Corrosion-resistant member

Abstract

A corrosion-resistant member according to the present disclosure includes a substrate that is composed of an aluminum-oxide-based ceramic and a covering layer that is composed of an O—Al—C layer that is located on the substrate.

Claims

1. A corrosion-resistant member, comprising: a substrate that is composed of an aluminum-oxide-based ceramic; and a covering layer that is composed of an O—Al—C layer that is located on the substrate, wherein the aluminum-oxide-based ceramic includes at least 90% by mass of aluminum oxide.

2. The corrosion-resistance member according to claim 1, wherein an element concentration of carbon on a surface of the covering layer is 25 atomic % or greater and 55 atomic % or less.

3. The corrosion-resistance member according to claim 1, wherein a thickness of the covering layer is 10 nm or greater and 100 nm or less.

4. The corrosion-resistance member according to claim 1, wherein a ratio A/B of the covering layer is 5 or greater in a case where A is an element concentration of carbon on a surface of the covering layer and B is an element concentration of carbon at a depth of 6 nm from the surface of the covering layer toward a side of the substrate in a perpendicular direction to the surface of the covering layer.

5. The corrosion-resistance member according to claim 1, wherein a ratio B/C of the covering layer is 2 or less in a case where B is an element concentration of carbon at a depth of 6 nm from a surface of the covering layer toward a side of the substrate and C is an element concentration of carbon at a depth of 10 nm from the surface of the covering layer toward a side of the substrate in a perpendicular direction to the surface of the covering layer.

Description

DESCRIPTION OF EMBODIMENTS

(1) A long service life is desired for a liquid-for-beverage supply apparatus. Hence, further improvement in a corrosion resistance is desired for a member such as a valve member and a pump member that compose a liquid-for-beverage supply apparatus so that it is possible to execute a use thereof over a long period of time.

(2) Accordingly, a corrosion-resistant member according to the present disclosure has an excellent corrosion resistance. Hereinafter, a corrosion-resistant member according to the present disclosure will be explained in detail.

(3) A corrosion-resistant member according to the present disclosure includes a substrate that is composed of an aluminum-oxide-based ceramic. Herein, an aluminum-oxide-based ceramic is provided in such a manner that aluminum oxide occupies 90% by mass or greater of 100% by mass of all components that compose such an aluminum-oxide-based ceramic. Thus, a substrate is composed of an aluminum-oxide-based ceramic and thereby has a high durability. Moreover, an aluminum-oxide-based ceramic provides an inexpensive raw material price and is readily processed, so that it is possible to manufacture a substrate more inexpensively than another ceramic.

(4) Additionally, it is sufficient that a material of a substrate is identified by a following method. First, a substrate is measured by using an X-ray diffractometer (XRD) and identification thereof is executed from a value of an obtained 2θ (where 2θ is a diffraction angle) by using a JCPDS card. Then, quantitative analysis of a component that is contained in a substrate is executed by using an Inductively Coupled Plasma (ICP) emission spectrophotometer (ICP) or an X-ray fluorescence spectrometer (XRF). Existence of aluminum oxide is confirmed by identification as described above, and if a value provided by converting a content of aluminum (Al) that is measured by an ICP or an XRF into that of aluminum oxide (Al.sub.2O.sub.3) is 90% by mass or greater, it is an aluminum-oxide-based ceramic.

(5) Then, a corrosion-resistant member according to the present disclosure further includes a covering layer that is composed of an O—Al—C layer that is located on a substrate. Herein, for alignment of each element in an O—Al—C layer, such alignment is provided in descending order of an average value of an element concentration that is obtained by an X-ray photoemission spectroscopy (XPS). Then, such an O—Al—C layer is excellent in a corrosion resistance as compared with aluminum oxide that is a material of a substrate. Hence, such an O—Al—C layer as a covering layer is located on a substrate that is composed of an aluminum-oxide-based ceramic, so that a component is not readily dissolved even when contacting a strongly acidic concentrated syrup and it has an excellent corrosion resistance. Hence, a corrosion-resistant member according to the present disclosure includes a substrate as described above and a covering layer as described above and has an excellent corrosion resistance, so that it is possible to execute a use thereof over a long period of time.

(6) Herein, although it is sufficient that a part of a surface of a substrate is covered by a covering layer in a corrosion-resistant member according to the present disclosure, a corrosion resistance is further improved if all surfaces of such a substrate are covered by such a covering layer.

(7) Furthermore, it is sufficient that whether or not a covering later that is composed of an O—Al—C layer exists is determined by a following method. First, a surface of a corrosion-resistant member is provided as a measuring surface and such a measuring surface is irradiated with an X-ray (hν) that has a particular energy by using an XPS apparatus (manufactured by PHI, Quantera SXM). Then, in order to investigate an element in a region from a surface of a corrosion-resistant member to a depth of several μm, a process for irradiating a surface with an Ar ion to eliminate it by etching and a process for measuring, in an XPS apparatus, a surface that is newly formed by such etching are repeated alternately. Herein, a kinetic energy (E.sub.KIN) of a photoelectron that is emitted from a measuring surface is measured to obtain a binding energy (E.sub.B) for binding such an photoelectron to an atom (E.sub.B=hν−E.sub.KIN−ϕ). Then, a value of a binding energy is inherent in an atom, so that it is possible to know an element that composes a measuring surface through identification of such a value of a binding energy. Furthermore, an intensity of an emitted photoelectron is proportional to a concentration of an element, so that a measurement is executed by an XPS and thereby it is possible to obtain such a concentration of an element.

(8) Then, if oxygen (O), aluminum (Al), and carbon (C) are simultaneously identified in a direction from a surface of a corrosion-resistant member toward an interior thereof as a result of such a measurement, it is assumed that a covering layer that is composed of an O—Al—C layer is included. Herein, it is assumed that a thickness of a covering layer is provided as a depth from a surface of a corrosion-resistant member where carbon is not detected thereat.

(9) Furthermore, an element concentration of carbon on a surface of a covering layer in a corrosion-resistant member according to the present disclosure may be 25 atomic % or greater and 55 atomic % or less. If such a configuration is satisfied, a crack is not readily generated on a surface of a covering layer, so that a corrosion resistance of such a covering layer that contacts a strongly acidic concentrated syrup is further improved while a durability thereof is maintained. Additionally, if an element concentration of oxygen on a surface of a covering layer is 24 atomic % or greater and 48 atomic % or less or an element concentration of aluminum thereon is 21 atomic % or greater and 46 atomic % or less, a corrosion resistance of such a covering layer is further improved.

(10) Furthermore, a thickness of a covering layer in a corrosion-resistant member according to the present disclosure may be 10 nm or greater and 100 nm or less. If such a configuration is satisfied, a corrosion resistance of a corrosion-resistant member according to the present disclosure is improved while a durability thereof is maintained.

(11) Furthermore, a ratio A/B of a covering layer in a corrosion-resistant member according to the present disclosure may be 5 or greater where A is an element concentration of carbon on a surface of such a covering layer and B is an element concentration of carbon at a depth of 6 nm from a surface of such a covering layer toward a side of a substrate. If such a configuration is satisfied, a corrosion resistance of a corrosion-resistant member according to the present disclosure is improved.

(12) Furthermore, a ratio B/C of a covering layer in a corrosion-resistant member according to the present disclosure may be 2 or less where B is described above and C is an element concentration of carbon at a depth of 10 nm from a surface of such a covering layer toward a side of a substrate. If such a configuration is satisfied, a corrosion resistance of a corrosion-resistant member according to the present disclosure is further improved.

(13) Furthermore, a substrate in a corrosion-resistant member according to the present disclosure may contain a total of 0.02% by mass or greater and 0.2% by mass or less of a minor constituent(s) such as iron oxide (Fe.sub.2O.sub.3), zirconium oxide (ZrO.sub.2), titanium oxide (TiO.sub.2), chromium oxide (Cr.sub.2O.sub.3), and/or yttrium oxide (Y.sub.2O.sub.3), other than aluminum oxide, among 100% by mass of all components that compose such a substrate.

(14) Next, an example of a manufacturing method for a corrosion-resistant member according to the present disclosure will be explained.

(15) First, a sintering aid, a binder, a solvent, a dispersant, and the like are appropriately added and mixed into an aluminum oxide powder to fabricate a slurry. Then, such a slurry is spray-dried by a spray drying granulation method (a spray drying method) to execute granulation thereof and thereby fabricate a granule, and an obtained granule is molded into a desired shape by a powder press molding method or the like to obtain a molded body.

(16) Then, a molded body is dried and degreased to fabricate a degreased body, and subsequently, held and fired in an atmospheric air atmosphere at a maximum temperature of 1500 to 1600° C. for 2 to 12 hours to obtain a substrate that is composed of an aluminum-oxide-based ceramic.

(17) Then, such a substrate is put into a container that is made of a carbon (a carbon element) and held and treated with heat in a nitrogen gas atmosphere at a maximum temperature of 800 to 950° C. for 0.25 hours or longer. Subsequently, cooling to a room temperature is executed in a nitrogen gas atmosphere. Thereby, a covering layer that is composed of an O—Al—C layer is formed on a surface of a substrate to obtain a corrosion-resistant member according to the present disclosure. Additionally, it is sufficient that a mask with an arbitrary shape is formed on a surface of a substrate and subsequently a heat treatment as described above is executed, in order to cause a covering layer to exist on only a part of a surface of such a substrate.

(18) Herein, it is sufficient that a maximum temperature in a heat treatment as described above is 820 to 930° C., in order to cause an element concentration of carbon on a surface of a covering layer to be 25 atomic % or greater and 55 atomic % or less.

(19) Furthermore, it is sufficient that a holding time in a heat treatment as described above is 0.5 hours or longer and 3 hours or shorter, in order to cause a thickness of a covering layer to be 10 nm or greater and 100 nm or less.

(20) Furthermore, a heat treatment as described above is divided into two stages and adjusted appropriately in a following condition, so that it is possible to cause an element concentration A of carbon on a surface of a covering layer, an element concentration B of carbon at a depth of 6 nm from a surface of such a covering layer toward a side of a substrate, and/or an element concentration C of carbon at a depth of 10 nm from a surface of such a covering layer toward a side of such a substrate to be an arbitrary value(s). Specifically, it is sufficient that, first, a heat treatment at a first stage is executed by holding a maximum temperature of 800 to 850° C. for 0.25 hours or longer, and subsequently, a heat treatment at a second stage is executed by holding a maximum temperature of 900 to 950° C. for 0.25 hours or longer.

(21) Hereinafter, although a practical example(s) according to the present disclosure will be explained specifically, the present disclosure is not limited to such a practical example(s).

Practical Example 1

(22) Samples with presence or absence of a covering layer that was composed of an O—Al—C layer and an element concentration A of carbon on a surface of the covering layer that were different were fabricated and a corrosion resistance and a durability were evaluated.

(23) First, 0.3 parts by mass of a calcium carbonate powder in an equivalent of calcium oxide (CaO), 0.6 parts by mass of a magnesium carbonate powder in an equivalent of magnesium oxide (MgO), and 0.3 parts by mass of a silicon oxide powder as sintering aids were added to 100 parts by mass of an aluminum oxide powder that was a main component to obtain a prepared powder.

(24) Then, 100 parts by mass of a solvent and 0.2 parts by mass of a dispersant were added and mixed into 100 parts by mass of such a prepared powder to fabricate a slurry.

(25) Then, such a slurry was spray-dried by a spray drying method to execute granulation thereof and thereby fabricate granules and obtained granules were molded into each of a cylindrical molded body A (with an outer diameter of 16 mm, an inner diameter of 10 mm, and a length of 13 mm) and an annular molded body B (with an outer diameter of 16 mm, an inner diameter of 10 mm, and a thickness of 3 mm) by a powder press molding method.

(26) Then, the molded bodies A and B were dried and degreased to fabricate degreased bodies and subsequently holding and firing thereof were executed in an atmospheric air atmosphere at a maximum temperature of 1550° C. for 5 hours to obtain substrates A and B that were composed of an aluminum-oxide-based ceramic. Additionally, dimensions of such a substrate A were an outer diameter of 13 mm, an inner diameter of 8 mm, and a length of 10 mm and dimensions of the substrate B were an outer diameter of 13 mm, an inner diameter of 8 mm, and a length of 2 mm.

(27) Then, such substrates A and B were put into a container that was made of carbon and a heat treatment was executed in a nitrogen gas atmosphere on a condition as illustrated in Table 1. Subsequently, cooling to a room temperature was executed in a nitrogen gas atmosphere. Thereby, sample Nos. 2 to 14 were obtained. Additionally, such a heat treatment was not executed for sample No. 1.

(28) Then, whether or not a covering layer that was composed of an O—Al—C layer existed was determined for sample Nos. 1 to 14 by a following method. First, a surface of each sample was provided as a measuring surface, and the measuring surface was irradiated with an X-ray (hν) that had a particular energy by using an XPS apparatus (made by PHI INCORPORATED, Quantera SXM). Then, in order to investigate an element in a region from a surface of each sample to a depth of 2 μm, a process for irradiating the surface with an Ar ion to eliminate it by etching and a process for measuring, by an XPS apparatus, a surface that was newly formed by the etching were repeated alternately. Then, a kinetic energy (EKIN) of a photoelectron that was emitted from the measuring surface was measured to obtain a binding energy (EB) for binding such a photoelectron in an atom (EB=hν−EKIN−ϕ). As a result, only oxygen and aluminum were identified for sample No. 1 and it was found that it did not have a covering layer that was composed of an O—Al—C layer. On the other hand, oxygen, aluminum, and carbon are simultaneously identified for sample Nos. 2 to 14 and it was found that it had a covering layer that was composed of an O—Al—C layer.

(29) Furthermore, an intensity of an emitted photoelectron was proportional to an element concentration, so that a measurement was executed by an XPS and thereby an element concentration A of carbon on a surface of a covering layer for sample Nos. 2 to 14 was obtained.

(30) Then, a durability test for a substrate B of each sample was executed by a following method. First, each sample was mounted on a plate that was made of a metal in such a manner that circumferential surfaces of respective annular samples contact them. Then, a pressure was applied to each sample from above and a pressure (N) to cause each sample to be broken was measured to provide it as a strength (N) of each sample.

(31) Furthermore, a corrosion resistance test for a substrate A of each sample was executed by a following method. First, each sample was dipped in a syrup of a carbonated beverage (a stock solution: pH 2.2, a solution volume: 100 ml) for 72 hours and its masses before and after dipping were measured to calculate its reduced mass after dipping. Specifically, a reduced mass after dipping (%) was calculated in accordance with {(W2−W1)/W1}×100(%) where W1 was a mass of a sample before dipping and W2 was a mass of a sample after dipping.

(32) Results are illustrated in Table 1. Additionally, if a reduced mass after dipping (%) in Table 1 is minus, it indicates that a mass was reduced.

(33) TABLE-US-00001 TABLE 1 Covering Layer that was composed of O—Al—C Layer Heat Treatment Element Thickness Conditions Concentration of Maximum Holding Presence A of Carbon Covering Reduced Sample Temperature Time or on Surface Layer Strength Mass No. (° C.) (h) Absence (atomic %) (nm) (N) (%) 1 — — Absence — — 240 −0.049 2 800 0.25 Presence 16 2 218 −0.038 3 800 4 Presence 16 106 208 −0.038 4 820 0.25 Presence 25 3 219 −0.027 5 820 0.5 Presence 25 10 217 −0.021 6 820 3 Presence 25 100 210 −0.021 7 820 4 Presence 25 115 206 −0.021 8 870 2 Presence 40 41 214 −0.02 9 930 0.25 Presence 55 8 218 −0.025 10 930 0.5 Presence 55 13 217 −0.02 11 930 3 Presence 55 100 210 −0.02 12 930 4 Presence 55 128 200 −0.02 13 950 0.25 Presence 68 9 195 −0.023 14 950 4 Presence 68 132 190 −0.02

(34) As illustrated in Table 1, whereas a reduced mass after dipping for sample No. 1 was −0.049%, a reduced mass after dipping for sample Nos. 2 to 14 was −0.038% or greater, so that it was found that a covering layer that was composed of an O—Al—C layer was included and thereby was excellent in a corrosion resistance.

(35) Moreover, for sample Nos. 4 to 12 where an element concentration of carbon on a surface of a covering layer was 25 atomic % or greater and 55 atomic % or less, among sample Nos. 2 to 14, a strength was 200 N or greater and a reduced mass after dipping was −0.027% or greater, so that it was found that a corrosion resistance was further improved while a durability was maintained.

(36) Moreover, for sample Nos. 5, 6, 8, 10, and 11 where a thickness of a covering layer was 10 nm or greater and 100 nm or less, among sample Nos. 4 to 12, a strength was 210 N or greater and a reduced mass after dipping was −0.021% or greater, so that it was found that a corrosion resistance was further improved while a durability was maintained.

Practical Example 2

(37) Then, samples where an element concentration A of carbon on a surface of a covering layer, an element concentration B of carbon at a depth of 6 nm from a surface of the covering layer toward a side of a substrate, and an element concentration C of carbon at a depth of 10 nm from a surface of the covering layer toward a side of the substrate were different were fabricated and a corrosion resistance was evaluated.

(38) Additionally, a fabrication method for sample Nos. 16 to 20 was similar to a fabrication method for Practical Example 1 except that a two-stage heat treatment was executed for a heat treatment. Specifically, a heat treatment at a first stage was executed by holding a maximum temperature of 800 to 850° C. for 1 hour or longer and 2.5 hours or shorter and subsequently a heat treatment at a second stage was executed by holding a maximum temperature of 900 to 950° C. for 0.5 hours or longer and 2 hours or shorter, so that each of element concentrations A, B, and C of carbon as illustrated in Table 2 was provided. Additionally, a total of holding times at the first stage and the second stage was 3 hours and a thickness of a covering layer for sample Nos. 16 to 20 was 41 nm. Furthermore, Table 2 illustrates sample No. in Practical Example 1 as sample No. 15 for a comparative example.

(39) Then, a measurement method that was similar to that of Practical Example 1 was executed for each sample, in order to measure, for each sample, an element concentration A of carbon on a surface of a covering layer, an element concentration B of carbon at a depth of 6 nm from a surface of the covering layer toward a side of a substrate, and an element concentration C of carbon at a depth of 10 nm from a surface of the covering layer toward a side of the substrate.

(40) Furthermore, a durability test for each sample was executed similarly to that of Practical Example 1. Results are illustrated in Table 2. Additionally, in Table 2, each of A/B and B/C is illustrated by rounding off it to one or more decimal places.

(41) TABLE-US-00002 TABLE 2 Sam- Element Concentration of Carbon ple A B C Strength No. (atomic %) (atomic %) (atomic %) A/B B/C (N) 15 40 9 4 4.4 2.3 207 16 40 4 5 10.0 0.8 227 17 40 6 5 6.7 1.2 226 18 40 7 6 5.7 1.2 226 19 40 8 4 5.0 2.0 225 20 40 7 3 5.7 2.3 215

(42) As illustrated in Table 2, a strength for sample Nos. 16 to 20 was 215 N or greater, so that it was found that a ratio A/B of element concentrations of carbon was 5 or greater and thereby a durability was improved.

(43) Furthermore, a strength for sample Nos. 16 to 19, among sample Nos. 16 to 20, was 225 N or greater, so that it was found that a ratio B/C of element concentrations of carbon was 2 or less and thereby a durability was further improved.

(44) An additional effect or variation can readily be derived by a person(s) skilled in the art. Hence, a broader aspect(s) of the present invention is/are not limited to a specific detail(s) and a representative embodiment(s) as illustrated and described above. Therefore, various modifications are possible without departing from the spirit or scope of a general inventive concept that is defined by the appended claim(s) and an equivalent(s) thereof.