Patent Grant
8876935
1. Technical Field
The present invention relates to a sintered material for valve guides that may be used in an internal combustion engine, and also relates to a production method for the sintered material for valve guides. Specifically, the present invention relates to a technique for further improving wear resistance of the sintered material for valve guides.
2. Background Art
A valve guide used in an internal combustion engine is a tubular component having an inner circumferential surface for guiding valve stems of an intake valve and an exhaust valve. The intake valve may be driven so as to take fuel mixed gas into a combustion chamber of the internal combustion engine, and the exhaust valve may be driven so as to exhaust combustion gas from the combustion chamber. For guiding the valve stems of the intake valve and the exhaust valve, the valve guide is required to have wear resistance and is also required to maintain smooth sliding conditions so as not to cause wear of the valve stems for long periods. Valve guides made of a cast iron are generally used, but valve guides made of a sintered alloy have recently come into wide use. This is because sintered alloys can have a specific metallic structure, which cannot be obtained from ingot materials, and therefore the sintered alloys can have wear resistance. Moreover, once a die assembly has been made, products having the same shape can be mass-produced, and therefore the sintered alloys are suitable for commercial production. Furthermore, a sintered alloy can be formed into a shape similar to that of a product, and thereby material yield can be high in machining. Valve guides made of a sintered alloy are disclosed in, for example, Japanese Examined Patent Publication No. 55-034858 and Japanese Patents Nos. 2680927, 4323069, and 4323467.
The sintered material for valve guides disclosed in Japanese Examined Patent Publication No. 55-034858 is made of an iron-based sintered alloy consisting of, by weight, 1.5 to 4% of C, 1 to 5% of Cu, 0.1 to 2% of Sn, not less than 0.1% and less than 0.3% of P, and the balance of Fe. A photograph and a schematic view of a metallic structure of this sintered material are shown in
The sintered material for valve guides disclosed in Japanese Patent No. 2680927 is an improved material of the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858. In this material, in order to improve machinability, magnesium metasilicate minerals and magnesium orthosilicate minerals are dispersed as intergranular inclusions in the metallic matrix of the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858. As with the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858, this sintered material has been mounted in automobiles and has been commercially used by domestic and international automobile manufacturers.
The sintered materials for valve guides disclosed in Japanese Patents Nos. 4323069 and 4323467 have further improved machinability. The machinabilities thereof are improved by decreasing amount of phosphorus. That is, the dispersion amount of the hard iron-phosphorus-carbon compound phase is decreased to only the amount that is required for maintaining wear resistance of a valve guide. These sintered materials for valve guides have been mounted in automobiles and have started to be commercially used by domestic and international automobile manufacturers.
Recently, requirements for reducing the production costs have been increasing for various industrial machine parts, and also the requirements for reducing the production costs have been increasing for automobile parts. In view of these circumstances, further reduction of the production costs is also required for sintered materials for valve guides for internal combustion engines.
In the meantime, in accordance with trends toward improving the performance and the fuel efficiency of automobile internal combustion engines in recent years, valve guides have been subjected to higher temperatures and higher pressures while internal combustion engines are running. Moreover, in view of recent environmental issues, amounts of lubricant supplied to an interface between a valve guide and a valve stem have decreased. Therefore, valve guides must withstand more severe sliding conditions. In view of these circumstances, a sintered material for valve guides is required to have high wear resistance equivalent to those of the sintered materials disclosed in Japanese Examined Patent Publication No. 55-034858 and Japanese Patent No. 2680927.
Accordingly, an object of the present invention is to provide a sintered material for valve guides and to provide a production method therefor. The sintered material is produced at low production cost and has wear resistance equivalent to those of the conventional sintered materials, that is, the sintered materials disclosed in Japanese Examined Patent Publication No. 55-034858 and Japanese Patent No. 2680927.
In order to achieve the above object, the present invention provides a sintered material for valve guides, consisting of, by mass %, 1.3 to 3% of C, 1 to 4% of Cu, 0.01 to 0.08% of P, 0.05 to 0.5% of Sn, and the balance of Fe and inevitable impurities. The sintered material exhibits a metallic structure made of pores and a matrix. The matrix is a mixed structure of a pearlite phase, a ferrite phase, an iron-phosphorus-carbon compound phase, and at least one of a copper-tin alloy phase and a combination of a copper phase and a copper-tin alloy phase. A part of the pores includes graphite that is dispersed therein. The iron-phosphorus-carbon compound phase is dispersed at 3 to 25% by area ratio and the copper-tin alloy phase and the combination of the copper phase and the copper-tin alloy phase are dispersed at 0.5 to 3.5% by area ratio with respect to a cross section of the metallic structure, respectively.
In the sintered material for valve guides of the present invention, the iron-phosphorus-carbon compound phase can be observed as a plate-shaped iron-phosphorus-carbon compound having an area of not less than 0.05% in a visual field in a cross-sectional structure at 200-power magnification. In this case, when a total area of the plate-shaped iron-phosphorus-carbon compounds having an area of not less than 0.15% in the above visual field is 3 to 50% with respect to a total area of the plate-shaped iron-phosphorus-carbon compounds, wear resistance is improved. In the present invention, iron carbides are also precipitated in addition to the iron-phosphorus-carbon compounds. However, the iron carbides are difficult to distinguish from the iron-phosphorus-carbon compounds by the metallic structure. Therefore, in the following descriptions and the descriptions in the claims, the phrase “iron-phosphorus-carbon compound” includes the iron carbide.
In addition, at least one kind selected from the group consisting of manganese sulfide particles, magnesium silicate mineral particles, and calcium fluoride particles are preferably dispersed in particle boundaries of the matrix and in the pores at not more than 2 mass %.
The present invention provides a production method for the sintered material for valve guides, and the production method includes preparing an iron powder, a graphite powder, an iron-phosphorus alloy powder including 15 to 21% of P, and one selected from the group consisting of a combination of a copper powder and a tin powder, a copper-tin alloy powder, and a combination of a copper powder and a copper-tin alloy powder. The production method also includes mixing the graphite powder, the iron-phosphorus alloy powder, and the one selected from the group with the iron powder into a raw powder consisting of, by mass %, 1.3 to 3% of C, 1 to 4% of Cu, 0.05 to 0.5% of Sn, 0.01 to 0.08% of P, and the balance of Fe and inevitable impurities. The production method also includes filling a tube-shaped cavity of a die assembly with the raw powder, and compacting the raw powder into a green compact having a tube shape. The production method further includes sintering the green compact at a heating temperature of 940 to 1040° C. in a nonoxidizing atmosphere so as to obtain a sintered compact.
In the production method for the sintered material for valve guides of the present invention, the green compact is preferably held at the heating temperature for 10 to 90 minutes in the sintering. Moreover, the sintered compact is cooled from the heating temperature to room temperature after the sintering, and the cooling rate is preferably 5 to 25° C. per minute while the sintered compact is cooled from 850 to 600° C. In addition, when the sintered compact is cooled from the heating temperature to room temperature, the sintered compact is preferably isothermally held in a temperature range of 850 to 600° C. for 10 to 90 minutes and is then cooled. In the mixing of the powders, at least one kind selected from the group consisting of a manganese sulfide powder, a magnesium silicate mineral powder, and a calcium fluoride powder is preferably added to the raw powder at not more than 2 mass %.
According to the sintered material for valve guides of the present invention, the amount of phosphorus is decreased, and thereby reducing the production cost. Moreover, the iron-phosphorus-carbon compound phase is dispersed in a similar shape and in similar amount as in the case of a conventional sintered material, whereby degree of wear resistance is maintained. Therefore, the sintered material for valve guides of the present invention can be obtained at low production cost but have superior wear resistance. According to the production method for the sintered material for valve guides of the present invention, the sintered material for valve guides of the present invention can be produced as easily as in a conventional manner.
In the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858, by adding 0.1 to 0.3 mass % of P, iron-phosphorus-carbon compounds are dispersed in the matrix. On the other hand, in the sintered material disclosed in Japanese Patent No. 4323069, by setting the amount of P to be 0.01 to less than 0.1%, a matrix mainly made of pearlite is formed. In addition, in the sintered material disclosed in Japanese Patent No. 4323467, precipitation amount of the iron-phosphorus-carbon compounds is decreased so as to make the sizes of the iron-phosphorus-carbon compounds smaller. From these points, in order to generate a predetermined amount of iron-phosphorus-carbon compounds having a predetermined size, it is assumed that a certain amount of P is required.
In these circumstances, the inventors of the present invention have investigated and found the following. The iron-phosphorus-carbon compounds are dispersed even when the amount of P is decreased and the entire composition is similar to those of the sintered materials disclosed in Japanese Patents Nos. 4323069 and 4323467. Moreover, the amount and the sizes of the iron-phosphorus-carbon compounds can be equivalent to those of the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858.
In the sintered materials disclosed in Japanese Examined Patent Publication No. 55-034858 and Japanese Patents Nos. 2680927, 4323069, and 4323467, Cu is used as an essential composition. Cu is an element for decreasing the critical cooling rate of a steel and improves hardenability of the steel. That is, Cu shifts the pearlite nose to the later time side (right side) in the continuous cooling transformation diagram. Therefore, when the sintered material is cooled from the heating temperature in a condition that Cu having such effects is uniformly diffused at a predetermined amount in the iron matrix, the pearlite nose is shifted to the later time side. As a result, the sintered material is cooled at a cooling rate in an ordinary sintering furnace before the iron-phosphorus-carbon compounds grow sufficiently. Accordingly, when the amount of P is small, the amount of the iron-phosphorus-carbon compounds as cores is decreased, whereby a fine pearlite structure is easily formed.
Conversely, by ununiformly diffusing Cu for improving the hardenability of a steel, a matrix is formed to include portions having high and low concentrations of Cu and not uniformly include Cu. In this case, the effect for improving the hardenability of a steel is decreased at the portions having low concentration of Cu in the matrix. As a result, the iron-phosphorus-carbon compounds sufficiently grow even when the amount of P is small. The present invention was achieved based on this finding.
Sintered Material for Valve Guides
In a sintered material for valve guides of the present invention based on the above finding, diffusion of Cu in an iron matrix is controlled. The matrix includes portions having high and low concentrations of Cu and not uniformly includes Cu. In the matrix, plate-shaped iron-phosphorus-carbon compounds are precipitated at the portion having low concentration of Cu.
A metallic structure of a cross section of a sintered material for valve guides of the present invention is shown in
The iron-phosphorus-carbon compound phase grew in the shape of plates, and the shape and the amount thereof were approximately the same as those of the conventional sintered material shown in
By controlling the diffusion amount of Cu as described above, iron-phosphorus-carbon compounds are obtained even when the amount of P is 0.01 to 0.08%. In this case, the amount and the sizes of the iron-phosphorus-carbon compounds are equivalent to those of the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858.
In the sintered material for valve guides of the present invention, Cu diffuses into a matrix and solid strengthens the matrix, thereby improving the strength of the sintered material. In addition, Cu forms at least one of soft copper phase and soft copper alloy phase, thereby improving adaptability to a mating material (valve stem). When the amount of Cu is less than 1 mass %, these effects are not sufficiently obtained. Therefore, the amount of Cu is set to be not less than 1 mass %. On the other hand, when the amount of Cu is more than 4 mass %, the amount of Cu diffused in the iron matrix becomes too great. Therefore, iron-phosphorus-carbon compounds are difficult to grow in the cooling after the sintering. Accordingly, the amount of Cu in the sintered material is set to be 1 to 4 mass %.
Sn is melted at a heating step in the sintering and generates a liquid phase, whereby Sn wets and covers the surface of the iron powder and facilitates dispersion of the iron powder particles. Therefore, Sn improves the strength of the sintered material for valve guides. In order to obtain this effect for improving the strength, the amount of Sn is set to be not less than 0.05 mass %. On the other hand, when the amount of Sn is too great, too much of Cu—Sn eutectic liquid phase is generated, as described below. In this case, the amount of the diffusion of Cu into the iron matrix is increased, and the plate-shaped iron-phosphorus-carbon compounds are difficult to obtain in the cooling after the sintering. Therefore, the upper limit of the amount of Sn is set to be 0.5 mass %.
Sn is alloyed with a part or entire amount of Cu and is thereby diffused as a copper-tin alloy phase in the matrix. Therefore, a combination of a copper phase and a copper-tin alloy phase, or a copper-tin alloy phase is dispersed in the matrix. The amount of these copper system phases (the copper phase and the copper-tin alloy phase, or the copper-tin alloy phase) is set to be not less than 0.5% by area ratio with respect to a metallic structure in cross-sectional observation in view of the adaptability to a mating material. On the other hand, when this area ratio is more than 3.5%, the diffusion amount of Cu into the iron matrix is increased, whereby the iron-phosphorus-carbon compound phase is difficult to grow. Therefore, the amount of the copper system phases (the copper phase and the copper-tin alloy phase, or the copper-tin alloy phase) is set to be 0.5 to 3.5% by area ratio with respect to a metallic structure in cross-sectional observation.
In the sintered material for valve guides of the present invention, C is essential for forming the iron-phosphorus-carbon compound phase and the graphite phase that can be used as a solid lubricant. Therefore, the amount of C is set to be not less than 1.3 mass %. In this case, C is added in the form of a graphite powder. If the amount of the graphite powder is more than 3.0 mass % in the raw powder, flowability, fillability, and compressibility of the raw powder are greatly decreased, and the sintered material is difficult to produce. Accordingly, the amount of C in the sintered material is set to be 1.3 to 3.0 mass %.
When the amount of the iron-phosphorus-carbon compound phase is small the wear resistance is decreased. Therefore, the amount of the iron-phosphorus-carbon compound phase is required to be not less than 3% by area ratio with respect to a metallic structure including pores in cross-sectional observation. In contrast, when the amount of the iron-phosphorus-carbon compound phase is too great, the degree of wear characteristics with respect to a mating material (valve stem) is increased, whereby the mating material may be worn. In addition, strength of a valve guide is decreased, and machinability of a valve guide is decreased. Therefore, the upper limit of the amount of the iron-phosphorus-carbon compound phase is set to be 25%. It should be noted that the pearlite has a lamellar structure of fine iron carbides and ferrite, and the pearlite is difficult to strictly separate from the iron-phosphorus-carbon compound. Nevertheless, the plate-shaped iron-phosphorus-carbon compound of the present invention is identified in a cross-sectional metallic structure as the dark colored portion as shown in
When the above image analysis is performed, each of the iron-phosphorus-carbon compounds is recognized as a portion having an area of not less than 0.05% in a visual field of a cross-sectional structure at 200-power magnification as described above. Accordingly, the area ratio of the iron-phosphorus-carbon compound phase also can be measured by adding up the areas of the portions having an area of not less than 0.05%. The area ratio of the plate-shaped iron-phosphorus-carbon compound phase is set to be the above area ratio in cross section. Moreover, as already described above, in view of the wear resistance, the amount of large plate-shaped iron-phosphorus-carbon compounds is preferably 3 to 50% with respect to the entire amount of the plate-shaped iron-phosphorus-carbon compounds. In this case, the large plate-shaped iron-phosphorus-carbon compounds have an area of not less than 0.15%, which is measured in a visual field of a cross-sectional structure at 200-power magnification.
Production Method for Sintered Material for Valve Guides
In the sintered material for valve guides, diffusion of Cu in the iron matrix is controlled, whereby the matrix includes portions having high and low concentration of Cu and not uniformly includes Cu. The iron-phosphorus-carbon compounds are made to grow at the portion having low concentration of Cu in the matrix. In the production method for the sintered material for valve guides of the present invention, a graphite powder, an iron-phosphorus alloy powder, and at least one selected from the following group, are mixed with an iron powder into a mixed powder. The iron-phosphorus alloy powder includes 15 to 21% of P. The group consists of a combination of a copper powder and a tin powder, a copper-tin alloy powder, and a combination of a copper powder and a copper-tin alloy powder. The mixed powder is used as a raw powder. In this case, sintering is performed at a heating temperature (sintering temperature) of 940 to 1040° C.
The graphite powder is added to the raw powder at not less than the amount so that C diffuses and forms hypereutectoid composition at the heating temperature. As a result, a part of the amount of C added in the form of the graphite powder is uniformly diffused and is solved in the iron matrix (austenite). The residual amount of C remains as a graphite phase which functions as a solid lubricant.
When the sintered compact in such conditions is cooled, in the portion having low concentration of Cu in the iron matrix, the effect for improving the hardenability of the iron matrix is decreased. Therefore, the pearlite nose is not greatly shifted to the later time side in the continuous cooling transformation diagram. As a result, iron-carbides precipitated from the austenite easily grow in the cooling after the sintering, and the iron-phosphorus-carbon compounds grow even when the amount of P is small.
The sintering is performed in a nonoxidizing atmosphere as is conventionally done. In this case, the upper limit of the heating temperature is set to be 1040° C. in view of decreasing diffusion of Cu. On the other hand, Cu is essential for improving the strength of the sintered material, and if the amount of Cu diffused into the iron matrix is too small, the strength of the sintered material is decreased. From this point of view, the lower limit of the heating temperature in the sintering is set to be 940° C.
The entire composition of the raw powder is selected based on the same reason for the entire composition of the sintered material for valve guides of the present invention. In order to perform the sintering at the above heating temperature, the amount of Cu is set to be 1 to 4 mass % in the entire composition of the raw powder. When the amount of Cu is less than 1 mass %, the strength of the sintered material is decreased. On the other hand, when the amount of Cu is more than 4 mass %, the amount of Cu diffused in the iron matrix becomes too great. Therefore, the plate-shaped iron-phosphorus-carbon compounds are difficult to obtain in the cooling after the sintering. Accordingly, the amount of Cu is set to be 1 to 4 mass % in the entire composition of the raw powder.
Sn has a melting point of 232° C., and the copper-tin alloy generates a liquid phase at a temperature, which varies with the amount of Sn. When the amount of Sn is increased in the copper-tin alloy, the liquid phase is generated at a lower temperature. Even when the amount of Sn is approximately 15 mass % in the copper-tin alloy, the liquid phase is generated at 798° C. Sn is added in the form of at least one of a tin powder and a copper-tin alloy powder. When the tin powder is used, Sn liquid phase is generated while the temperature is rising in the sintering. The Sn liquid phase is filled in the spaces among the raw powder particles by capillary force. Then, a part of the Sn liquid phase covers the copper powder particles and generates a Cu—Sn eutectic liquid phase on the surface of the copper powder particles. When the copper-tin alloy powder is used, a Cu—Sn eutectic liquid phase is generated in accordance with the temperature while the temperature is increasing in the sintering. The Cu—Sn liquid phase is filled in the spaces among the raw powder particles by capillary force and wets and covers the iron powder particles. Therefore, the Cu—Sn liquid phase activates dispersion of the iron powder particles and accelerates growth of necks between the iron powder particles, thereby facilitating the diffusion bonding of the iron powder particles.
In order to obtain the effect of Sn for facilitating the sintering, not less than 0.05 mass % of Sn is required. On the other hand, if the amount of Sn is too great, too much of the Cu—Sn eutectic liquid phase is generated. In this case, the diffusion of Cu into the iron matrix is increased, whereby the plate-shaped iron-phosphorus-carbon compounds are difficult to obtain in the cooling after the sintering. Therefore, the upper limit of the amount of Sn is set to be 0.5 mass %.
In the production method for the sintered material for valve guides of the present invention, Su is used as described above. Since the effect for facilitating the sintering is obtained by the Cu—Sn liquid phase, predetermined diffusion conditions of Cu are obtained at a heating temperature of 940° C. in the sintering. On the other hand, the amount of the diffusion of Cu into the iron matrix is increased with the increase of the heating temperature. Therefore, in order to control the diffusion of Cu into the iron matrix, the upper limit of the heating temperature is required to be 1040° C. in the sintering.
When the copper-tin alloy powder is used, in order to generate the Cu—Sn eutectic liquid phase in the heating temperature range (940 to 1040° C.), a copper-tin alloy powder including not less than 8 mass % of Sn (eutectic liquid phase generating temperature: 900° C.) may be used.
The amount of P is 0.01 to 0.08% in the entire composition of the raw powder, and P is added in the form of an iron-phosphorus alloy powder including 15 to 21% of P. The iron-phosphorus alloy powder including 15 to 21% of P has a melting point of 1166° C., and thereby do not generate a liquid phase at the heating temperature in the sintering and is solid phase dispersed. Therefore, generation of liquid phases other than the Cu—Sn liquid phase is avoided. Accordingly, the iron powder particles are wetted by the Cu—Sn liquid phase and neck growth thereof is facilitated, and the diffusion of Cu into the matrix is controlled.
In order to perform the sintering at the above heating temperature, the amount of the graphite powder is selected so that C diffused in the iron matrix forms an eutectoid composition or a hypereutectoid composition. In addition, the amount of the graphite powder is selected so that a part of the amount of the graphite powder remains as a solid lubricant. Therefore, the graphite powder is added to the raw powder at not less than 1.3 mass %. On the other hand, when the graphite powder is added to the raw powder at more than 3.0 mass %, the flowability, the fillability, and the compressibility of the raw powder are greatly decreased, and the sintered material is difficult to produce. Therefore, the graphite powder is added to the raw powder at 1.3 to 3.0 mass %.
The diffusions of the elements of Cu and C are greatly affected by the heating temperature and are relatively less affected by the holding time at the heating temperature. Nevertheless, because Cu and C may not be sufficiently diffused if the holding time is too short in the sintering, the holding time is preferably set to be not less than 10 minutes. On the other hand, because Cu may be too diffused if the holding time is too long in the sintering, the holding time is preferably set to be not more than 90 minutes.
After the sintering, while the sintered compact is cooled from the heating temperature to room temperature, the sintered compact is preferably cooled from 850 to 600° C. at a cooling rate of not more than 25° C./minute. In this case, the precipitated iron-phosphorus-carbon compounds tend to grow in the shape of plates. On the other hand, if the cooling rate is too low, a long time is required for the cooling and thereby the production cost is increased. Therefore, the cooling rate in the temperature range of 850 to 600° C. is preferably not less than 5° C./minute.
In addition, in the cooling from the heating temperature to room temperature after the sintering, the sintered compact may be isothermally held at a temperature during cooling from 850 to 600° C. and may be then cooled. By the isothermal holding, the precipitated iron-phosphorus-carbon compounds grow in the shape of plates. In this case, the isothermal holding time is preferably not less than 10 minutes. On the other hand, if the isothermal holding time is too long, a long time is required for the cooling, and thereby the production cost is increased. Therefore, the isothermal holding time is preferably not more than 90 minutes in the temperature range of 850 to 600° C.
In the production method for the sintered material for valve guides of the present invention, the raw powder is filled in a tube-shaped cavity of a die assembly, and the raw powder is compacted into a green compact having a tube shape. Then, the green compact is sintered in a nonoxidizing atmosphere. The compacting and the sintering are conventionally performed as processes for producing a sintered material for valve guides.
In the sintered material for valve guides, the machinability may be improved by conventional methods such as the method disclosed in Japanese Patent No. 2680927. That is, at least one kind selected from the group consisting of a manganese sulfide powder, a magnesium silicate mineral powder, and a calcium fluoride powder may be added to the raw powder at not more than 2 mass %. Then, by compacting and sintering this raw powder, a sintered material for valve guides is obtained. This sintered material has particle boundaries in the matrix and pores, in which at least one of manganese sulfide particles, magnesium silicate mineral particles, and calcium fluoride particles are dispersed at not more than 2 mass %. Accordingly, the machinability of the sintered material is improved.
Effects of the amount of P in the entire composition on characteristics of a valve guide were investigated. First, an iron powder, an iron-phosphorus alloy powder, a copper-tin alloy powder, and a graphite powder were prepared. The iron-phosphorus alloy powder consisted of 20 mass % of P and the balance of Fe and inevitable impurities, and the copper-tin alloy powder consisted of 10 mass % of Sn and the balance of Cu and inevitable impurities. The iron-phosphorus alloy powder and the copper-tin alloy powder in the amounts shown in Table 1, and 2 mass % of the graphite powder, were added to the iron powder, and they were mixed to form a raw powder. The raw powder was compacted at a compacting pressure of 650 MPa into a green compact with a tube shape. Some of the green compacts had an outer diameter of 11 mm, an inner diameter of 6 mm, and a length of 40 mm (for a wear test). The other green compacts had an outer diameter of 18 mm, an inner diameter of 10 mm, and a length of 10 mm (for a compressive strength test). These green compacts with the tube shapes were sintered at a heating temperature of 1000° C. for 30 minutes in an ammonia decomposed gas atmosphere. Then, the sintered compacts were cooled from the heating temperature to room temperature, whereby sintered compact samples of samples Nos. 01 to 07 were formed. In the cooling, the cooling rate in the temperature range from 850 to 600° C. was 10° C./minute.
Another sintered compact sample of sample No. 08 was formed as a conventional example as follows. A copper-tin alloy powder consisting of 10 mass % of Sn and the balance of Cu and inevitable impurities, and an iron-phosphorus alloy powder consisting of 20 mass % of P and the balance of Fe and inevitable impurities, were also prepared. Then, 5 mass % of the copper-tin alloy powder, 1.4 mass % of the iron-phosphorus alloy powder, and 2 mass % of the graphite powder were added to the iron powder, and they were mixed to form a raw powder. This raw powder was also compacted into two kinds of green compacts having the above shapes and was sintered under the above sintering conditions, whereby a sintered compact sample of sample No. 08 was obtained. This conventional example corresponds to the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858. The entire compositions of these sintered compact samples are shown in Table 1.
In these sintered compact samples, wear amounts of valve guides and wear amounts of valve stems were measured by the wear test, and compressive strength was measured by the compressive strength test. In addition, an area ratio of an iron-phosphorus-carbon compound phase and an area ratio of copper system phase were measured by observing a cross section of a metallic structure. The copper system phase was a copper-tin alloy phase or a combination of a copper phase and a copper-tin alloy phase.
The wear test was performed as follows by using a wear testing machine. The sintered compact sample having the tube shape was secured to the wear testing machine, and a valve stem of a valve was inserted into the sintered compact sample. The valve was mounted at a lower end portion of a piston that would be vertically reciprocated. Then, the valve was reciprocated at a stroke speed of 3000 times/minute and at a stroke length of 8 mm at 500° C. in an exhaust gas atmosphere, and at the same time, a lateral load of 5 MPa was applied to the piston. After the valve was reciprocated for 30 hours, wear amount (in μm) of the inner circumferential surface of the sintered compact and wear amount (in μm) of the outer circumferential surface of the valve stem were measured.
The compressive strength test was performed as follows according to the method described in Z2507 specified by the Japanese Industrial Standard. A sintered compact sample with a tube shape had an outer diameter of D (mm), a wall thickness of e (mm), and a length of L (mm). The sintered compact sample was radially pressed by increasing the pressing load, and a maximum load F (N) was measured when the sintered compact sample broke. Then, a compressive strength K (N/mm2) was calculated from the following first formula.
K=F×(D−e)/(L×e2) First formula
The area ratio of the copper system phase was measured as follows. The cross section of the sample was mirror polished and was etched with a nital. This metallic structure was observed by a microscope at 200-power magnification and was analyzed by using image analyzing software “WinROOF” that is produced by Mitani Corporation. Thus, the area of the copper system phase was measured so as to obtain an area ratio. The area ratio of the iron-phosphorus-carbon compound phase was measured in the same manner as in the case of the area ratio of the copper system phase except that Murakami's reagent was used as the etching solution. The area of each phase identified by the image analysis is not less than 0.05% with respect to the visual field. Since the sample of the sample No. 01 did not include P, an area ratio of iron-carbon compound phase was measured.
These results are shown in Table 2. It should be noted that the total of the wear amounts of the valve guide and the valve stem is represented by the symbol “Total” in the Tables. The samples were evaluated based on acceptable levels to use as a valve guide. That is, the target level of the compressive strength is approximately not less than 500 MPa, and the target level of the wear amount is not more than 75 μm in the total wear amount.
According to the samples of the samples Nos. 01 to 08 in Table 2, the effects of the amount of P in the entire composition of the sintered material are shown. In the samples of the samples Nos. 01 to 06 including not more than 0.08 mass % of P, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was approximately constant in the cross-sectional metallic structure and was approximately the same as that of the conventional example (sample No. 08). In these samples, the compressive strengths, and the wear amounts of the valve guides and the valve stems, were approximately the same as those of the conventional example. Thus, a sintered material having high wear resistance was obtained at low cost even when the amount of P was decreased.
Effects of the amount of Cu in the entire composition on characteristics of a valve guide were investigated. The iron powder, the iron-phosphorus alloy powder, and the graphite powder, which were used in the First Example, were prepared. Moreover, a copper powder and a tin powder were prepared. Then, the iron-phosphorus alloy powder, the copper powder, and the tin powder, which were in the amounts shown in Table 3, and 2 mass % of the graphite powder, were added to the iron powder, and they were mixed to form a raw powder. The raw powder was compacted and was sintered in the same conditions as in the First Example, whereby samples of samples Nos. 09 to 19 were formed. The entire compositions of these samples are shown in Table 3. In these samples, the wear test and the compressive strength test were performed under the same conditions as those in the First Example. Moreover, the area ratio of the iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were measured. These results are shown in Table 4. It should be noted that the values of the sample of the sample No. 04 in the First Example are also shown in Tables 3 and 4 as an example including 2 mass % of the copper-tin alloy powder.
According to the samples of the samples Nos. 04 and 09 to 19 in Table 4, the effects of the amount of Cu in the entire composition of the sintered material and the effects of the amount of the copper powder in the raw powder are shown. In the samples of the samples Nos. 09 to 15 including not more than 2.5 mass % of Cu (the copper powder), the area ratio of the plate-shaped iron-phosphorus-carbon compound phase in the cross sectional metallic structure was slightly decreased with the increase of the amount of Cu. In this case, the amounts of the iron-phosphorus-carbon compounds were approximately the same as that of the conventional example (sample No. 08). On the other hand, when the amount of Cu (the copper powder) was more than 2.5 mass %, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was suddenly decreased in the cross sectional metallic structure. In the sample of the sample No. 18 including 4.0 mass % of Cu, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was decreased to approximately 4%. Moreover, in the sample of the sample No. 19 including more than 4.0 mass % of Cu, the area ratio of the iron-phosphorus-carbon compound phase was decreased to 2.3%.
The copper system phase was increased in proportion to the amount of Cu (the copper powder). In the sample of the sample No. 11 including 1.0 mass % of Cu (the copper powder), the area ratio of the copper system phase was 0.5% in the cross-sectional metallic structure. In the sample of the sample No. 18 including 4.0 mass % of Cu (the copper powder), the area ratio of the copper system phase was increased to 2.6%. Moreover, in the sample of the sample No. 19 including more than 4.0 mass % of Cu (the copper powder), the area ratio of the copper system phase was increased to 2.9%.
In the sample of the sample No. 09 including 0 mass % of Cu (the copper powder), since Cu was not included, the strength of the matrix was low, and the compressive strength was low. According to the increase in the amount of Cu (the copper powder), the effect of Cu for strengthening the matrix was increased. Therefore, the compressive strength was increased in proportion to the amount of Cu (the copper powder). In the samples of the samples Nos. 09 and 10 including less than 1.0 mass % of Cu (the copper powder), the compressive strength was low, whereby these samples cannot be used as a valve guide. On the other hand, in the samples of the samples Nos. 11 to 19 including not less than 1.0 mass % of Cu (the copper powder), the compressive strength was not less than 500 MPa, and the strength was at an acceptable level sufficient to use as a valve guide.
In the sample of the sample No. 09 including 0 mass % of Cu (the copper powder), since the copper system phase for improving the adaptability was not included, the valve stem was greatly worn. On the other hand, in the sample of the sample No. 10 including 0.5 mass % of Cu (the copper powder), the copper system phase was dispersed and thereby the adaptability was improved. Therefore, the wear amount of the valve stem was decreased. Moreover, in the samples of the samples Nos. 11 to 19 including not less than 1.0 mass % of Cu (the copper powder), sufficient amount of the copper system phase was dispersed, whereby the wear amount of the valve stem was low and was constant.
In the sample of the sample No. 09 including 0 mass % of Cu (the copper powder), since Cu was not included, the strength of the matrix was low. Therefore, the wear amount of the valve guide was great, and the total wear amount was large. In contrast, in the sample of the sample No. 10 including 0.5 mass % of Cu (the copper powder), the strength of the matrix was improved by the effect of Cu. Therefore, the wear amount of the valve guide was decreased, and the total wear amount was also decreased. In the samples of the samples Nos. 11 to 15 including 1.0 to 2.5 mass % of Cu (the copper powder), the effect of Cu for strengthening the matrix was sufficiently obtained, and the precipitation amount of the plate-shaped iron-phosphorus-carbon compounds was great. Accordingly, the wear amounts of the valve guides were approximately the same as that of the conventional example (sample No. 08) and were approximately constant and low. As a result, the total wear amounts were also approximately the same as that of the conventional example (sample No. 08) and were approximately constant and low. On the other hand, in the samples of the samples Nos. 16 to 18 including 3.0 to 4.0 mass % of Cu (the copper powder), the influence of the decrease in the amount of the plate-shaped iron-phosphorus-carbon compounds was greater than the effect of Cu for strengthening the matrix. Therefore, the wear resistances were decreased, and the wear amounts of the valve guides were slightly increased. In the sample of the sample No. 19 including more than 4.0 mass % of Cu (the copper powder), the wear resistance was greatly decreased due to the decrease in the amount of the iron-phosphorus-carbon compounds. As a result, the wear amount of the valve guide was increased, and the total wear amount was greatly increased.
According to the above results, when the amount of Cu (the copper powder) was 1.0 to 4.0 mass %, the wear resistance of the sintered compacts were approximately equal to that of the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858. In addition, when the amount of Cu was in this range, the sintered compacts had strength at an acceptable level to use as a valve guide. The area ratio of the copper system phase was 0.5 to 2.6% in the cross-sectional metallic structure when the amount of Cu was in this range. In this case, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was required to be approximately not less than 3% in the cross-sectional metallic structure.
Effects of the amount of Sn in the entire composition on the characteristic of a valve guide were investigated. The iron powder, the iron-phosphorus alloy powder, and the graphite powder, which were used in the First Example, were prepared. In addition, the copper powder and the tin powder were prepared. Then, the iron-phosphorus alloy powder, the copper powder, and the tin powder, which were in the amounts shown in Table 5, and 2 mass % of the graphite powder, were added to the iron powder, and they were mixed to form a raw powder. The raw powder was compacted and was sintered in the same conditions as in the First Example, whereby samples of samples Nos. 20 to 26 were formed. The entire compositions of these samples are also shown in Table 5. In these samples, the wear test and the compressive strength test were performed under the same conditions as those in the First Example. Moreover, the area ratio of the iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were measured. These results are shown in Table 6.
According to the samples of the samples Nos. 20 to 26 in Table 6, the effects of the amount of Sn are shown. By adding Sn to the sintered material, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were decreased in the cross-sectional metallic structure. The decrease amounts of the area ratio of the iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were increased with the increase of the amount of Sn. This was because a greater amount of the Cu—Sn liquid phase was generated in the sintering according to the increase of the amount of Sn, whereby the diffusion amount of Cu into the matrix was increased. In the sample of the sample No. 25 including 0.5 mass % of Sn, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was approximately 5% and the area ratio of the copper system phase was approximately 0.5% in the cross-sectional metallic structure. On the other hand, in the sample of the sample No. 26 including more than 0.5 mass % of Sn, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was decreased to less than 3% and the area ratio of the copper system phase was decreased to 0.3% in the cross-sectional metallic structure.
In the samples of the samples Nos. 21 to 26 including not less than 0.05 mass % of Sn, the compressive strength was increased compared with the sample of the sample No. 20 including 0.01 mass % of Sn. The compressive strength was increased with the increase of the amount of Sn. This was because a greater amount of the Cu—Sn liquid phase was generated in the sintering according to the increase of the amount of Sn. In this case, the diffusion amount of Cu into the matrix was increased, and the Cu—Sn liquid phase wetted and covered the surface of the iron powder particles and thereby accelerating neck growth between the iron powder particles. In the sample of the sample No. 20 including less than 0.05 mass % of Sn, the effect for improving the compressive strength was small. In the samples of the samples Nos. 21 to 26 including not less than 0.05% of Sn, the effect for improving the compressive strength was great.
In the samples of the samples Nos. 20 to 24 including 0.01 to 0.4 mass % of Sn, the wear amounts of the valve guides were approximately the same. The wear amount of the valve guide was slightly increased when the amount of Sn was 0.5 mass % (sample No. 25). Although the plate-shaped iron-phosphorus-carbon compounds were decreased with the increase of the amount of Sn as described above, the wear amount of the valve guide was not greatly increased. This was because the neck between the iron powder particles grew and thereby the strength was improved. In the sample of the sample No. 26 including more than 0.5 mass %, the wear resistance was greatly decreased due to the decrease of the plate-shaped iron-phosphorus-carbon compound phase. Therefore, the wear amount of the valve guide was suddenly increased. The wear amount of the valve stem was approximately constant when the amount of Sn was 0.01 to 0.5 mass % and was suddenly increased when the amount of Sn was 0.6 mass %. Accordingly, when the amount of Sn was in the range of not more than 0.5 mass %, the total wear amount was small, and superior wear resistance was obtained.
As described above, by adding not less than 0.05 mass % of Sn to the sintered material, the strength of the sintered material was improved. In this case, when the amount of Sn was more than 0.5 mass %, the wear resistance was decreased. Therefore, it is required that the amount of Sn be 0.05 to 0.5 mass %.
Effects of the amount of C in the entire composition on the characteristics of a valve guide were investigated. The iron powder, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were used in the First Example, were prepared. Then, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were in the amounts shown in Table 7, were added to the iron powder, and they were mixed to form a raw powder. The raw powder was compacted and was sintered in the same conditions as in the First Example, whereby samples of samples Nos. 27 to 32 were formed. The entire compositions of these samples are also shown in Table 7. In these samples, the wear test and the compressive strength test were performed under the same conditions as those in the First Example. Moreover, the area ratio of the iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were measured. These results are shown in Table 8. It should be noted that the values of the sample of the sample No. 04 in the First Example are also shown in Tables 7 and 8 as an example including 2 mass % of the graphite powder.
According to the samples of the samples Nos. 04 and 27 to 32 in Table 8, the effects of the amount of C in the entire composition of the sintered material and the effects of the amount of the graphite powder in the raw powder are shown. In the sample of the sample No. 27 including 1 mass % of C (the graphite powder), the amount of C diffused in the matrix was small, whereby the plate-shaped iron-phosphorus-carbon compound phase was not precipitated. In contrast, in the sample of the sample No. 28 including 1.3 mass % of C (the graphite powder), the amount of C diffused in the matrix was sufficient, and the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was 3.4% in the cross-sectional metallic structure. According to the increase of the amount of C (the graphite powder), the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was increased in the cross-sectional metallic structure. That is, in the sample of the sample No. 31 including 3 mass % of C (the graphite powder), the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was approximately 25%. Moreover, in the sample of the sample No. 32 including more than 3 mass % of C (the graphite powder), the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was increased to 28%. On the other hand, the area ratio of the copper system phase was constant in the cross-sectional metallic structure regardless of the amount of C (the graphite powder). This was because the amount of Cu (the copper powder) was constant and the sintering conditions were the same.
In the sample of the sample No. 27, the plate-shaped iron-phosphorus-carbon compound phase was not precipitated in the matrix, and the compressive strength was the highest. When the amount of C (the graphite powder) was increased, the iron-phosphorus-carbon compound phase precipitated in the matrix was increased, whereby the compressive strength was decreased. In the sample of the sample No. 31 including 3 mass % of C (the graphite powder), the compressive strength was 504 MPa. Therefore, when the amount of C (the graphite powder) was not more than 3 mass %, the strength of the sintered compact was at an acceptable level sufficient to use as a valve guide.
In the sample of the sample No. 27 including 1 mass % of C (the graphite powder), since the iron-phosphorus-carbon compound phase for improving the wear resistance was not precipitated, the wear amount of the valve guide was great. In contrast, in the sample of the sample No. 28 including 1.3 mass % of C (the graphite powder), the plate-shaped iron-phosphorus-carbon compound phase was precipitated in the matrix, and the wear amount of the valve guide was decreased. According to the increase of the amount of C (the graphite powder), the amount of the plate-shaped iron-phosphorus-carbon compound phase precipitated in the matrix was increased. Therefore, according to the increase of the amount of C (the graphite powder), the wear resistance was improved by the plate-shaped iron-phosphorus-carbon compound phase, and the wear amount of the valve guide was decreased. This tendency was observed until the sample of the sample No. 30 including 2.5 mass % of C (the graphite powder). On the other hand, in the sample of the sample No. 31 including 3 mass % of C (the graphite powder), since the plate-shaped iron-phosphorus-carbon compounds were greatly increased, the strength of the sintered compact sample was decreased. Therefore, the wear amount of the valve guide was slightly increased. Moreover, in the sample of the sample No. 32 including more than 3 mass % of C (the graphite powder), the wear amount of the valve guide was greatly increased. The amount of the plate-shaped iron-phosphorus-carbon compound phase precipitated in the matrix was increased with the increase of C (the graphite powder), and the iron-phosphorus-carbon compound phase was hard. Therefore, the wear amount of the valve stem was increased with the increase of C (the graphite powder) from 2 mass %. According to these wear conditions, the total wear amount was decreased when the amount of C (the graphite powder) was in the range of 1.3 to 3 mass %.
As described above, when the amount of C (the graphite powder) was 1.3 to 3 mass %, the wear resistances of the sintered compacts were approximately equal to that of the sintered material disclosed in Japanese Examined Patent Publication No. 55-034858. In addition, when the amount of C was in this range, the sintered compacts had strength at an acceptable level to use as a valve guide. In this case, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was 3 to 25% in the cross-sectional metallic structure when the amount of C was in this range.
Effects of the heating temperature on the characteristics of a valve guide were investigated. The iron powder, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were used in the First Example, were prepared. Then, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were in the amounts shown in Table 9, were added to the iron powder, and they were mixed to form a raw powder. The raw powder was compacted in the same conditions as in the First Example so as to obtain a green compact. The green compact was sintered at the heating temperature shown in Table 9 for 30 minutes and was cooled, whereby samples of samples Nos. 33 to 39 were formed. In the cooling from the heating temperature to room temperature, the cooling rate in the temperature range from 850 to 600° C. was 10° C./minute. The entire compositions of these samples are also shown in Table 9. In these samples, the wear test and the compressive strength test were performed under the same conditions as those in the First Example. Moreover, the area ratio of the iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were measured. These results are shown in Table 10. It should be noted that the values of the sample of the sample No. 04 in the First Example are also shown in Tables 9 and 10 as an example in which the heating temperature was 1000° C.
According to the samples of the samples Nos. 04 and 33 to 39 in Table 10, the effects of the heating temperature in the sintering are shown. According to the increase of the heating temperature in the sintering, the diffusion amount of Cu into the matrix was increased, whereby the amount of Cu remained as a copper system phase was decreased. Therefore, the area ratio of the copper system phase in the cross-sectional metallic structure was decreased with the increase of the heating temperature in the sintering. In the sample of the sample No. 39 in which the heating temperature was more than the melting point of Cu (1085° C.) and was 1100° C., most of the amount of Cu added in the form of the copper-tin alloy powder was diffused into the matrix. Therefore, the area ratio of the copper system phase was only 0.25%.
In the sample of the sample No. 33 in which the heating temperature was 900° C., since the heating temperature was low in the sintering, C was not sufficiently diffused, and the plate-shaped iron-phosphorus-carbon compound phase was hardly precipitated. In contrast, in the samples of the samples Nos. 04 and 34 to 37 in which the heating temperature was 940 to 1040° C., C was sufficiently diffused. Therefore, sufficient amounts of the plate-shaped iron-phosphorus-carbon compound phases were obtained in the cross-sectional metallic structures. In this case, some of the area ratios of the iron-phosphorus-carbon compound phases were approximately equal to that of the conventional example (sample No. 08). When the heating temperature was further increased, the amount of Cu diffused in the matrix was increased, whereby the plate-shaped iron-phosphorus-carbon compound phase was difficult to be formed. Therefore, the precipitation amount of the plate-shaped iron-phosphorus-carbon compound phase was decreased, and the area ratio thereof was decreased in the cross-sectional the metallic structure. In the sample of the sample No. 39 in which the heating temperature was more than the melting point of Cu (1085° C.) and was 1100° C., Cu was uniformly diffused into the matrix. As a result, the iron carbides were not precipitated as a large plate-shaped iron-phosphorus-carbon compound phase, but most of the iron carbides were precipitated in the shape of pearlite. Therefore, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was greatly decreased in the cross-sectional metallic structure.
According to the increase of the heating temperature in the sintering, since a greater amount of Cu for strengthening the matrix was diffused in the matrix, the compressive strength was increased. In the sample of the sample No. 33 in which the heating temperature was 900° C., Cu was not sufficiently diffused. Therefore, the compressive strength was less than 500 MPa and was not at a level that is required in a case of using the sintered compact as a valve guide. On the other hand, in the samples of the samples Nos. 04 and 34 to 39 in which the heating temperature was not less than 940° C., the diffusion amount of Cu into the matrix was increased. As a result, the compressive strengths were not less than 500 MPa and were at acceptable levels to use for valve guides.
In the sample of the sample No. 33 in which the heating temperature was 900° C., C was not sufficiently diffused, and the plate-shaped iron-phosphorus-carbon compound phase for improving the wear resistance was hardly precipitated. Therefore, the wear amount of the valve guide was great. On the other hand, in the sample of the sample No. 34 in which the heating temperature was 940° C., C was sufficiently diffused. Therefore, the plate-shaped iron-phosphorus-carbon compound phase was sufficiently precipitated, and the wear amount of the valve guide was decreased. Moreover, in the samples of the samples Nos. 04 and 35 to 37 in which the heating temperature was 970 to 1040° C., the wear amount of the valve guide was even less due to the above effects. According to the increase of the heating temperature, the diffusion amount of Cu into the matrix was increased. Therefore, in the samples of the samples Nos. 38 and 39 in which the heating temperature was 1070 to 1100° C., the area ratio of the precipitated plate-shaped iron-phosphorus-carbon compound phase was greatly decreased with the increase of the heating temperature. Accordingly, the wear resistances were decreased, and the wear amounts of the valve guides were further increased. The wear amount of the valve stem was approximately constant regardless of the heating temperature. Accordingly, the total wear amount was decreased when the heating temperature was in the range of 940 to 1040° C.
According to the above results, in the case of forming a sintered material for valve guides by using the iron-copper-carbon sintered alloy, when the heating temperature was 940 to 1040° C. in the sintering, the wear resistance was superior. In addition, when the heating temperature was in this range, the sintered compacts had strength at an acceptable level to use as a valve guide.
Effects of the cooling rate on the characteristics of a valve guide were investigated. In the cooling of the sintered compact from the heating temperature to room temperature, the sintered compact was cooled from 850 to 600° C. at this cooling rate. The iron powder, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were used in the First Example, were prepared. Then, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were in the amounts shown in Table 11, were added to the iron powder, and they were mixed to form a raw powder. The raw powder was compacted in the same conditions as in the First Example so as to obtain a green compact. The green compact was sintered at 1000° C. for 30 minutes, whereby samples of samples Nos. 40 to 44 were formed. The sintered compact was cooled from 850 to 600° C. at the cooling rate shown in Table 11. The entire compositions of these samples are also shown in Table 11. In these samples, the wear test and the compressive strength test were performed under the same conditions as those in the First Example. Moreover, the area ratio of the iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were measured. These results are shown in Table 12. It should be noted that the values of the sample of the sample No. 04 in the First Example are also shown in Tables 11 and 12 as an example in which the cooling rate in the above temperature range was 10° C./minute.
When the cooling rate in the temperature range from 850 to 600° C. was lower, the area ratio of the iron-phosphorus-carbon compounds was increased in the cross-sectional metallic structure. In other words, when the cooling rate was greater, the area ratio of the iron-phosphorus-carbon compounds was decreased. That is, C at amount in which C was supersaturated at room temperature, was solved in the austenite in the heating temperature range in the sintering, and supersaturated C in this heating temperature range was precipitated as iron carbides (Fe3C). If the sintered compact in this temperature range is cooled at a low cooling rate, the precipitated iron carbides grow, whereby the amount of the iron-phosphorus-carbon compound phase is increased. On the other hand, if the sintered compact in this temperature range is cooled at a high cooling rate, the precipitated iron carbides do not sufficiently grow. Therefore, the ratio of the pearlite, in which fine iron carbides are dispersed, is increased, and the amount of the iron-phosphorus-carbon compounds is decreased. When the cooling rate was increased to 25° C./minute during the cooling from 850 to 600° C., the area ratio of the iron-phosphorus-carbon compound phase came to 4.9% in the cross-sectional metallic structure. Moreover, when the cooling rate was more than 25° C./minute, the area ratio of the iron-phosphorus-carbon compound phase was 1.8%.
On the other hand, the copper system phase was not formed of supersaturated Cu that was precipitated and was diffused, but was formed of copper powder that was not dispersed and remained as a copper system phase. Therefore, the area ratio of the copper system phase in the cross-sectional metallic structure was constant regardless of the cooling rate.
When the cooling rate was greater during the cooling from 850 to 600° C., the amount of the fine iron carbides was increased, and the amount of the plate-shaped iron-phosphorus-carbon compound phase was decreased. Therefore, the compressive strength was increased with the increase of the cooling rate. When the cooling rate was greater during the cooling from 850 to 600° C., since the amount of the iron-phosphorus-carbon compound phase for improving the wear resistance was decreased, the wear amount of the valve guide was slightly increased. Moreover, when the cooling rate was increased to more than 25° C./minute during the cooling from 850 to 600° C., the area ratio of the iron-phosphorus-carbon compound phase was less than 5%, and the wear amount of the valve guide was suddenly increased.
According to the above results, by controlling the cooling rate during the cooling from 850 to 600° C., the amount of the plate-shaped iron-phosphorus-carbon compound phase was controlled. In this case, by setting the cooling rate to be not more than 25° C./minute, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was made to be not less than 5% in the cross-sectional metallic structure, and superior wear resistance was obtained. It should be noted that if the cooling rate is too low during the cooling from 850 to 600° C., the time required for cooling from the heating temperature to room temperature becomes long, and the production cost is increased. Accordingly, the cooling rate is preferably set to be not less than 5° C./minute during the cooling from 850 to 600° C.
Effects of holding time on the characteristics of a valve guide were investigated. The sintered compact was isothermally held at a predetermined time in the temperature range of 850 to 600° C. in the cooling from the heating temperature to room temperature. The iron powder, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were used in the First Example, were prepared. Then, the iron-phosphorus alloy powder, the copper-tin alloy powder, and the graphite powder, which were in the amounts shown in Table 13, were added to the iron powder, and they were mixed to form a raw powder. The raw powder was compacted in the same conditions as in the First Example so as to obtain a green compact. The green compact was sintered at 1000° C. for 30 minutes and was cooled from the heating temperature to room temperature, whereby samples of samples Nos. 45 to 48 were formed. The sintered compact was cooled at a cooling rate of 30° C./minute during the cooling from 850 to 780° C. Then, the sintered compact was isothermally held at 780° C. for a holding time shown in Table 13 and was cooled from 780 to 600° C. at a cooling rate of 30° C./minute. In these samples, the wear test and the compressive strength test were performed under the same conditions as those in the First Example. Moreover, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase and the area ratio of the copper system phase were measured. These results are shown in Table 14. It should be noted that the values of the sample of the sample No. 44 in the Sixth Example are also shown in Tables 13 and 14 as an example. The sample of the sample No. 44 was cooled from 850 to 600° C. at a cooling rate of 30° C./minute and was not isothermally held.
The samples of the samples Nos. 45 to 48 were cooled at the cooling rate at which the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was less than 5% in the cross-sectional metallic structure in the Sixth Example. In this case, these samples were isothermally held at the temperature in the range of 850 to 600° C. during the cooling from the heating temperature to room temperature. Therefore, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was increased to not less than 5%. According to the increase of the isothermal holding time, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was increased. That is, by isothermal holding at the temperature range in which supersaturated C in the austenite was precipitated as iron carbides, the precipitated iron carbides sufficiently grew. As a result, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was increased. Therefore, according to the increase of the isothermal holding time in this temperature range, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase can be increased. Accordingly, when the sintered compact is isothermally held in this temperature range, since the plate-shaped iron-phosphorus-carbon compound phase grows during the isothermal holding, the cooling rate before and after the isothermal holding can be increased.
On the other hand, the copper system phase was not formed of supersaturated Cu that was precipitated and was diffused, but was formed of copper powder that was not dispersed and remained as a copper system phase. Therefore, the area ratio of the copper system phase in the cross-sectional metallic structure was constant regardless of the isothermal holding time.
When the isothermal holding time in the temperature range of 850 to 600° C. was shorter, the time required for growing the iron carbides was shorter, and the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was decreased. In other words, when the isothermal holding time was longer, the time required for growing the iron carbides was longer, and the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was increased. Therefore, the compressive strength was decreased with the increase of the isothermal holding time. When the isothermal holding time in the temperature range of 850 to 600° C. was longer, the amount of the plate-shaped iron-phosphorus-carbon compound phase for improving the wear resistance was increased. Therefore, the wear amount of the valve guide was decreased with the increase of the isothermal holding time.
According to the above results, by isothermal holding in the temperature range of 850 to 600° C., the amount of the plate-shaped iron-phosphorus-carbon compound phase was controlled. By isothermal holding for not less than 10 minutes, the area ratio of the plate-shaped iron-phosphorus-carbon compound phase was made to be not less than 5% in the cross-sectional metallic structure, and superior wear resistance was obtained. In this case, if the isothermal holding time is too long, the time required for cooling from the heating temperature to room temperature becomes long, and the production cost is increased. Therefore, the isothermal holding time is preferably set to be not more than 90 minutes.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-222915 | Sep 2010 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 5259860 | Ikenoue et al. | Nov 1993 | A |
| 5507257 | Sakai et al. | Apr 1996 | A |
| 8617288 | Fujitsuka et al. | Dec 2013 | B2 |
| 20020023518 | Chikahata et al. | Feb 2002 | A1 |
| 20030061905 | Wang et al. | Apr 2003 | A1 |
| 20060032328 | Chikahata et al. | Feb 2006 | A1 |
| Number | Date | Country |
|---|---|---|
| 0 481 763 | Apr 1992 | EP |
| 0 621 347 | Oct 1994 | EP |
| 1 300 481 | Apr 2003 | EP |
| 1 619 263 | Jan 2006 | EP |
| B2-55-34858 | Sep 1980 | JP |
| B2-2680927 | Nov 1997 | JP |
| A-2002-069599 | Mar 2002 | JP |
| B2-4323069 | Sep 2009 | JP |
| B2-4323467 | Sep 2009 | JP |
| Entry |
|---|
| Extended Search Report issued in European Application No. 11007961.3 dated Mar. 28, 2012. |
| Number | Date | Country | |
|---|---|---|---|
| 20120082585 A1 | Apr 2012 | US |
