Iron-based prealloy powder, iron-based diffusion-bonded powder, and iron-based alloy powder for powder metallurgy using the same

Abstract

The present disclosure relates to an iron-based prealloy powder having excellent strength and processability, and an iron-based alloy powder for powder metallurgy and a sinter-forged member using the same. The iron-based prealloy powder for powder metallurgy according to an embodiment of the present disclosure includes 0.5 to 5.0 wt % of Cu, 0.1 to 0.5 wt % of Mo, and a balance of Fe and other inevitable impurities. A Cu content (Cu %) and a Mo content (Mo %) satisfy the following Relational Equation (1):
0.3×Cu %+3×Mo %≤2.7  (1).

Claims

1. An iron-based prealloy powder for powder metallurgy, consisting of: 0.5 to 5.0 wt % of Cu (a Cu content), 0.1 to 0.5 wt % of Mo (a Mo content), 0.05 to 0.4 wt % of Mn (a Mn content), and a balance of Fe and other inevitable impurities, wherein the Cu content (Cu %) and the Mo content (Mo %) satisfy Relational Equation (1) and Relational Equation (2):
2.2≤0.3×Cu %+3×Mo %≤2.7  Relational Equation (1)
2.2≤0.3×Cu %+3×Mo %+4×Mn %≤2.7  Relational Equation (2).

2. A diffusion-bonded powder for powder metallurgy, comprising: a Cu powder bonded to a surface of an iron-based prealloy powder in an amount of 5 wt % or less, wherein the iron-based prealloy powder consists of 0.5 to 5.0 wt % of Cu (a Cu content), 0.1 to 0.5 wt % of Mo (a Mo content), 0.05 to 0.4 wt % of Mn (a Mn content), and a balance of Fe and other inevitable impurities, and in which the Cu content (Cu %) and the Mo content (Mo %) satisfy Relational Equation (1) and Relational Equation (2):
2.2≤0.3×Cu %+3×Mo %≤2.7  Relational Equation (1)
2.2≤0.3×Cu %+3×Mo %+4×Mn %≤2.7  Relational Equation (2).

3. An iron-based alloy powder for powder metallurgy, comprising: 0.4 to 1.0 wt % of a C powder, based on a total weight of the iron-based powder mixed with a diffusion-bonded powder, wherein the diffusion-bonded powder includes a Cu powder bonded to a surface of an iron-based prealloy powder in an amount of 5 wt % or less, and the iron-based prealloy powder consists of 0.5 to 5.0 wt % of Cu (a Cu content), 0.1 to 0.5 wt % of Mo (a Mo content), 0.05 to 0.4 wt % of Mn (a Mn content), and a balance of Fe and other inevitable impurities, wherein the Cu content (Cu %) and the Mo content (Mo %) satisfy Relational Equation (1) and Relational Equation (2):
2.2≤0.3×Cu %+3×Mo %≤2.7  Relational Equation (1)
2.2≤0.3×Cu %+3×Mo %+4×Mn %≤2.7  Relational Equation (2).

4. The iron-based alloy powder of claim 3, wherein the iron-based alloy powder further includes 0.1 to 0.3 wt % of S.

5. The iron-based alloy powder of claim 3, wherein the iron-based alloy powder is further mixed with a lubricant.

6. A sinter-forged member manufactured using the iron-based prealloy powder of claim 1 as a raw material, wherein a martensite phase of the sinter-forged member is less than 5% by area, and wherein the sinter-forged member has a yield strength of 800 MPa or more.

7. The sinter-forged member of claim 6, wherein the sinter-forged member is an automotive connecting rod.

8. A sinter-forged member manufactured using the iron-based diffusion-bonded powder of claim 2 as a raw material, wherein a martensite phase of the sinter-forged member is less than 5% by area, and wherein the sinter-forged member has a yield strength of 800 MPa or more.

9. The sinter-forged member of claim 8, wherein the sinter-forged member is an automotive connecting rod.

10. A sinter-forged member manufactured using the iron-based alloy powder of claim 3 as a raw material, wherein a martensite phase of the sinter-forged member is less than 5% by area, and wherein the sinter-forged member has a yield strength of 800 MPa or more.

11. The sinter-forged member of claim 10, wherein the sinter-forged member is an automotive connecting rod.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other objects, features and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is a photograph showing a structure of a specimen according to an Example; and

(3) FIG. 2 is a photograph showing a structure of a specimen according to a Comparative Example.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(4) Hereinafter, Examples of the present disclosure will be described in detail with reference to the accompanying drawings. However, the present disclosure may be embodied in many different forms and should not be construed as being limited to the Examples set forth herein. Rather, these Examples are provided so that the disclosure of this disclosure will be thorough and complete and those skilled in the art can fully understand the scope of the disclosure. In the drawings, like reference numerals refer to like elements throughout.

(5) The present disclosure relates to an iron-based alloy powder for powder metallurgy. In order to form the iron-based alloy powder, a prealloy powder in which main components are included in alloys is preliminarily prepared, and an iron-based diffusion-bonded powder in which remaining constituents, other than the main alloy components, are bonded, preferably diffusion-bonded, to the surface of the prealloy powder is formed. In addition, various additives are mixed with the prepared iron-based diffusion-bonded powder in order to additionally improve the physical properties, thereby forming the iron-based alloy powder.

(6) Therefore, hereinafter, a matter obtained by preliminarily forming main components mostly including alloys, followed by powderization, is referred to as “prealloy powder,” a matter obtained by bonding the remaining constituents other than the main alloy components to the prealloy powder by diffusion is referred to as “diffusion-bonded powder,” and a matter obtained by mixing the diffusion-bonded powder with various additives is referred to as “alloy powder.”

(7) To be specific, the present disclosure includes an iron-based prealloy powder and an iron-based diffusion-bonded powder prepared in order to manufacture an iron-based alloy powder, and also includes a sinter-forged member including the iron-based prealloy powder, the iron-based diffusion-bonded powder, and the iron-based alloy powder as raw materials. The sinter-forged member is used as a material for manufacturing an automotive connecting rod. Of course, the iron-based prealloy powder and the iron-based alloy according to the present disclosure are not to be construed to be limited to those used for manufacturing the connecting rod.

(8) Meanwhile, the iron-based prealloy powder according to the present disclosure, prepared to manufacture the iron-based alloy powder according to an embodiment of the present disclosure, includes 0.5 to 5.0 wt % of Cu (a Cu content), 0.1 to 0.5 wt % of Mo (a Mo content), and a balance of Fe and other inevitable impurities based on a total weight of the iron-based prealloy powder.

(9) Preferably, the Cu content (Cu %) and the Mo content (Mo %) satisfy the following Relational Equation (1).
0.3×Cu %+3×Mo %≤2.7  (1)

(10) Further, preferably, the iron-based prealloy powder for powder metallurgy according to the present disclosure further includes 0.4 wt % or less of Mn based on a total weight of the iron-based prealloy powder.

(11) In addition, in the iron-based prealloy powder further including Mn, the Cu content (Cu %), the Mo content (Mo %), and an Mn content (Mn %) preferably satisfy the following Relational Equation (2).
0.3×Cu %+3×Mo %+4×Mn %≤2.7  (2)

(12) In the present disclosure, the reason why the main alloy components and the composition ranges thereof are limited is as follows.

(13) The content of copper (Cu) is preferably 0.5 to 5.0 wt %. When the content of copper is lower than the range proposed, the strength is lowered. In addition, when the content of copper is higher than the range proposed, the effect of improving strength is insufficient, formability is reduced, and a dimensional change ratio is increased, making it difficult to manufacture a stable molded body.

(14) The content of molybdenum (Mo) is preferably 0.1 to 0.5 wt %. When the content of molybdenum is lower than the range proposed, since the effect of improving strength is insufficient, the desired level of strength may not be secured. When the content of molybdenum is higher than the range proposed, formability may be reduced, thus damaging a mold. Further, when the content of molybdenum is higher than the range proposed, the effect of improving strength is insufficient and too much martensite structure is folioed, so processability and toughness are reduced. Accordingly, the content of molybdenum (Mo) is preferably limited to 0.1 to 0.5 wt %. More preferably, the content of molybdenum (Mo) is limited to 0.1 to 0.3 wt %. The reason is that the limitation contributes to the refinement of ferrite, pearlite, and bainite structures and it becomes easy to convert pearlite into bainite, thus increasing the effect of improving strength and toughness.

(15) The content of manganese (Mn) is preferably 0.4 wt % or less. When the content of manganese is higher than 0.4 wt %, formability is reduced and oxides are generated, thus reducing strength. It is further preferable to limit the minimum value of the manganese content to 0.05 wt %. The reason is that the pearlite structure becomes finer when manganese is included in an amount of 0.05 wt % or more.

(16) In addition, in the iron-based prealloy powder for powder metallurgy, the remaining constituents other than the above-described components are Fe and inevitably contained impurities.

(17) Meanwhile, in the iron-based diffusion-bonded powder for powder metallurgy according to the present disclosure, a Cu powder may be bonded in an amount of less than 5 wt % to the surface of the iron-based prealloy powder.

(18) When the amount of copper (Cu) bonded to the surface of the iron-based prealloy powder is 5 wt % or more, there are problems in that the effect of improving strength is saturated and the dimensional change ratio before and after sintering becomes large.

(19) Meanwhile, it is preferable to diffusion-bond copper (Cu) to the surface of the iron-based prealloy powder in order to improve the strength, rather than merely mixing copper (Cu) with the iron-based prealloy powder. As the copper (Cu) powder used for the diffusion bonding, it is preferable to use a powder having a size of 50 μm or less.

(20) Diffusion bonding means the state in which the copper powder is diffused to the surface of the prealloy powder through heat treatment after mixing the prepared prealloy powder and the copper powder, thereby achieving bonding.

(21) For example, in order to perform diffusion bonding, first, the prealloy powder and the copper powder are mixed using a predetermined conventionally known method (V-type mixer, double-cone mixer, Henschel mixer, or Nauta mixer). When the powders are mixed, a binder such as machine oil may be added in order to prevent segregation of the copper powder. When the prealloy powder and the copper powder are mixed as described above, the mixture may be maintained in a reduction atmosphere at a temperature ranging from 700 to 1000° C. for about 0.5 to 2 hours so as to be heat-treated, thus diffusion-bonding the copper powder to the surface of the prealloy powder.

(22) Of course, the method of diffusion-bonding the copper powder to the surface of the prealloy powder is not limited to the above-described method and conditions, but may be performed in the state of being modified into various methods and conditions capable of diffusion-bonding the copper powder to the surface of the prealloy powder.

(23) Meanwhile, the iron-based alloy powder for powder metallurgy according to the present disclosure is folioed by mixing various additives with the above-described iron-based diffusion-bonded powder.

(24) For example, the iron-based alloy powder may be formed by mixing carbon (C) powder with the iron-based diffusion-bonded powder to improve the strength. For example, as the carbon (C) powder, any one or both of graphite powder and carbon black powder may be used. Either of natural graphite and synthetic graphite may be used as the graphite powder.

(25) Meanwhile, the content of carbon (C) is preferably 0.4 to 1.0 wt %. When the content of carbon is lower than the range proposed, the formation of ferrite structure is increased, thus reducing the strength. When the content of carbon is higher than the range proposed, carbide is formed, so processability is reduced or the formation of austenite structure is increased, thus reducing the strength.

(26) Further, the iron-based alloy powder may be folioed by further mixing sulfur (S) with the iron-based diffusion-bonded powder in order to improve processability.

(27) The content of sulfur (S) is preferably 0.1 to 0.3 wt %. When the content of sulfur (S) is less than 0.1 wt %, the effect of improving processability cannot be expected. When the content of sulfur (S) is more than 0.3 wt %, the tensile strength is reduced.

(28) Meanwhile, sulfur (S) is preferably mixed with the prealloy powder in the form of MnS powder separately from the prealloy powder and the diffusion-bonded powder. MnS has a composite bonding constitution, rather than a bonding ratio of 1:1, and a ratio of about 3:1 to 5:1 is preferable.

(29) Further, the iron-based alloy powder may be formed by further mixing a lubricant with the iron-based diffusion-bonded powder in order to improve lubricity.

(30) The iron-based alloy powder may be formed by mixing one or more of carbon (C), sulfur (S), and the lubricant described above together if necessary. Further, functional additives other than the proposed additive may be further mixed within the range in which the physical properties of the iron-based alloy powder are not reduced, thus forming the iron-based alloy powder.

(31) In the present disclosure, molten steel or powder having the above-described composition and additives are used to manufacture the iron-based prealloy powder having excellent strength and processability, the iron-based diffusion-bonded powder, and the iron-based alloy powder for powder metallurgy using the same.

(32) In particular, when the contents of the prealloy powder, the diffusion-bonded powder, and the alloy powder are adjusted, the amounts of Cu, Mo, and Mn are preferably limited so as to satisfy the above-described Relational Equations (1) and (2) so that the martensite area ratio of the sinter-forged member manufactured using the prealloy powder, the diffusion-bonded powder, and the alloy powder as raw materials is maintained at less than 5%, the yield strength thereof is maintained at 500 MPa or higher, and processability thereof is improved.

(33) When the amounts do not satisfy Relational Equations (1) and (2), processability is reduced.

(34) Meanwhile, in order to maintain the martensite area ratio of the sinter-forged member manufactured using the alloy powder as a raw material at less than 5% and to maintain the yield strength at 800 MPa or more while maintaining excellent machinability, it is preferable to form the diffusion-bonded powder by diffusion-bonding the copper (Cu) powder at a content of less than 5 wt % to the surface of the prealloy powder.

(35) Hereinafter, the present disclosure will be described using Comparative Examples and Examples.

(36) The final products were produced according to the production conditions for commercially produced iron-based powder for powder metallurgy. The final products were used to manufacture specimens, and the martensite area ratio, yield strength, and processability thereof were then measured.

(37) First, in order to check the characteristics of the iron-based prealloy powder, molten steel in which the content of each component was adjusted as shown in Table 1 below was prepared, and then an prealloy powder was manufactured using a water atomization method. To the iron-based prealloy powder, 0.7 parts by weight of graphite powder, 0.8 parts by weight of a lubricant (zinc stearate), and 0.5 parts by weight of MnS powder were added as additives based on 100 parts by weight of the iron-based prealloy powder before diffusion bonding of Cu, followed by mixing in a double-cone mixer.

(38) In Table 1, First Example Group is an Example in which manganese (Mn) is not contained as a prealloy component, and Second Example Group is an Example in which manganese (Mn) is contained as a prealloy component.

(39) Meanwhile, each of Comparative Examples and Examples included Fe and inevitable impurities as the remaining constituents other than Cu, Mo, Mn, and C constituting the iron-based prealloy powder.

(40) TABLE-US-00001 TABLE 1 Classifi- cation Cu Mo Mn A (No.) (wt %) (wt %) (wt %) value Note 1 0.5 — 0.1 0.55 Comparative Example 2 — 0.1 0.1 0.7 Comparative Example 3 — 0.4 0.1 1.6 Comparative Example 4 3 0.5 0.1 2.8 Comparative Example 5 0.5 0.6 0.1 2.35 Comparative Example 6 0.5 0.1  0.05 0.65 Second Example Group 7 3 0.1 — 1.2 First Example Group 8 3.5 0.4 0.1 2.65 Second Example Group 9 5 0.1 0.1 2.2 Second Example Group 10 3 0.45 0.1 2.65 Second Example Group 11 5 0.25 0.1 2.65 Second Example Group 12 0.5 0.1 0.4 2.05 Second Example Group 13 0.5 0.5 0.1 2.05 Second Example Group 14 0.5 0.3 0.4 2.65 Second Example Group 15 2.5 0.1 0.4 2.65 Second Example Group

(41) In Table 1, the A value means a value calculated using 0.3×Cu %+3×Mo %+4×Mn %.

(42) Meanwhile, with respect to the manufacture of a specimen, a specimen having a size of 10×15×55 mm was molded at a molding pressure of 7 ton/cm.sup.2 and then heat-treated at 1120° C. for 20 minutes in an RXgas atmosphere, and forging was performed so that a density was 7.76 or more. In addition, final processing was performed to obtain L50×W13×t4 mm.

(43) With the specimen thus prepared, the area ratio of the structure, especially the martensite area ratio, was measured, and the yield strength and processability were also measured.

(44) The processability was evaluated according to the following Tables 2 and 3.

(45) TABLE-US-00002 TABLE 2 Drilling Hole mm 1 condition diameter Material High speed drill No coated (Fujikoshi, Type sd 1.0) Speed m/min 31.4 Feed rate Mm/rev 0.05 RPM Rev/min 10000 Feed Mm/min 500 Cooling water Used

(46) TABLE-US-00003 TABLE 3 Evaluation result (example) Thrust Torque Width of flank force (N) (N .Math. m) wear (μm) Perforation number 10 50 10 50 10 50 Result 150 152 0.114 0.107 112 103

(47) The results of the martensite area ratio, the yield strength, and the processability measured by the above-described measurement method are shown in the following Table 4.

(48) TABLE-US-00004 TABLE 4 Martensite Yield Classifi- area ratio strength cation (%) (Mpa) Processability Note 1 0 484 ∘ Comparative Example 2 0 451 ∘ Comparative Example 3 0 490 ∘ Comparative Example 4 5 770 x Comparative Example 5 5 532 x Comparative Example 6 0 531 ∘ Second Example Group 7 0 785 ∘ First Example Group 8 2 855 ∘ Second Example Group 9 0 813 ∘ Second Example Group 10 3 827 ∘ Second Example Group 11 2 862 ∘ Second Example Group 12 0 534 ∘ Second Example Group 13 0 547 ∘ Second Example Group 14 4 684 ∘ Second Example Group 15 3 760 ∘ Second Example Group

(49) As shown in Table 4, it was confirmed that all of specimens No. 6 to No. 15, which were the specimens according to First and Second Example Groups according to the present disclosure, had a martensite area ratio of less than 5%, a yield strength of 500 MPa or more, and excellent processability.

(50) In particular, No. 8 to No. 11 had A values of 2.20 or higher, satisfactory martensite area ratios of less than 5%, excellent processability, and yield strength exceeding 800 MPa, which indicate a very high strength improvement effect. As a result, it was confirmed that limiting the A value to 2.20 or higher can maximize the yield strength improvement effect.

(51) Meanwhile, specimen No. 1 was a Comparative Example in which Mo was not contained, no martensite was formed, and the processability was excellent but the yield strength was lower than the desired level.

(52) No. 2 and No. 3 specimens were Comparative Examples in which Cu was not contained, no martensite was formed, and the processability was excellent but the yield strength was lower than the desired level.

(53) The contents of Cu, Mo, and Mn in specimen No. 4 satisfied the contents proposed in the present disclosure. However, specimen No. 4 was a Comparative Example in which the condition for the A value was not satisfied. Excellent yield strength was exhibited but it was confirmed that martensite was excessively formed, resulting in poor processability.

(54) Specimen No. 5 was a Comparative Example in which Mo was contained in an amount exceeding the content proposed in the present disclosure. Comparatively excellent yield strength was exhibited, but it was confirmed that martensite was excessively folioed, resulting in poor processability.

(55) Next, an experiment was performed to investigate the effect of forming the prealloy using the Cu and Mo components.

(56) For this purpose, the content of each component was adjusted as shown in the following Table 5. Specimen No. 16 was prepared as a specimen including a prealloy of all of Cu, Mo, and Mn. In addition, in specimens No. 17 and No. 18, a prealloy of Mo and Mn was prepared and a Cu component was bonded to the prealloy. In specimens No. 19 and No. 20, a prealloy of Cu and Mn was prepared and a Mo component was bonded to the prealloy. In specimens No. 17 and No. 19, the Cu powder or the Mo powder was diffusion-bonded to the prealloy. In specimens No. 18 and No. 20, the Cu powder or the Mo powder was simply mixed with (simply bonded to) the prealloy.

(57) In addition, the martensite area ratio, yield strength, and processability were measured for each specimen, and the results are shown in the following Table 6.

(58) TABLE-US-00005 TABLE 5 Classifi- cation Cu Mo Mn A (No.) (wt %) (wt %) (wt %) value Note 16 3 0.1 0.1 1.6 Example 17 3 0.1 0.1 0.7 Comparative Example of Cu diffusion bonding 18 3 0.1 0.1 0.7 Comparative Example of Cu mixing 19 3 0.1 0.1 1.3 Comparative Example of Mo diffusion bonding 20 3 0.1 0.1 1.3 Comparative Example of Mo mixing

(59) TABLE-US-00006 TABLE 6 Classifi- Martensite Yield cation area ratio strength (No.) (%) (Mpa) Processability Note 16 0 792 ∘ Example 17 0 660 ∘ Comparative Example of Cu diffusion bonding 18 0 642 ∘ Comparative Example of Cu mixing 19 0 754 ∘ Comparative Example of Mo diffusion bonding 20 0 739 ∘ Comparative Example of Mo mixing

(60) As shown in Table 6, it was confirmed that all of specimens No. 16 to No. 20 had a martensite area ratio of less than 5%, yield strength of 500 MPa or more, and excellent processability. However, it was confirmed that the yield strength of specimen No. 16 in which the prealloy of Cu, Mo, and Mn was prepared was relatively higher than the yield strength of specimens No. 17 to No. 20 obtained by diffusion-bonding or mixing the Cu powder or the Mo powder with the prealloy. Further, in the case of the bonded powders, it was confirmed that the yield strength of specimens No. 17 and No. 19 in which the Cu powder or the Mo powder was diffusion-bonded was higher than the yield strength of specimens No. 18 and No. 20 in which the Cu powder or the Mo powder was bonded by simple mixing.

(61) Next, an experiment was performed to investigate the effect of a change in the physical properties of the diffusion-bonded powder depending on the amount of Cu diffusion-bonded to the prealloy.

(62) For this purpose, the amount of Cu powder diffusion-bonded to the prealloy according to No. 16 described above was adjusted as shown in Table 7 below. The martensite area ratio, yield strength, and processability were measured for each specimen, and the results are shown together in the following Table 7.

(63) TABLE-US-00007 TABLE 7 Additional diffusion Martensite Yield Classifi- adhesion area ratio strength cation Cu(wt %) (%) (Mpa) Machinability Note 21 0.5 0 813 ∘ Inventive Example 22 2.5 0 847 ∘ Inventive Example 23 4 0 875 ∘ Inventive Example 24 5 0 865 ∘ Comparative Example

(64) As shown in Table 7, it was confirmed that all of specimens No. 21 to No. 23, in which the amount of diffusion-bonded Cu was less than 5%, had a martensite area ratio of less than 5%, yield strength of 800 MPa or more, and excellent processability.

(65) However, it was confirmed that specimen No. 24, in which the amount of diffusion-bonded Cu was 5%, had yield strength lower than that of specimen No. 23.

(66) Therefore, it was confirmed that it is preferable to limit the amount of diffusion-bonded Cu to less than 5% so as to maximize the strength improvement effect.

(67) Next, an experiment was performed to investigate the influence of prealloying individual components constituting the alloy powder on refinement of the structure.

(68) For this purpose, the specimens according to the Examples, in which the alloy elements according to the above-mentioned No. 7 were prealloyed, and the Comparative Examples, in which only Fe and Cu were prealloyed, were manufactured, and the structure thereof was observed. The results are shown in FIGS. 1 and 2.

(69) FIG. 1 is a photograph showing a structure of a specimen according to an Example, and FIG. 2 is a photograph showing a structure of a specimen according to a Comparative Example. It was confirmed that the structure of the specimen according to the Example was relatively finer than the structure of the specimen according to the Comparative Example.

(70) Based on these results, it can be deduced that preliminary prealloying of alloy components such as Cu and Mo for the manufacture of the iron-based powder as in the present disclosure is effective in improving strength and processability.

(71) Although the present disclosure has been described with reference to the accompanying drawings and the preferred embodiments described above, the present disclosure is not limited thereto but is limited by the following claims. Accordingly, those skilled in the art will appreciate that various modifications and changes may be made thereto without departing from the spirit of the following claims.