Sliding member and piston ring
10823288 ยท 2020-11-03
Inventors
Cpc classification
F16J9/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C23C28/347
CHEMISTRY; METALLURGY
C23C28/044
CHEMISTRY; METALLURGY
C23C28/343
CHEMISTRY; METALLURGY
C23C28/046
CHEMISTRY; METALLURGY
C23C28/36
CHEMISTRY; METALLURGY
C23C28/048
CHEMISTRY; METALLURGY
International classification
Abstract
A sliding member includes a base material and an amorphous hard carbon film formed on a surface of the base material, and the amorphous hard carbon film has a graded structure in which a sp.sup.2 ratio increases from an inner surface side corresponding to the base material side toward an outer surface side. A piston ring includes the sliding member.
Claims
1. A sliding member comprising: a base material; and an amorphous hard carbon film formed on a surface of the base material, wherein the amorphous hard carbon film has a graded structure in which a sp.sup.2 ratio increases from an inner surface side adjacent to the base material toward an outer surface side, and wherein when a sp.sup.2 ratio of the inner surface side of the amorphous hard carbon film is indicated by A % and a sp.sup.2 ratio of the outer surface side of the amorphous hard carbon film is indicated by B %, a value of (BA) is 20 or more.
2. The sliding member according to claim 1, wherein the sp.sup.2 ratio of the inner surface side of the amorphous hard carbon film is smaller than 40%, and the sp.sup.2 ratio of the outer surface side of the amorphous hard carbon film is larger than 65%.
3. The sliding member according to claim 1, wherein a hydrogen content of the amorphous hard carbon film is smaller than 5 atomic %.
4. The sliding member according to claim 1, wherein a thickness of the amorphous hard carbon film is 3 m to 40 m.
5. The sliding member according to claim 1, wherein a density of droplets of 300 m.sup.2 or more in size existing on a surface of the amorphous hard carbon film is 600 pieces/mm.sup.2 or less.
6. The sliding member according to claim 1, wherein the base material is formed of a steel material having a thermal conductivity of 30 W/(m.Math.K) or more.
7. The sliding member according to claim 1, further comprising an intermediate layer provided between the base material and the amorphous hard carbon film.
8. A piston ring comprising the sliding member according to claim 1.
9. The sliding member according to claim 2, wherein a hydrogen content of the amorphous hard carbon film is smaller than 5 atomic %.
10. The sliding member according to claim 9, wherein a thickness of the amorphous hard carbon film is 3 m to 40 m.
11. The sliding member according to claim 10, wherein a density of droplets of 300 m.sup.2 or more in size existing on a surface of the amorphous hard carbon film is 600 pieces/mm.sup.2 or less.
12. The sliding member according to claim 11, wherein the base material is formed of a steel material having a thermal conductivity of 30 W/(m.Math.K) or more.
13. The sliding member according to claim 12, further comprising an intermediate layer provided between the base material and the amorphous hard carbon film.
14. The sliding member according to claim 3, wherein a thickness of the amorphous hard carbon film is 3 m to 40 m.
15. The sliding member according to claim 14, wherein the base material is formed of a steel material having a thermal conductivity of 30 W/(m.Math.K) or more.
16. The sliding member according to claim 15, further comprising an intermediate layer provided between the base material and the amorphous hard carbon film.
17. The sliding member according to claim 2, wherein a density of droplets of 300 m.sup.2 or more in size existing on a surface of the amorphous hard carbon film is 600 pieces/mm.sup.2 or less.
18. The sliding member according to claim 2, wherein the base material is formed of a steel material having a thermal conductivity of 30 W/(m.Math.K) or more.
19. The sliding member according to claim 18, further comprising an intermediate layer provided between the base material and the amorphous hard carbon film.
20. The sliding member according to claim 2, further comprising an intermediate layer provided between the base material and the amorphous hard carbon film.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
DETAILED DESCRIPTION
(8) Hereinafter, embodiments of the disclosure will be described with reference to the drawings. The invention is not limited to the following embodiments.
(9) <Sliding Member>
(10)
(11) (Amorphous Hard Carbon Film)
(12) In a cross-section of the amorphous hard carbon film 3 illustrated in
(13) In the amorphous hard carbon film 3, the sp.sup.2 ratio may increase continuously or stepwisely.
(14) In the amorphous hard carbon film 3, an area on the side of the inner surface F1 is formed of amorphous hard carbon having a low sp.sup.2 ratio (a high sp.sup.3 ratio) and a relatively small deformability. An area having a low sp.sup.2 ratio existing on the side of the inner surface F1 serves as a base film. That is, even when a material not subjected to a thermosetting treatment or surface modification for securing adhesion on its surface or a material having a relatively high thermal conductivity (for example, 30 W/(m.Math.K) or more) is used as the base material 1, an area having a low sp.sup.2 ratio suppresses the deformation of the interface and prevents the chipping or peeling of the amorphous hard carbon film 3. Additionally, the amorphous hard carbon having a low sp.sup.2 ratio (a high sp.sup.3 ratio) has a high thermal conductivity as compared with the amorphous hard carbon having a high sp.sup.2 ratio (a low sp.sup.3 ratio).
(15) In the amorphous hard carbon film 3, an area on the side of the outer surface F2 is formed of amorphous hard carbon having a high sp.sup.2 ratio (a low sp.sup.3 ratio) and relative deformability. An area existing on the side of the outer surface F2 and having a high sp.sup.2 ratio means that the bond strength of carbon atoms is relatively weak, that is, the film is relatively deformable. For example, when foreign substances such as wear powder and dust generated by sliding pass through the sliding surface, the surface of the film serves as a cushion and hence the peeling due to the cracking of the film can be prevented. Particularly, in the case of the application to a part such as a piston ring having a curved sliding surface, the contact area with an adjacent member is narrow in an initial sliding state in which the film is not worn out. Additionally, since there is a risk that a crack is generated due to a locally high surface pressure when foreign substances leak, the sp.sup.2 ratio may be high on the surface layer side. Additionally, since the surface pressure gradually decreases as the film wears out with use, the sp.sup.2 ratio may decrease toward the inner surface side in relation to the outer surface side. For the sp.sup.2 ratio, the strength of the film is low when the sp.sup.2 ratio of the entire film is high. However, when there is a gradation between the inner surface side and the outer surface side, it is possible to secure the adhesion while maintaining the film strength (the wear resistance). Further, since the outer surface F2 is formed of a material having a high sp.sup.2 ratio, there is an advantage that a finishing process is facilitated.
(16) When the sp.sup.2 ratio on the side of the inner surface F1 of the amorphous hard carbon film 3 is indicated by A % and the sp.sup.2 ratio on the side of the outer surface F2 of the amorphous hard carbon film 3 is indicated by B %, a value of (BA) is preferably 20 or more, more preferably 20 to 60, and further preferably 40 to 60. Since the value of (BA) is 20 or more, it is easy to sufficiently secure the adhesion of the amorphous hard carbon film 3 with respect to the base material 1. Accordingly, it is possible to highly suppress the chipping or peeling of the amorphous hard carbon film 3 and to readily achieve excellent wear resistance of the amorphous hard carbon film 3. Meanwhile, there is an advantage that the amorphous hard carbon film 3 of which the value of (BA) is 60 or less can be readily formed, the film does not become excessively inhomogeneous, and minute chipping or peeling rarely occurs.
(17) The sp.sup.2 ratio (A %) on the side of the inner surface F1 of the amorphous hard carbon film 3 is preferably smaller than 40%, more preferably 10 to 35%, and further preferably 15 to 30%. Since the sp.sup.2 ratio (A %) on the side of the inner surface F1 is smaller than 40%, it is easy to sufficiently secure the adhesion of the amorphous hard carbon film 3 with respect to the base material 1, for example, even when a thermosetting treatment or surface modification for securing the adhesion is not performed on the surface of the base material 1. Meanwhile, there is an advantage that the amorphous hard carbon film 3 of which the sp.sup.2 ratio (A %) on the side of the inner surface F1 is 10% or more can be readily formed and chipping rarely occurs.
(18) The sp.sup.2 ratio (B %) on the side of the outer surface F2 of the amorphous hard carbon film 3 is preferably larger than 65%, more preferably 65% to 80%, and further preferably 70 to 75%. Since the sp.sup.2 ratio (B %) on the side of the outer surface F2 is larger than 65%, the initial conformability with an adjacent member is excellent, the chipping or peeling of the amorphous hard carbon film 3 can be highly suppressed, and the excellent wear resistance of the amorphous hard carbon film 3 can be readily achieved. In addition, there is an advantage that the finishing processability of the amorphous hard carbon film 3 is excellent. Meanwhile, there is an advantage that the amorphous hard carbon film 3 of which the sp.sup.2 ratio (B %) on the side of the outer surface F2 is 80% or less can be readily formed, an excessive decrease in strength does not occur, and durability can be secured.
(19) The thickness of the amorphous hard carbon film 3 is, for example, in the range of 3 to 40 m. The wear rarely occurs when the thickness of the amorphous hard carbon film 3 is 3 m or more. Meanwhile, when the thickness of the amorphous hard carbon film 3 is 40 m or less, an excessive increase in internal stress of the film can be suppressed and the occurrence of the chipping or peeling can be readily suppressed. From the viewpoint of the productivity or durability of the sliding member 10, the thickness of the amorphous hard carbon film 3 is preferably 3 to 20 m and more preferably 5 to 12 m. Additionally, since the amorphous hard carbon film 3 has the graded structure of the sp.sup.2 ratio, it is possible to sufficiently secure the adhesion with the base material 1 even when the amorphous hard carbon film 3 is relatively thick. The lower limit value of the thickness of the amorphous hard carbon film 3 may be 8 m or 10 m and may be 16 m or 22 m, for example, when excellent durability is required.
(20) It is preferable that the amorphous hard carbon film 3 does not substantially include hydrogen from the viewpoint of achieving the low friction coefficient. Specifically, the hydrogen content of the amorphous hard carbon film 3 is preferably smaller than 5 atomic %, more preferably smaller than 3 atomic %, further preferably smaller than 2 atomic %, and particularly preferably smaller than 1 atomic %. When the amorphous hard carbon film 3 does not substantially include hydrogen, dangling bonds of surface carbon atoms of the amorphous hard carbon film 3 are not terminated by hydrogen. For this reason, since an oil agent constituent molecule having an OH group in the lubricant is readily adsorbed to the surface of the amorphous hard carbon film 3, it is observed that a very low friction coefficient is exhibited. Further, the amorphous hard carbon which substantially does not include hydrogen has excellent thermal conductivity. The hydrogen content of the amorphous hard carbon film 3 can be measured by Rutherford Backscattering Spectrometry (RBS) and Hydrogen Forward Scattering (HFS).
(21) It is preferable that the density of the relatively large droplets (for example, a size of 300 m.sup.2 or more) existing on the surface of the amorphous hard carbon film 3 be 600 pieces/mm.sup.2 or less. Since the density is set to 600 pieces/mm.sup.2 or less, the initial conformability with an adjacent member is excellent, the chipping of the amorphous hard carbon film 3 or the peeling of the surface layer can be suppressed, and the wear resistance is excellent. The density of droplets is more preferably 300 pieces/mm.sup.2 or less. The density of droplets can be calculated by visually counting the number of the concave portions or the convex portions having a size of 300 m.sup.2 or more due to the incorporation of droplet particles or the separation of particles existing within a predetermined range of the surface by using a microscope. Of course, this may be counted by using an image process or the like.
(22) (Base Material)
(23) As the base material 1, a suitable material may be employed in response to the application of the sliding member 10. When the sliding member 10 is required to have high thermal conductivity, for example, the piston ring having a configuration illustrated in
(24) In general, the thermal conductivity of the steel material becomes higher as the content of the alloy component becomes smaller. In contrast, since the high temperature characteristics are inferior, the material cannot be used as a sliding member of an automobile engine in a high heat load environment. However, for example, it is possible to achieve both of thermal conductivity and high temperature characteristics by performing system control of improving high temperature characteristics by reinforcing particle dispersion of spheroidized cementite, or the like. As such a steel material, material symbols SUP9, SUP10, and the like defined in HS G4801 can be exemplified.
(25) (Intermediate Layer)
(26) The intermediate layer 5 is used to further improve the adhesion between the base material 1 and the amorphous hard carbon film 3. The intermediate layer 5 is preferably formed of a component which has lattice matching with the metal of the base material 1 and which is more likely to form carbon and carbide of the amorphous hard carbon film 3 as compared with the metal of the base material 1. Specifically, the intermediate layer 5 is preferably formed of at least one metal selected from a group consisting of Ti, Cr, Si, Co, V, Mo, and W or its metal carbide. Further, when the sliding member 10 is used in a severe environment such as high surface pressure, the intermediate layer 5 is preferably formed of a nitride of at least one metal selected from the group consisting of Ti, Zr, Cr, Si, and V. In this case, even when the amorphous hard carbon film 3 is worn away, the sliding property can be maintained by the presence of the intermediate layer 5.
(27) It is preferable that the thickness of the intermediate layer 5 be thin to a degree that the deformation of the intermediate layer 5 does not influence the adhesion of the amorphous hard carbon film 3. Specifically, the thickness of the intermediate layer 5 is preferably 0.01 to 0.4 m, more preferably 0.03 to 0.3 m, and further preferably 0.05 to 0.2 m.
(28) When sufficient adhesion can be secured even when the amorphous hard carbon film 3 is directly formed on the surface of the base material 1, the intermediate layer 5 may not be provided. For example, when the amorphous hard carbon film 3 substantially does not include hydrogen, it is easy to secure sufficient adhesion even when the intermediate layer 5 is not provided if scale, oil, or the like does not adhere to the base material 1. For the excellent adhesion, it is preferable to clean the surface of the base material 1 before the formation of the amorphous hard carbon film 3. For example, it is preferable to remove the oxide film on the surface of the base material 1 by a mechanical pre-processing and to clean the surface by a hydrocarbon type cleaning agent.
(29) <Method of Forming Amorphous Hard Carbon Film>
(30) The amorphous hard carbon film 3 can be formed by using, for example, an arc ion plating device equipped with a graphite cathode as an evaporation source. According to this device, the amorphous hard carbon film 3 is formed in such a manner that a vacuum arc discharge is generated between a graphite cathode and an anode in a vacuum atmosphere to evaporate and ionize a carbon material from a surface of a carbon cathode and carbon ions are deposited on a sliding surface of a base material (the sliding member to be provided with an amorphous hard carbon film) to which a negative bias voltage is applied.
(31) The distribution of the sp.sup.2 ratio of the amorphous hard carbon film 3 can be adjusted according to, for example, the following method. That is, it is possible to obtain a target sp.sup.2 ratio distribution (a graded structure) by appropriately adjusting the bias voltage applied to the sliding member during the formation of the film in the arc ion plating device.
(32) In order to form the amorphous hard carbon film 3 which substantially does not include hydrogen, the film may be formed without introducing a carbon-based gas. Additionally, hydrogen may be included at less than 5 atomic % due to the moisture remaining on the wall surface in the device. Since the droplets characteristically formed in the arc ion plating are incorporated into the amorphous hard carbon film 3 to reduce the film strength, a filtered arc system equipped with a magnetic filter for removing the droplets may be used. In this case, it is possible to form the amorphous hard carbon film 3 which is very homogeneous and has excellent wear resistance with fewer droplets.
(33) As described above, the embodiments of the disclosure have been described in detail, but the invention is not limited to the above-described embodiments. For example, in an above-described embodiment, the sliding member 10 including the intermediate layer 5 formed between the base material 1 and the amorphous hard carbon film 3 if necessary has been exemplified. However, for example, a wear resistant surface treatment layer may be further formed on the outer surface side of the amorphous hard carbon film 3 or a base film may be formed on the inner surface side thereof.
EXAMPLES
(34) Hereinafter, Examples and Comparative Examples of the disclosure will be described. The invention is not limited to the following examples.
Example 1
(35) A piston ring was manufactured as below by using an arc ion plating device. First, a pre-cleaned piston ring base material (SUP10 equivalent material) was set in a jig. An arc ion plating device with a graphite cathode and a Cr cathode was prepared in an evaporation source. After the above-described jig was attached to a rotation shaft of a rotation table of this device, the inside of a chamber of the device was set to a vacuum atmosphere of 110.sup.3 Pa or less. An Ar gas was introduced into the chamber, a bias voltage was applied to the base material, and the surface of the base material was cleaned by a glow discharge. Then, an intermediate layer was formed of Cr. Next, the evaporation source of the graphite cathode was discharged to form an amorphous hard carbon film on the surface of the intermediate layer.
(36) In this example, at the time of forming the amorphous hard carbon film, an arc current was made constant and a pulse bias voltage was linearly decreased from 1500 V to 100 V as the film forming time elapsed. Accordingly, the piston ring according to Example 1 having a graded structure in which the sp.sup.2 ratio increases from the inner surface side toward the outer surface side was manufactured. Additionally, a relationship between the pulse bias voltage and the sp.sup.2 ratio was measured in a separately conducted preliminary test.
Example 2
(37) A piston ring was manufactured similarly to Example 1 except that a film was formed by adjusting a pulse bias voltage in order to obtain a sp.sup.2 ratio profile shown in
Example 3
(38) A piston ring was manufactured similarly to Example 1 except that a film was formed by adjusting a pulse bias voltage in order to obtain a sp.sup.2 ratio profile shown in
Example 4
(39) A piston ring was manufactured similarly to Example 1 except that a film was formed so that a value of B A was smaller than 20% by reducing a change width of a pulse bias voltage.
Comparative Example 1
(40) A piston ring was manufactured similarly to Example 1 except that an amorphous hard carbon film was formed while maintaining a constant bias voltage without continuously changing the bias voltage with the elapse of the film forming time.
(41) The piston rings according to Examples 1 to 4 and Comparative Example 1 were measured and evaluated as below. The result is shown in Table 1.
(42) (1) Evaluation of Sp.sup.2 Ratio Profile of Amorphous Hard Carbon Film
(43) The profile of the sp.sup.2 ratio of the hard carbon film in the film thickness direction was evaluated as below. That is, the sp.sup.2 ratio was measured at the interval of about 2 m from the inner surface side of the amorphous hard carbon film toward the outer surface side thereof while observing the cross-section of the amorphous hard carbon film using a transmission electron microscope (TEM). The vicinity of the inner surface of Table 1 is a measurement value of the sp.sup.2 ratio at a position of about 0.2 m within the amorphous carbon film from the interface with the intermediate layer. Additionally, when the intermediate layer is not formed, the vicinity of the inner surface may be a measurement value of the sp.sup.2 ratio at a position of about 0.2 m within the amorphous carbon film from the interface with the base material. The vicinity of the outer surface is a measurement value of the sp.sup.2 ratio at a position about 0.2 m within the amorphous carbon film from the surface. The sp.sup.2 ratio was calculated on the basis of the spectrum obtained according to electron energy loss spectroscopy (EELS).
(44) The hard carbon layer of the thin sample is observed by TEM-EELS and the obtained observation value is subjected to the correction of the influence of the background signal, and the like. The sp.sup.2 ratio is calculated as below by the analysis based on the corrected data.
(45) (1) Based on the energy loss spectrum, data is acquired in an area of 240 eV to 550 eV.
(46) (2) An approximate curve is calculated for data with an energy loss of 320 eV or more.
(47) (3) The observed values are normalized on the basis of the obtained approximate curve.
(48) (4) Peaks are separated by using a Gaussian function in the range of 280 to 295 eV using normalized data, the peak area on the low energy side is obtained, and the value is set as S.
(49) (5) In the normalized data, an area of 280 to 310 eV is calculated and is set as S+.
(50) (6) Similarly, diamond and graphite samples are observed in order from (1) to (5) and each of an area of a peak in the vicinity of 285 eV and an area of 280 to 310 eV is calculated. An area obtained for diamond is set as Sd and Sd (+) and an area for graphite is set as Sg and Sg (+). Then, the sp.sup.2 ratio is calculated by the following equation.
(51)
(52) (2) Measurement of Hydrogen. Content of Amorphous Hard Carbon Film
(53) The hydrogen content of the amorphous hard carbon film was obtained by Rutherford Backscattering Spectroscopy (RBS) and Hydrogen Forward Scattering (HFS). The hydrogen content for the outer surface side of the amorphous hard carbon film was measured. As a measurement device, RBS made by CEA was used and the measurement conditions were set as below. Incident Ion: 2.275 MeV 4He.sup.++ (RBS, HFS) Beam Diameter: 1 to 2 mm RBS Detection Angle: 160 Grazing Angle: 110 HFS Detection Angle: 130
(54) (3) Thickness Measurement of Amorphous Hard Carbon Film
(55) The thickness of the amorphous hard carbon film was measured by so-called CALOTEST (dimension measurement of polishing marks) according to a spherical polishing method.
(56) (4) Evaluation of Peel Resistance and Wear Resistance by Reciprocal Sliding Test
(57) The peel resistance was measured by a reciprocation sliding test. As a test device, one having a configuration illustrated in
(58) TABLE-US-00001 TABLE 1 Com- Exam- Exam- Exam- Exam- parative ple ple ple ple Exam- 1 2 3 4 ple 1 sp.sup.2 Vicinity 24 45 23 21 45 Ratio of inner (%) surface A Dis- 1.0 27 47 24 24 45 tance m from 3.0 40 55 28 28 47 inner m surface 5.0 51 60 32 31 45 m 7.0 59 62 40 34 45 m 9.0 73 65 50 38 46 m Vicinity 78 66 55 39 46 of outer surface B B-A 54 21 32 18 2 Hydrogen content 1.2 2.4 0.8 3.2 1.0 (atomic %) Thickness of 9.8 9.7 9.8 9.9 11.8 amorphous hard carbon film (m) Pres- Vertical 500 No No No No No ence load N of 600 No No No No No peeling N 700 No No No Yes Yes N 800 No Yes No Yes Yes N 900 No Yes Yes Yes Yes N Wear amount ratio 1 0.9 0.8 1.5 2.1 (Based on vertical load of 500 N of Example 1)
INDUSTRIAL APPLICABILITY
(59) According to the disclosure, a sliding member and a piston ring capable of sufficiently suppressing an amorphous hard carbon film from being peeled off from a base material and having sufficiently high wear resistance are provided.
REFERENCE SIGNS LIST
(60) 1: base material, 3: amorphous hard carbon film, 5: intermediate layer, 10: sliding member (piston ring), 21: FC (cast iron) plate, 22: piston ring piece, 23: lubricant, 24: sliding portion, F1: inner surface of amorphous hard carbon film, F2: outer surface of amorphous hard carbon film.