taken as a threshold.
Also, as a preferable mode, the process by mechanical cutting for use as the way of removing the initial flaw (such as a fine crack, wrinkle flaw, or weld defect part) on the inner peripheral surface of the pipe material may be preferably carried out by a gun drill processing machine for use in deep hole processing.
Furthermore, as a preferable mode, an ultrasonic flaw detection method may be preferably used as a means of detecting the initial flaw on the inner peripheral surface of the pipe material.
According to the method of manufacturing a steel fuel-conveying pipe of the present invention, the initial flaw (such as a fine crack, wrinkle flaw, or weld defect part) on the inner peripheral surface of a pipe material such as a drawn pipe, semi-seamless pipe, or welded pipe is detected or predicted, and the inner peripheral surface of the pipe material the detection value of which does not exceed a predefined threshold is removed by mechanical cutting, thereby achieving excellent effects of causing removal of the initial flaw to be completely performed, enhancing smoothness on the inner peripheral surface of the pipe, improving corrosion resistance of the surface treatment on the inner peripheral surface of the pipe, and acquiring a high-quality steel fuel-conveying pipe that is highly resistant to corrosive fuel.
Also, by using a gun drill processing machine for use in deep hole processing as means of removing the initial flaw (such as a fine crack, wrinkle flaw, or weld defect part) on the inner peripheral surface of the pipe material, with the favorable straight-ahead movement of the blade, cutting can be performed uniformly in the axial and circumferential directions of the pipe, thereby allowing the initial flaw to be completely removed.
In the method of manufacturing a steel fuel-conveying pipe according to the present invention, as one example of the manufacturing process is depicted in
Next, as acceptance inspection of the base material of pipe, flaw detection is performed on the inner peripheral surface of the pipe material by a flaw detector to detect an initial flaw (such as a fine crack, wrinkle flaw, or weld defect part) in a flaw detection step 2 of the pipe material. Subsequently, in a screening and classifying step 3 of the pipe material, the pipe material is screened and classified as a pipe material with a value detected in the flaw detection step exceeding a predefined threshold or a pipe material with the detected value not exceeding the threshold. As for the threshold of the initial flaw (such as a fine crack, wrinkle flaw, or weld defect part), its reference value is set at, for example, a depth of 150 μm. The pipe material exceeding this threshold is processed as a defective piece, and the pipe material not exceeding the threshold is fed to a next initial flaw removal step 4. In this regard, the threshold is determined, for example, based on the type, inner diameter, and material thickness of the pipe material; and the size of the fine crack, wrinkle flaw, weld defect part, or the like.
In the initial flaw removal step 4, the inner peripheral surface of the pipe material not exceeding the threshold is subjected of mechanical cutting with a magnitude equal to or larger than the threshold, thereby removing the initial flaw. As the method using mechanical cutting for use as a method of removing the initial flaw (such as a fine crack, wrinkle flaw, or weld defect part) on the inner peripheral surface of the pipe material not exceeding the threshold, a method using a gun drill processing machine 7 for use in deep hole processing depicted in
The pipe material not exceeding the threshold with the initial flaw on its inner peripheral surface removed by the gun drill processing machine 7 for use in deep hole processing in the initial flaw removal step 4 is subsequently subjected to a surface treatment such as Ni plating in a surface treatment step 5 on the inner surface of the pipe material. On that occasion, the surface treatment is performed along the inner surface of the pipe material. In the case of the pipe material with the initial flaw on its inner peripheral surface removed in the initial flaw removal step 4, the inner surface is free from a fine crack, wrinkle flaw, or weld defect part, and therefore a portion to which the plating solution is not applied is not present at all, and the entire inner surface is reliably subjected to the surface treatment. Therefore, a product with the inner peripheral surface of the pipe material subjected to the surface treatment such as Ni plating in the surface treatment step 5 retains sufficient anti-rust power with respect to corrosive fuel, and thus the occurrence of corrosion or rust is completely eliminated and it is clear that the product is excellent in corrosion resistance.
In the pipe material manufacturing step 1, steel-made drawn pipe materials (samples Nos. 1 to 6) manufactured by a drawing apparatus and having an outer diameter of 15.6 mm and an inner diameter of 9.8 mm were each used as a base material of pipe. In the flaw detection step 2, flaw detection was performed on the inner peripheral surface of each of the drawn pipe materials by a flaw detector to detect an initial flaw (such as a fine crack, wrinkle flaw, or weld defect part). Then in the screening and classifying step 3 of the drawn pipe materials, the pipe materials were screened and classified as one having a value detected in the flaw detection step 2 exceeding a preset threshold (150 μm) and one having the detected value not exceeding the threshold. In the next initial flaw removal step 4, the inner peripheral surface of each drawn pipe material not exceeding the threshold was cut by the gun drill processing machine 7 for use in deep hole processing. The machining allowance at that time was 0.2 mm (each surface). Subsequently in the surface treatment step 5, electroless Ni plating was performed on the inner peripheral surface of each drawn pipe material with the inner peripheral surface being cut to form a Ni—P (electroless Ni) plated layer having a film thickness of 3 μm to 5 μm.
The results of a corrosion resistance test performed on the steel drawn pipe materials in the present examples in the following manner are depicted in Table 1.
Corrosion Resistance Test
The inside of each steel drawn pipe material with Ni plating on the entire inner surface of the pipe material was filled with corrosive fuel (containing 20% alcohol-mixed fuel (gasoline), organic acid of 500 ppm, moisture of 5%, and chlorine of 10 ppm), and a corrosion situation inside the pipe when left at a temperature of 100° C. for 1000 hours was checked. A corrosion resistance evaluation was made by checking the presence or absence of red rust by a visual check and a stereomicroscope.
Steel-made drawn pipe materials having an outer diameter of 15.6 mm and an inner diameter of 9.8 mm, which were equal to those of Embodiments 1 to 6, were used, and the inner peripheral surface of each of the drawn pipe materials was subjected to the same electroless Ni plating as that of Embodiments 1 to 6 without mechanical cutting of the inner peripheral surface of the pipe materials after drawing to form a Ni—P (electroless Ni) plated layer having a film thickness of 3 μm to 5 μm. The results of a corrosion resistance test performed in a method similar to that of Embodiments 1 to 6 are also depicted in Table 1.
From the results in Table 1, in any of the steel drawn pipe materials of the present invention in Embodiments 1 to 6 in which flaw detection was performed on the inner peripheral surface of each pipe material after drawing, the inner peripheral surface of the drawn pipe material not exceeding the preset threshold was removed by mechanical cutting, and then an electroless Ni plated layer was formed, no occurrence of red rust inside the pipe was observed and excellent corrosion resistance was recognized.
On the other hand, in any of Conventional Examples 1 to 3, occurrence of red rust was found on the inner peripheral surface of each drawn pipe material, and it was found out that corrosion resistance is inferior, compared with the steel drawn pipe material of the present invention.
In the pipe material manufacturing step 1, steel-made welded pipe materials (sample Nos. 7 to 12) manufactured by a welding pipe manufacturing apparatus and having an outer diameter of 15.9 mm and an inner diameter of 9.9 mm were used as base materials of pipe. As for the depth of a weld defect, a depth to be removed was investigated in advance by a statistical scheme, the machining allowance of the inner surface of each of the pipe materials was set based on that predicted maximum flaw depth, and the inner peripheral surface was cut by the gun drill processing machine 7 for use in deep hole processing for a cutting amount with a threshold (150 μm) of the preset machining allowance. The machining allowance of the inner peripheral surface at that time was 0.2 mm (each surface). Subsequently in the surface treatment step 5, electroless Ni plating was performed on the inner peripheral surface of each welded pipe material with the inner peripheral surface being cut to form a Ni—P (electroless Ni) plated layer having a film thickness of 3 μm to 5 μm.
The results of a corrosion resistance test performed on the steel welded pipe material in the present examples in the same manner as that of Embodiment 1 are depicted in Table 2.
Steel-made welded pipe materials having an outer diameter of 15.9 mm and an inner diameter of 9.9 mm, which were equal to those of Embodiments 7 to 12, were used, and the inner peripheral surface of each welded pipe material was subjected to the same electroless Ni plating as that of Embodiments 7 to 12 without mechanical cutting of the inner peripheral surface of the pipe material after pipe manufacture to form an Ni—P (electroless Ni) plated layer having a film thickness of 3 μm to 5 μm. The results of a corrosion resistance test performed in a method similar to that of Embodiments 1 to 6 are also depicted in Table 2.
From the results in Table 2, also in the present embodiments, in any of the welded pipe materials of the present invention in Embodiments 7 to 12 in which the depth of a weld defect part after welded pipe manufacture was preset by a statistical scheme, the inner peripheral surface of each welded pipe material was removed by mechanical cutting by more than the preset threshold, and then an electroless Ni plated layer was formed, no occurrence of red rust inside the pipe material was observed and excellent corrosion resistance was recognized. On the other hand, in any of Conventional Examples 4 to 6, occurrence of red rust was found on the inner peripheral surface of the welded pipe material, and it was found out that corrosion resistance is inferior, compared with the steel welded pipe material of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2017-036159 | Feb 2017 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2017/046980 | 12/27/2017 | WO | 00 |
