IMPELLER FOR ROTARY MACHINE, COMPRESSOR, SUPERCHARGER, AND METHOD FOR PRODUCING IMPELLER FOR ROTARY MACHINE

Abstract

An impeller for a rotary machine includes: a base material of the impeller comprising Al or an Al alloy; and an electroless plating layer disposed so as to cover the base material, the electroless plating layer forming a surface layer of the impeller. The electroless plating layer comprises a NiP based alloy having an amorphous structure, the NiP based alloy having a P content rate of not less than 5 wt % and not more than 11 wt % in the electroless plating layer.

Claims

1. An impeller for a rotary machine, comprising: a base material of the impeller comprising Al or an Al alloy; and an electroless plating layer disposed so as to cover the base material, the electroless plating layer forming a surface layer of the impeller, wherein the electroless plating layer comprises a NiP based alloy having an amorphous structure, the NiP based alloy having a P content rate of not less than 5 wt % and not more than 11 wt % in the electroless plating layer.

2. The impeller for a rotary machine according to claim 1, wherein the electroless plating layer has a layer thickness of not less than 15 m and not more than 60 m.

3. The impeller for a rotary machine according to claim 1, wherein the electroless plating layer has a Vickers hardness of not less than 500 HV and not more than 700 HV.

4. The impeller for a rotary machine according to claim 1, wherein a fracture ductility strain of the electroless plating layer is not less than 0.5%.

5. The impeller for a rotary machine according to claim 1, wherein the impeller is a compressor impeller of a supercharger.

6. A compressor comprising a compressor impeller which comprises the impeller according to claim 1.

7. A supercharger, comprising: the compressor according to claim 6; and a turbine for driving the compressor.

8. The supercharger according to claim 7, wherein the compressor is disposed in an intake passage of an internal combustion engine, wherein the turbine is configured to be driven by exhaust gas from the internal combustion engine, and wherein a part of the exhaust gas is circulated to the intake passage at an upstream side of the compressor.

9. A method of producing an impeller for a rotary machine, comprising: a step of forming an electroless plating layer as a surface layer of the impeller comprising Al or an Al alloy, so as to cover a base material of the impeller, wherein the electroless plating layer comprises a NiP based alloy having an amorphous structure, the NiP based alloy having a P content rate of not less than 5 wt % and not more than 11 wt % in the electroless plating layer.

10. The method of producing an impeller for a rotary machine according to claim 9, further comprising a step of cutting out a test piece from the impeller on which the electroless plating layer is formed, and using the test piece to evaluate a fracture ductility of the electroless plating layer.

11. The method of producing an impeller for a rotary machine according to claim 10, wherein the test piece is collected from a region on a back surface of the hub of the impeller, the region being a projection of a blade root portion of the hub on the back surface of the hub.

12. The method of producing an impeller for a rotary machine according to claim 10, further comprising a step of changing a plating condition of the electroless plating layer if the fracture ductility is smaller than a threshold.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0040] FIG. 1 is a system diagram of a diesel engine provided with a supercharger according to an embodiment.

[0041] FIG. 2 is a schematic cross-sectional view of a compressor impeller according to an embodiment.

[0042] FIG. 3 is a diagram showing a relationship between the P content rate and the anti-erosion property of an electroless plating layer.

[0043] FIG. 4 is a diagram showing a relationship between the P content rate and the LCF fracture lifetime of an electroless plating layer.

[0044] FIG. 5 is a diagram of an example of a cyclic load in an LCF test.

[0045] FIG. 6 is a diagram showing a relationship between the crystal structure and the anti-erosion property of an electroless plating layer.

[0046] FIG. 7 is a diagram showing a relationship between the crystal structure and the LCF fracture lifetime of an electroless plating layer.

[0047] FIG. 8 is a diagram showing a relationship between the layer thickness and the anti-erosion property of an electroless plating layer.

[0048] FIG. 9 is a diagram showing a result of a corrosion test on an electroless plating layer.

[0049] FIG. 10 is a diagram showing the fracture ductility of an electroless plating layer.

[0050] FIG. 11 is an explanatory diagram of a method of testing the fracture ductility with a test piece.

[0051] FIG. 12 is a flowchart of a method of producing a compressor impeller according to an embodiment.

[0052] FIGS. 13A and 13B are diagrams showing a section where a test piece is cut out from a compressor impeller, FIG. 13A showing a side cross-sectional view of a compressor impeller and FIG. 13B showing a front view of the same.

[0053] FIG. 14 is a perspective view of a strain distribution which is generated in the compressor impeller.

DETAILED DESCRIPTION

[0054] Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It is intended, however, that unless particularly specified, dimensions, materials, shapes, relative positions and the like of components described in the embodiments shall be interpreted as illustrative only and not intended to limit the scope of the present invention.

[0055] For instance, an expression of relative or absolute arrangement such as in a direction, along a direction, parallel, orthogonal, centered, concentric and coaxial shall not be construed as indicating only the arrangement in a strict literal sense, but also includes a state where the arrangement is relatively displaced by a tolerance, or by an angle or a distance whereby it is possible to achieve the same function.

[0056] For instance, an expression of an equal state such as same equal and uniform shall not be construed as indicating only the state in which the feature is strictly equal, but also includes a state in which there is a tolerance or a difference that can still achieve the same function.

[0057] Further, for instance, an expression of a shape such as a rectangular shape or a cylindrical shape shall not be construed as only the geometrically strict shape, but also includes a shape with unevenness or chamfered corners within the range in which the same effect can be achieved.

[0058] On the other hand, an expression such as comprise, include, have, contain and constitute are not intended to be exclusive of other components.

[0059] FIG. 14 is a diagram of a compressor impeller 100 of a supercharger provided for an automobile internal combustion engine, coated with a typical NiP based plating layer, shown with an analysis result of a distribution of strain generated in the compressor impeller projected on a back surface 102a of a hub 102. FIG. 14 shows that the greatest strain, that is, stress, is generated in a region 102b of the hub 102, where the root portions of blades 104 are projected. This stress is mainly generated by a centrifugal force generated when the supercharger rotates at a high speed, and is further combined with a stress due to a thermal expansion difference between the NiP based plating layer and a base material comprising an Al alloy, for instance.

[0060] As depicted in FIG. 1, a supercharger 12 according to at least one embodiment of the present invention is provided for an in-vehicle internal combustion engine, for instance, a diesel engine 10 equipped with an EGR system.

[0061] The supercharger 12 includes an exhaust turbine 14 which is disposed in an exhaust passage 20 of the diesel engine 10 and which is rotated by exhaust gas e, and a compressor 16 which operates in conjunction with the exhaust turbine 14 via a rotational shaft 13. The compressor 16 is disposed in an intake passage 22, and supplies the diesel engine 10 with intake air a. A part of exhaust gas is circulated to the intake passage 22 at an upstream side of the compressor 16.

[0062] As an exemplary embodiment, as depicted in FIG. 1, a high-pressure EGR system 24 has a high-pressure EGR passage 26 branched from the exhaust passage 20 at the upstream side of the exhaust turbine 14 and connected to the intake passage 22 at the upstream side of the compressor 16.

[0063] In the high-pressure EGR system 24, a part of the exhaust gas e discharged from the diesel engine 10 is returned to the intake passage 22 at the inlet side of the diesel engine 10 via the high-pressure EGR passage 26.

[0064] In an exemplary configuration, an EGR cooler 28 and an EGR valve 30 are disposed in the high-pressure EGR passage 26.

[0065] In an exemplary embodiment, a low-pressure EGR system 32 has a low-pressure EGR passage 34 branched from the exhaust passage 20 at the downstream side of the exhaust turbine 14 and connected to the intake passage 22 at the upstream side of the compressor 16.

[0066] In the low-pressure EGR system 32, a part of the exhaust gas e discharged from the diesel engine 10 is returned to the intake passage 22 at the inlet side of the compressor 16 via the low-pressure EGR passage 34.

[0067] In an exemplary configuration, an EGR cooler 36 and an EGR valve 38 are disposed in the low-pressure EGR passage 34.

[0068] In an exemplary embodiment, an air cleaner 40 is disposed in the intake passage 22 at the upstream side of the compressor 16, and an inter cooler 42 is disposed in the intake passage 22 at the downstream side of the compressor 16.

[0069] Further, an exhaust bypass passage 20a is connected to the exhaust passage 20 so as to bypass the exhaust turbine 14. A waste valve 44 is disposed in the exhaust bypass passage 20a, and an actuator 44a for adjusting the opening degree of the waste valve 44 is provided.

[0070] Further, a DPF filter 48 for capturing particulate matter in the exhaust gas, and an oxidation catalyst 46 for oxidizing NOx in the exhaust gas to NO.sub.2 and combusting the particulate matter captured by the DPF filter 48 by oxidation of NO.sub.2 are disposed in the exhaust passage 20 at the downstream side of the exhaust turbine 14.

[0071] A compressor according to at least one embodiment of the present invention is the compressor 16 provided for the supercharger 12 depicted in FIG. 1. The compressor 16 includes a compressor impeller 50 disposed on an end of the rotational shaft 13 inside a compressor housing (not depicted). The compressor impeller 50 has, for instance, a configuration as depicted in FIG. 13.

[0072] As schematically shown in FIG. 2, the compressor impeller 50 includes a base material 52 comprising Al or an Al alloy and an electroless plating layer 54 formed on the surface of the base material 52. The electroless plating layer 54 comprises a NiP based alloy having an amorphous structure and containing P of not less than 5 wt % and not more than 11 wt % in the layer.

[0073] The electroless plating layer 54 has an amorphous structure and thus has a high strength, thus being able to exert a high anti-erosion property. Furthermore, the electroless plating layer 54 contains P of not less than 5 wt % and not more than 11 wt %, which makes it possible to achieve an excellent anti-crack property (fatigue strength) while having a high Vickers hardness. Accordingly, it is possible to achieve both of the anti-erosion property and the anti-crack property.

[0074] Moreover, the electroless plating layer 54 is an electroless plating layer and thus can be formed uniformly, for instance, in terms of the layer thickness, and thus it is possible to exert the above two properties uniformly over a broad range.

[0075] As depicted in FIG. 2, the intake air a may contain a foreign substance such as a droplet L. For instance, if the low-pressure EGR system 32 depicted in FIG. 1 is employed, the exhaust gas e containing a water droplet L is circulated via the low-pressure EGR passage 34 and is supplied to the compressor with the intake gas a. As described above, even if the intake air a contains a foreign substance (e.g. droplet L), the electroless plating layer 54 has a good anti-erosion property and a good anti-crack property, thus being resistant to erosion by the exhaust gas e and being capable of suppressing generation of cracks.

[0076] FIG. 3 is a test result showing a relationship between the P content rate and the anti-erosion property of the electroless plating layer 54. FIG. 4 is a test result showing a relationship between the P content rate and the low-cycle fatigue (LCF) test fracture lifetime of the electroless plating layer 54. The low-cycle fatigue (LCF) is a fatigue fracture that develops on a member when such a great cyclic load that causes plastic deformation is applied to the member.

[0077] FIG. 5 is a diagram of an example of a cyclic load applied to a compressor impeller in an LCF test, where x-axis is time and y-axis is rotation speed of a supercharger equipped with the compressor impeller. A change in the rotation speed of the supercharger changes the cyclic load applied to the electroless plating layer 54.

[0078] As depicted in FIGS. 3 and 4, the anti-erosion property rapidly decreases when the P content rate exceeds 11 wt %, while the LCF fracture lifetime decreases when the P content rate is less than 5 wt % or more than 11 wt %.

[0079] From the above result, the electroless plating layer 54 contains P of not less than 5 wt % and not more than 11 wt % to balance the anti-erosion property and the LCF fracture lifetime.

[0080] FIG. 6 is a test result showing a relationship between different crystal structures and the anti-erosion property of the electroless plating layer 54. FIG. 7 is a test result showing a relationship between different crystal structures and the LCF fracture lifetime of the electroless plating layer 54. The crystallization in the drawings means that the electroless plating layer 54 having an amorphous structure is crystallized by heat treatment or the like.

[0081] As depicted in FIGS. 6 and 7, when the electroless plating layer 54 is crystallized, the anti-erosion property and the LCF fracture lifetime deteriorate rapidly.

[0082] From the above result, the electroless plating layer 54 is formed so as to have an amorphous structure to improve the anti-erosion property and the LCF fracture lifetime.

[0083] In an illustrative embodiment, the electroless plating layer 54 has a layer thickness of not less than 15 m and not more than 60 m. If the layer thickness of the electroless plating layer 54 is less than 15 m, it may be difficult to exert the anti-erosion property and the anti-crack property sufficiently. On the other hand, even if the layer thickness is increased to exceed 60 m, the effect to improve the anti-erosion property and the anti-crack property is limited, which rather increases the plating time and costs.

[0084] Accordingly, it is possible to achieve both of the anti-erosion property and the anti-crack property when the electroless plating layer 54 has a layer thickness of not less than 15 m, and it is possible to reduce the plating costs when the electroless plating layer 54 has a layer thickness of not more than 60 m.

[0085] FIG. 8 is a test result showing a relationship between the layer thickness and the anti-erosion property of the electroless plating layer 54. FIG. 9 is a test result showing a relationship between the layer thickness and the anti-corrosion property of the electroless plating layer 54.

[0086] As depicted in FIG. 8, the electroless plating layer 54 cannot exert the anti-erosion property when having a layer thickness of about 1 to 2 m, but can exert a high anti-erosion property when the layer thickness is in the range of from 15 to 60 m. The lines A, B, and C in FIG. 9 show the progress of corrosion on the electroless plating layer 54 for different corrosion environments. FIG. 9 shows that the requirement lifetime can be satisfied when the electroless plating layer 54 has a layer thickness of not less than 15 m, even in the severest corrosion environment.

[0087] In an illustrative embodiment, the electroless plating layer 54 has a Vickers hardness of not less than 500 HV and not more than 700 HV. In this case, the electroless plating layer 54 has a Vickers hardness of not less than 500 HV and thus can exert an anti-erosion property, while having a Vickers hardness of not more than 700 HV and thus being able to exert a high anti-crack property.

[0088] In an illustrative embodiment, as depicted in FIG. 10, if the fracture ductility strain of the electroless plating layer 54 having the above configuration is not less than 0.5%, the fracture lifetime in a LCF fracture test clears an allowable repetition number and a crack does not occur.

[0089] Accordingly, the electroless plating layer 54 having the above configuration is a plating layer with a high anti-fatigue fracture property, thus being capable of suppressing generation of cracks of an impeller and of improving the lifetime of an impeller.

[0090] The fracture ductility is measured by a test as depicted in FIG. 11, for instance. In FIG. 11, both ends of a test piece T having a plate shape with a rectangular cross section are placed on support bases 60 so that a side on which the electroless plating layer 54 is formed faces down. Subsequently, a load F is applied downward by placing an indenter 62 on an upper surface of the test piece T at the center in the axial direction to generate a predetermined strain. The above operation is repeated while changing the load until the plating layer fractures.

[0091] The compressor impeller 50 having the above configuration is used as the compressor impeller of the supercharger 12 that rotates at a high speed, and thereby it is possible to improve the anti-erosion property of the compressor impeller 50 and to restrict development of cracks, thus improving the lifetime of the compressor 16 and the supercharger 12 provided with the compressor 16.

[0092] Furthermore, even if the supercharger 12 is provided for the diesel engine 10 having the low-pressure EGR system 32 and the intake air a that contains exhaust gas containing droplets and having a high erosive property is introduced into the compressor 16, the supercharger 12 can endure high-speed rotation for a long time and the lifetime can be improved.

[0093] A method of producing an impeller for a rotary machine according to at least one embodiment of the present invention comprises a step (S14) of forming the electroless plating layer 54 on a surface of the compressor impeller 50 formed of Al or an Al alloy, so as to cover the compressor impeller 50, as depicted in FIG. 12.

[0094] The electroless plating layer 54 comprises a NiP based alloy having an amorphous structure and containing P of not less than 5 wt % and not more than 11 wt % in the electroless plating layer 54.

[0095] The compressor impeller 50 produced by the above method has the electroless plating layer 54 formed on the surface. The electroless plating layer 54 has an amorphous structure and thus has a high strength, thereby achieving an excellent anti-erosion property. Furthermore, the electroless plating layer contains P of not less than 5 wt % and not more than 11 wt %, thus having a high Vickers hardness and an excellent anti-crack property (fatigue strength).

[0096] Moreover, the electroless plating layer 54 can be formed uniformly, for instance, in terms of the layer thickness, and thus it is possible to exert a high anti-erosion property and a high anti-crack property (fatigue strength) uniformly over the entire range of the plating layer.

[0097] In an illustrative embodiment, as depicted in FIG. 12, prior to step S14, the method further comprises a step S12 of cutting out a test piece from the compressor impeller 50 having the electroless plating layer 54 formed thereon, and using the test piece to evaluate the fracture ductility of the electroless plating layer 54.

[0098] In other words, as depicted in FIG. 13, the test piece T is cut out from the compressor impeller 50 to be used to evaluate the fracture ductility.

[0099] Hardness and ductility of a plating layer changes depending on plating treatment conditions such as the total area of an object to be plated by a plating solution during plating treatment, and the relative velocity between the flow of the plating solution and the object to be plated.

[0100] Since the fracture ductility is evaluated by using the test piece T cutout from the compressor impeller 50 on which the electroless plating layer 54 is formed, it is possible to accurately obtain the fracture ductility of the electroless plating layer 54 of the actually-produced compressor impeller 50.

[0101] In an illustrative embodiment, as depicted in FIG. 13, the test piece T is collected from a region 56b on a back surface 56a of a hub 56 of the compressor impeller 50, the region 56b being projection of a blade root portion of the hub 56 on the back surface 56a of the hub 56.

[0102] While a stress is generated in the compressor impeller 50 due to a centrifugal force caused by rotation, for instance, the greatest stress is generated at the blade root portion of the hub 56, as shown in FIG. 14.

[0103] By collecting the test piece T from the region 56b, it is possible to obtain the fracture ductility under the severest stress condition.

[0104] In an illustrative embodiment, as depicted in FIG. 12, if the measured fracture ductility is less than a threshold (S16), the method further comprises a step S18 of changing plating conditions for forming the electroless plating layer 54 (e.g. relative velocity between the flow of the plating solution and the object to be plated, plating time, etc.)

[0105] Accordingly, the plating conditions of the electroless plating layer 54 are changed on the basis of the result of the fracture ductility, and thus it is possible to set the fracture ductility of the electroless plating layer 54 to be not less than a threshold.

[0106] In an illustrative embodiment, as depicted in FIG. 12, a pretreatment S10 is performed on the test piece T that is cut out prior to step S12, as shown in FIG. 12.

[0107] The pretreatment S10 includes: an alkali degreasing step S10a of removing grease or the like adhering to the surface of the test piece T with an alkali solution or the like; an etching treatment step S10b of removing a passive state layer (alumina layer) formed on the surface of the degreased test piece T by using an acid solution or an alkali solution; and a smut removing step S10c of removing smut which is C and Si less soluble to acid or the like remaining in the form of black powder after the etching treatment.

[0108] In a plating layer forming step S14, as an illustrative embodiment, the surface of the test piece T is plated with Zn, and then Zn is replaced with a NiP based alloy, thereby forming the electroless plating layer 54.

[0109] In an illustrative embodiment, after the plating layer forming step S14, performed are a step S20 of finishing the surface of the test piece T and a check step S22 of checking the finished test piece T.

INDUSTRIAL APPLICABILITY

[0110] According to at least one embodiment of the present invention, it is possible to form an electroless plating layer on an impeller for a rotary machine, whereby it is possible to achieve both of a good anti-erosion property and a good anti-crack property (fatigue strength), and thereby improve the lifetime of the impeller and apparatuses including the impeller.

DESCRIPTION OF REFERENCE NUMERALS

[0111] 10 Diesel engine [0112] 12 Supercharger [0113] 13 Rotational shaft [0114] 14 Exhaust turbine [0115] 16 Compressor [0116] 20 Exhaust passage [0117] 22 Intake passage [0118] 24 High-pressure EGR system [0119] 26 High-pressure EGR passage [0120] 28, 36 EGR cooler [0121] 30, 38 EGR valve [0122] 32 Low-pressure EGR system [0123] 34 Low-pressure EGR passage [0124] 40 Air cleaner [0125] 42 Inter cooler [0126] 44 Waste valve [0127] 44a Actuator [0128] 46 Oxidation catalyst [0129] 48 DPF filter [0130] 50, 100 Compressor impeller [0131] 52 Base material [0132] 54 Electroless plating layer [0133] 56, 102 Hub [0134] 56a, 102a Back surface [0135] 58, 104 Blade [0136] 60 Support base [0137] 62 Indenter [0138] C Crack [0139] S Strain [0140] a Intake air [0141] e Exhaust gas