Sliding material, shaft sleeve, and pump provided with shaft sleeve

Abstract

Provided is a TiC.sub.x(TiMo) sliding material having a binder phase made of a TiMo alloy, and a hard phase containing TiC.sub.x, wherein the TiC.sub.x(TiMo) sliding material satisfies all the following conditions: (1) a total area of the binder phase and the hard phase is 90% or more of an area of a field of view; (2) a total area of the binder phase is 15% or more and 20% or less of the area of the field of view; (3) in the binder phase, a total area of the binder phase having a diameter equivalent to 10 m or more and 50 m or less; (4) in the binder phase, a total area of the binder phase having a diameter equivalent to less than 10 m; and (5) a Mo concentration in the binder phase is 25 wt % or more and 35 wt % or less.

Claims

1. A TiC(TiMo) sliding material comprising: a binder phase made of a TiMo alloy; and a hard phase containing TiC.sub.x where x is in a range of 0.5 to 0.7, wherein in a backscattered electron image by a scanning electron microscope (SEM) at a magnification of 400 times of the TiC(TiMo) sliding material in a field of view of 317 m220 m, which are values converted from the number of pixels of the image observed by the SEM, the TiC(TiMo) sliding material satisfies all the following conditions (1) to (5): (1) a total area of the binder phase and the hard phase is 90% or more of an area of the field of view; (2) a total area of the binder phase is 15% or more and 20% or less of the area of the field of view; (3) in the binder phase, a total area of the binder phase having a diameter equivalent to 10 m or more and 50 m or less calculated on an assumption that an area of the binder phase has a circular shape is 60% or more and 80% or less of the total area of the binder phase; (4) in the binder phase, a total area of the binder phase having a diameter equivalent to less than 10 m calculated on an assumption that an area of the binder phase has a circular shape is 20% or more and 40% or less of the total area of the binder phase; and (5) a Mo concentration in the binder phase is 25 wt % or more and 35 wt % or less.

2. The TiC(TiMo) sliding material according to claim 1 further comprising a third phase different from the binder phase and the hard phase in an amount of less than 10% of the area of the field of view by the SEM.

3. A sleeve composed of a TiC(TiMo) sliding material according to claim 1, comprising: a sliding bearing for supporting a rotating shaft of a rotating machine while sliding; and a fixing member for fixing the sliding bearing, wherein the sleeve is cylindrical form and provided on a surface of the rotating shaft at which the rotating shaft slides with the sliding bearing.

4. A pump comprising: an impeller; a rotating shaft for rotating the impeller; and a casing for fixing a sliding bearing supporting the rotating shaft while sliding, the casing surrounding the impeller and the rotating shaft, wherein the pump is provided with a sleeve in a cylindrical form composed of a TiC(TiMo) sliding material according to claim 1, the sleeve being fixed on a sliding face of the sliding bearing of the rotating shaft.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a graph showing a relationship between hardness and a fracture toughness value of a material.

(2) FIG. 2 is a sectional view of one embodiment of a pump according to the present invention.

(3) FIG. 3 is a sectional view of one embodiment of a bearing system according to the present invention.

(4) FIG. 4 is an SEM image of sample No. E1.

(5) FIG. 5 is a binarized image of a left half region of the SEM image of FIG. 4.

DESCRIPTION OF EMBODIMENTS

(6) Hereinafter, the present invention is described in detail with reference to the accompanying drawings. However, the present invention is not limited to these embodiments.

(7) FIG. 2 is a sectional view showing an entirety of a vertical shaft pump 3. As shown in FIG. 2, the vertical shaft pump 3 includes a discharge elbow 30 provided and fixed to an installation floor for the pump, a casing 29 connected to a lower end of the discharge elbow 30, a discharge bowl 28 which is connected to a lower end of the casing 29 and houses an impeller 22 inside, and a suction bell 27 which is connected to a lower end of the discharge bowl 28 and suctions water.

(8) Through a radially approximately central part of the casing 29, the discharge bowl 28, and the suction bell 27 of the vertical shaft pump 3, one rotating shaft 10 formed by two shafts including top and bottom shafts that are connected with each other by a shaft coupling 26 is provided.

(9) The rotating shaft 10 is supported by an upper bearing 32 fixed to the casing 29 via a supporting member and a lower bearing 33 fixed to the discharge bowl 28 via a supporting member. The impeller 22 for suctioning water into the pump is connected to one end side (suction bell 27 side) of the rotating shaft 10. The other end side of the rotating shaft 10 extends outside the vertical shaft pump 3 through a hole provided in the discharge elbow 30 and is connected to a driving machine, which is not shown in the drawing, such as an engine and a motor for rotating the impeller 22.

(10) A shaft seal 34 such as a floating seal, a gland packing, and a mechanical seal is provided between the rotating shaft 10 and the hole provided in the discharge elbow 30. This shaft seal 34 prevents water handled by the vertical shaft pump 3 from flowing out of the vertical shaft pump 3.

(11) The driving machine is provided on land so that a maintenance check can be easily performed. The rotation of the driving machine is transferred to the rotating shaft 10, enabling the impeller 22 to rotate. As the impeller 22 rotates, water is suctioned from the suction bell 27 and discharged from the discharge elbow 30 through the discharge bowl 28 and the casing 29.

(12) FIG. 3 is an enlarged view of a bearing system applied to the bearings 32 and 33 shown in FIG. 2. As shown in FIG. 3, the bearing system has a sleeve 11 composed of the sliding material of the present invention around an outer periphery of the rotating shaft 10.

(13) A sliding bearing 1 made of ceramics in a form of a hollow cylinder is provided on the outer periphery side of the sleeve 11. The outer periphery surface of the sleeve 11 is structured in such a manner as to face an inner periphery surface (sliding face) of the sliding bearing 1 via a very narrow clearance and to slide relative to the sliding bearing 1. The sliding bearing 1 is fixed to a supporting member 13 which leads to the casing 29 of the pump (see FIG. 2) via a flange part 12a of a bearing case 12 made of a metal or a resin. The sliding bearing 1 is in a form of a hollow cylinder, and an inner periphery surface 1a faces the outer periphery surface of the sleeve 11 and an outer periphery surface 1b is fit with the bearing case 12.

(14) The vertical shaft pump 3 shown in FIG. 2 is operated in air at the time of starting the pumping operation. That is, the bearings 32 and 33 are operated in a dry condition without lubrication with liquid. The dry condition herein refers to a condition in which atmosphere for the bearings 32 and 33 during the pumping operation is air where no lubrication with liquid is present, and a dry operation refers to an operation performed in that condition. The bearings shown in FIG. 3 are also operated in a water-discharging condition in which water flows through the bearings. The water-discharging condition herein refers to a condition in which atmosphere for the bearings 32 and 33 during the pumping operation is water with foreign objects (slurry) such as earth and sand mixed in, and a water-discharging operation is an operation performed in that condition. The bearings 32 and 33 are used in such conditions.

EXAMPLES

Example 1

(15) Commercially available TiC.sub.x (x=0.5 to 0.9, average particle size: 1.0 m), Ti powder (particle size: <45 m), Mo powder (average particle size: 4.2 m), and TaC.sub.y (y=1, average particle size: 1.0 m) were blended in a proportion prescribed for each material and then mixed in a mortar machine or a Henschel mixer for 1 hour to 2 hours. A resultant mixture of powder was press-molded at 1000 kgf/cm.sup.2 to 2000 kgf/cm.sup.2, which was then sintered at 1250 C. to 1500 C. for 2 hours under a vacuum or a reduced pressure atmosphere of inert gas such as nitrogen or argon. Using the above-described production method, a plurality of samples, which differ from each other in terms of a ratio of the binder phase (bonding phase) and the hard phase, an amount of Mo present in the binder phase, a size of the binder phase, and a percentage of the third phase, were produced by changing a blend ratio of TiC.sub.x, Ti, Mo, and TaC.sub.y and a temperature.

(16) Production conditions of each sample are shown in Table 1.

(17) [Table 1]

(18) TABLE-US-00001 TABLE 1 Production conditions Mixing Molding Sintering TiC.sub.x Ti Mo TaC.sub.y time pressure temperature Sample No. mass % mass % mass % mass % Hr MPa C. E1 85 10 5 2 98 1300 E2 85 10 5 2 98 1300 E3 86.5 10 3.5 2 98 1300 E4 90 5 5 2 98 1300 E5 80 15 5 2 98 1300 E6 82.5 10 7.5 2 98 1300 E7 78 10 5 7.0 2 98 1300 C1 85 0 5 10.0 2 98 1300 C2 91.5 5 3.5 2 98 1300 C3 77.5 15 7.5 2 98 1300 C4 84 12.5 3.5 2 98 1300 C5 85 7.5 7.5 2 98 1300 C6 85 10 5 2 98 1250 C7 85 10 5 1 98 1500 C8 85 10 5 1 98 1400

(19) The produced samples were assessed in regard to the following categories.

(20) [Wear Volume]

(21) Each sample was molded into a form of a sleeve having an outer diameter of 65 mm, which was placed under water having a foreign object concentration of 300 mg/L, applied a bearing surface pressure of 0.12 MPa, and then rotated for 8 hours at a sliding velocity on a sliding surface of 5.0 m/sec. A wear volume was subsequently measured by a wear test. As for the foreign objects, silica sand (main component: SiO.sub.2) having an average particle size of 5 m and silica sand having an average particle size of 30 m mixed at a ratio of 1:1 were used. The wear volume was measured with a stylus type surface profilometer.

(22) Based on the results of the wear test, a development rate of wearing depth of 2 m/h or less was determined as and that of more than 2 m/h was determined as .

(23) [Deflective Strength]

(24) A test piece having a predetermined dimension (2584 mm) was prepared for each sample in accordance with the JIS H5501 Cemented Carbide Tool Industrial Standards (CIS026B), and deflective strength of the test piece was measured by a three-point bending test.

(25) The deflective strength of 0.5 GPa or more was determined as and that of less than 0.5 GPa was determined as . The deflective strength of less than 0.5 GPa is not preferable as a material having such strength is easily broken.

(26) [Fracture Toughness]

(27) Using an IF method (Indentation Fracture method), fracture toughness was determined from a size of a crack and a size of an indentation (Vickers indentation) produced when an indenter was pressed against the sample (10 mm10 mm5 mm). An assessment formula is based on the formula of Evans.

(28) A fracture toughness value of 9 MPa.Math.m.sup.0.5 or more was determined as and that of less than 9 MPa.Math.m.sup.0.5 was determined as . The fracture toughness value of less than 9 MPa.Math.m.sup.0.5 is not preferable as a material having the fracture toughness of such a value is easily broken.

(29) [Corrosion Resistance]

(30) Corrosion resistance was assessed based on current density of a potentiostatic polarization test. The potentiostatic polarization test was performed on the test piece at +0.441 V .sub.VS SSE for 72 hours in artificial seawater at 25 C. using platinum as a counter electrode and a silver-silver chloride electrode as a reference electrode.

(31) The current density of 1.010.sup.3 mA/cm.sup.2 or less was determined as and that of more than 1.010.sup.3 mA/cm.sup.2 was determined as . When the current density is more than 1.010.sup.3 mA/cm.sup.2, a material is significantly damaged due to corrosion.

(32) [Hardness]

(33) Hardness was measured using the Vickers indentation method by applying a load of 30 kgf.

(34) [TiMo Phase Area]

(35) Each sample was cut into a test piece, and a backscattered electron image by SEM at an observing magnification of 400 times of the test piece was observed. Image analysis was conducted on a field of view (317 m220 m which were converted from the number of pixels of the image by the SEM observation). FIG. 4 is the SEM image of sample No. E1, and FIG. 5 is the image of which binarization processing was performed on a left half region of the SEM image of FIG. 4 for the image analysis. Tiny black dots in FIG. 4 are residual pores. In the SEM image for the image analysis shown in FIG. 5, regions displayed in white are a metal phase or an alloy phase, and regions displayed in black are non-metallic phase such as a carbide phase, a nitride phase, and a carbonitride phase. The area of each region displayed in white was determined to calculate a diameter on an assumption that the area has a circular shape. A total area of the regions having a diameter equivalent to 10 m or more and 50 m or less (gray regions where white regions are shaded as shown in FIG. 5), a total area of regions having a diameter equivalent to less than 10 m (white regions as shown in FIG. 5), and a total area of regions having a diameter equivalent to more than 50 m were determined to calculate a ratio of the total area of each region to the total area of regions displayed in white. Five SEM observation fields of view were selected and their average value was determined as an area ratio.

(36) [Mo Concentration in TiMo Phase]

(37) After the SEM observation, any white region in the SEM observation field of view of the test piece was selected, and point analysis was conducted with an energy-dispersive X-ray spectrometry (hereinafter, abbreviated as EDX) to analyze a Mo concentration. Ten analysis points were selected and their average value was determined as the Mo concentration.

(38) [Area of Third Phase]

(39) A third phase cannot be confirmed in FIG. 5. Since a difference in chromaticity and brightness based on a density difference of each phase can be observed in the backscattered electron image of the SEM, a phase other than the TiMo phase and the TiC phase can be confirmed and its area ratio can be determined by the image analysis. The assessment results are shown in Table 2 below. Since Ti is dispersed into the TiC.sub.x phase due to mixture of TiC.sub.x with Ti powder and Mo powder and sintering, a relative amount of C in the TiC.sub.x phase is reduced and consequently x is fallen into a range of 0.5 to 0.7 as x cannot be maintained within the range of 0.5 to 0.9.

(40) [Table 2]

(41) TABLE-US-00002 TABLE 2 Assessment results Area Mo HV ratio of concentration Area ratio by diameters of (30 kgf) TiMo in TiMo TiMo phase Third Sample Wear Deflective Fracture Corrosion Vickers phase phase >50 m 50-10 m 10 m > phase Overall No. volume strength toughness resistance hardness N sq % wt % sq % sq % sq % sq % judgment E1 930 16 29 0 73 27 0 E2 986 19 31 0 78 22 0 E3 980 15 25 0 64 36 0 E4 1025 15 35 0 65 35 0 E5 810 20 25 0 68 32 0 E6 850 20 35 0 72 28 0 E7 830 18 33 0 75 15 10 C1 x 840 17 31 0 77 23 15 x C2 x 1000 13 35 0 67 33 0 x C3 x 790 21 26 0 66 34 0 x C4 x 880 15 24 0 61 39 0 x C5 x 780 20 36 0 67 33 0 x C6 x 980 19 32 0 50 50 0 x C7 x 820 20 32 30 50 20 0 x C8 x 825 19 33 0 90 10 0 x

(42) As shown in Table 2, sample No. C1 showing that the area ratio of the third phase was 15% failed to pass the deflective strength assessment, and samples No. E1 to E7 each showing that the area ratio of the third phase was 10% or less passed all assessment categories including wear volume, deflective strength, fracture toughness, and corrosion resistance. That is, when requirement (1) in which a total area of the binder phase (TiMo phase) and the hard phase (TiC phase) is 90% or more of an area of the SEM observation field of view was not satisfied, a desired sliding material was not produced.

(43) Sample No. C3 showing that the area ratio of the TiMo phase (binder phase) was 21% failed to pass the wear volume assessment, and samples No. E1 to E7 each showing that the area ratio of the TiMo phase (binder phase) was 15% or more and 20% or less passed all assessment categories including wear volume, deflective strength, fracture toughness, and corrosion resistance. That is, when requirement (2) in which a total area of the binder phase is 15% or more and 20% or less of the area of the SEM observation field of view was not satisfied, a desired sliding material was not produced.

(44) Further, samples No. C6 and C7 each showing that the total area of the TiMo phase having a diameter of 10 m or more and 50 m or less determined on an assumption that the area of the TiMo phase has a circular shape was 50% and sample No. C8 showing that the total area of the same was 90% failed to pass the fracture toughness or deflective strength assessments, and samples No. E1 to E7 each showing that the total area of the same was 60% or more and 80% or less passed all assessment categories including wear volume, deflective strength, fracture toughness, and corrosion resistance. Sample No. C6 shows that the total area of the TiMo phase having a diameter of more than 50 m determined on an assumption that the area of the TiMo phase has a circular shape was 50%, and sample No. C7 shows that the total area of the TiMo phase having a diameter of less than 10 m determined on an assumption that the area of the TiMo phase has a circular shape was 30%. That is, when requirement (3) in which in the binder phase, a total area of the binder phase having a diameter equivalent to 10 m or more and 50 m or less calculated on an assumption that an area of the binder phase has a circular shape is 60% or more and 80% or less of the total area of the binder phase and requirement (4) in which in the binder phase, a total area of the binder phase having a diameter equivalent to less than 10 m calculated on an assumption that an area of the binder phase has a circular shape is 20% or more and 40% or less of the total area of the binder phase were not satisfied, a desired sliding material was not produced.

(45) Moreover, sample No. C4 showing that the Mo concentration in the TiMo phase was 24 wt % failed to pass the fracture toughness assessment, sample No. C5 showing that the Mo concentration in the TiMo phase was 36 wt % failed to pass the wear volume assessment, and samples No. E1 to E7 each showing that the Mo concentration was 25 wt % or more and 35 wt % or less passed all assessment categories including wear volume, deflective strength, fracture toughness, and corrosion resistance. That is, when requirement (5) in which a Mo concentration in the binder phase is 25 wt % or more and 35 wt % or less was not satisfied, a desired sliding material was not produced.

(46) Based on the above, when any one of requirements (1) to (5) is not satisfied, a desired effect is not obtained in at least one of the categories including wear volume, deflective strength, fracture toughness, and corrosion resistance. Therefore, it is necessary to satisfy all the requirements.

(47) The ratio of the binder phase which is soft and the hard phase has an effect on the fracture toughness and the hardness, and there is a correlation between the hardness and the wear volume to a certain extent. As the ratio of the binder phase increases, the fracture toughness increases and the hardness decreases, and consequently the wear volume increases. The Mo concentration in the TiMo phase also has an effect on the fracture toughness and the hardness. A too low Mo concentration reduces an amount of the TiMo phase strengthened by solid solution strengthening, which reduces the fracture toughness and the hardness and increases the wear volume. A high Mo concentration increases the fracture toughness and the hardness and reduces the wear volume. However, as a too high Mo concentration deteriorates sintering properties, it is difficult for the TiMo phase to obtain dense compositions.

(48) The fracture toughness or the deflective strength is also used as an index to indicate fragility. Based on the results shown in Table 2, it is considered that a large or uneven-sized TiMo phase leads to an ongoing increase in an abrasive wear volume caused by hard impurities in water, which makes a crack easily produced and therefore the material becomes more fragile. When hard particles in slurry hit a surface of the sliding material while sliding, although a crack is produced on the surface of the sliding material, fracture energy at the time is absorbed by plastic deformation of the TiMo phase surrounded by the TiC.sub.x phase. Thus, if the TiMo phase surrounded by the TiC.sub.x phase is large in some degree, this serves to prevent propagation of a crack on the surface of the sliding material caused by a slurry wear (wear caused by fluids containing hard particles). Accordingly, it is considered that development of a crack caused by fracture and wear is prevented and wear resistance performance is improved.

(49) Based on the above, the fracture toughness and the hardness have a conflicting effect. However, a sliding material having compositions which satisfy all of requirements (1) to (5) was found to be able to have the wear resistance suitable for a sliding member even if a sliding material having a high hardness is not selected, in other words, even if the material having a high fracture toughness value is selected.

Example 2

(50) Next, a bearing sleeve composed of the sliding material of sample No. E3, E4, E5, E6, C1, C2, or C3 was installed in a vertical shaft mixed flow pump (FIGS. 2 and 3), and an acceleration test in which seawater is discharged was conducted. That is, to create a rough operating environment, hard ceramics was used for the sliding bearing which is a corresponding sliding part of the sleeve, earth and sand were mixed as foreign objects in the same way as in the actual situation, and a start-and-stop motion was repeated to produce large vibrations. A thickness of the sleeve was made half the actually designed thickness, and the pump was operated with a rotational speed set at a normal rotational speed plus an additional 20%.

(51) Each sleeve was installed and the start-and-stop motion of the water-discharge operation was repeated the same number of times to observe the bearing sleeve. No breakage or crack was found on the bearing sleeve composed of the sliding material of sample No. E3, E4, E5, or E6, and also their wear volumes were perfectly acceptable. However, a formation of a crack was confirmed on the bearing sleeve composed of the sliding material of sample No. C1 or C2. Further, the crack was not found in sample No. C3, but its wear volume was significantly large.

(52) Therefore, the pump incorporating a sleeve composed of the sliding member according to the present invention was confirmed to have good corrosion resistance and wear resistance as well as great resistance to breakage in any situations including a case where corrosive fluids such as seawater or sewage are handled, a case where a rotating shaft, which is adapted for a high lifting height and a large amount of pumping water, is long and the rotational speed is fast, and a case where a large amount of earth and sand and gravel get mixed into the pumping water.