A hard alloy particle dispersion type wear resisting sintered ferro alloy and method of forming the same

Abstract: A material for valve seats comprising a wear resisting sintered ferro alloy formed by dispersing particles of a high speed steel in a matrix in which hard alloy particles are dispersed. Steps for forming include mixing particles of a matrix material, carbide material and a hard alloy, and blending the mixture with high speed steel particles, pressurizing and casting the mixture after blending, then sintering them at 1000 to 1200°C. In the preferred method, at least one element of Fe, C, Ni, Co, Si or Mn is included as the matrix material, and at least one element of Fe, Cr, Mo or V as the carbide material and at least one element of Fe, Cr, Mo, Co, C or W as the hard alloy are prepared. Furthermore, preferably includes the following amounts of the above mentioned elements, 0.5 to 2.0 wt% of C, 1 to 25 wt% of one or more of Cr, Mo, V, or W and 1 to 15 wt% of one or more of Co, Ni, Mn, or Si.

Description: BACKGROUND OF THE INVENTION Technical Field This invention is related to the improvement of a hard alloy particle dispersion type wear resisting sintered ferro alloy. Background Art In the various fields, demand for ferro alloy with higher wear resistance becomes stronger. For example, according to the current trend of automotive internal combustion engine toward higher speed and higher performance, higher wear resistance has been required for the ferro alloy as a material for forming valve seats to be installed on an induction port and exhaust port of the engine. In order to answer such demand, Japanese Patent First Publication No. 53-81410 and Japanese Patent Second (allowed) Publication No. 57-3741 proposes a ferro alloy containing hard alloy dispersed in a base matrix. As is well known, hard alloy has relatively low sintering ability. Therefore, when using hard alloy as particles for dispersion it tends to cause formation of gaps in the sintered body and provides relatively weak coupling with the material of the base matrix. As a result, spalling of the hard alloy particle which is dispersed in the base matrix can occur to cause degradation of wear resistance of the ferro alloy which can be lowered substantially. Therefore, if such a ferro alloy is used for forming the valve seat of the automotive engine, it may raise a problem of durability. To protect hard alloy from wear in it has been attempted to improve sintering by raising the sintering temperature, strengthening the alloy, and preventing the hard alloy from spalling by infiltrating Cu into gaps in the sintered alloy. However, there remain some problems. Raising the sintering temperature causes the elements of the hard alloy to diffuse and in some cases, causes loss of or degradation of its property as a hard alloy. For this reason, it is necessary to restrict and control the range of the sintering temperature. This causes extra steps to be taken, thereby lowering productivity and raising the cost of production. Additionally, when using Cu or infiltration Cu and ferro alloy are layered while heating. These steps are time consuming and again cause lower productivity and high production costs. A sintered substance of high speed steel particles is used for valve seat material in Europe. Though as a material for valve seats it has substantial wear resistance, it has about five times the production cost of using particles of hard alloy material, and a sintered substance of high speed steel has not enough wear resistance against automotive engines having high revolution speeds, such as Japanese automotive vehicles. From Patent Abstract of Japan, Vol., 11, No. 371 JP-A-62 146 246 there is known a powder mixture of high speed steel powder and mixed powder of two or more kinds of hard materials. In the resulting sintered compact many hard material grains are dispersed in the sintered structure of high speed steel grains in which many high speed steel grains are formed by sintering in the sintered structure of high speed steel grains is bound to the above dispersed hard material grains so as to form a compound sintered body. The hard material grains consists of titanium carbide or titanium nitride. From GB-A-2157711 there is known a combination of high speed steel powder particles and an austenitic binding phase formed from nickel-maganese or nickel-maganese-copper alloys. Thereby a structure is produced in which relatively hard regions are partly or completely surrounded by a softer matrix. In view of the drawbacks in the prior art, the present invention is intended to provide a method of forming a ferro alloy having higher wear resistance which is suitable to use in forming valve seats of automotive engines, for example. SUMMARY OF THE INVENTION Therefore, it is an object of this invention to provide a hard alloy particle dispersion type sintered ferro alloy which has higher wear resistance than that which can be produced through the conventional process. Another object of the invention is to provide a method of efficiently producing the hard alloy dispersed type ferro alloy according to the invention. The above objects are achieved by claim 1 with regard to a method and by claim 5 with regard to a ferrous alloy. This invention takes advantage of the characteristics of high speed steel according to JISG4403, which forms a liquid phase on its surface at a relatively low temperature of about, 1070°C, to improve sintering ability of particles via surface tension. Further more, in high speed steel particles there are fine-grained intermetallic compounds or carbides, therefore they function as hard alloy particles and alloy elements of high speed steel particles are dispersed from them during sintering, thereby causing a strengthening of the matrix and improving the wear resistance of the sintered ferro alloy. According to this present invention, high speed steel particles are mixed with hard alloy particles dispersed in material particles of a matrix of the wear resisting ferro alloy. Then the mixture is compacted and sintered. The sintering is promoted due to the forming of the liquid phase on the surface of the high speed steel particles. This enhances the degree of sealing between the hard alloy and the matrix. Concurrently, it results that the wear resistance of the sintered substance is enhanced by the fine grains of high speed steel particles themselves which are dispersed therein. Therefore, it has great advantages in utility as a material to form parts which are subjected to extreme striking or rubbing actions, such as valve seats for high speed rotary engines. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: Figure 1 is a photograph showing a microstructure of sintered ferro alloy according to the present invention; Figure 2 is a sketch of Figure 1; Figure 3 is a photograph showing a microstructure of conventional alloy according to the prior art; and Figure 4 is a sketch of Figure 3. DESCRIPTION OF THE PREFERRED EMBODIMENT Following is a discussion concerning the details of the preferred embodiment according to the present invention. The present invention includes a ferro sintered alloy comprising the mixture of Fe, matrix, hard alloy and high speed steel. High speed steel particles are mixed with hard alloy particles dispersed in material particles of a matrix of the wear resisting ferro alloy to fill gaps formed between the hard alloy and the matrix. Then the mixture is compacted and sintered. High speed steel particles have the characteristic of forming a liquid phase on their surface . This enhances the degree of sealing between the hard alloy and the matrix. Concurrently, it results that the wear resistance of the sintered substance is enhanced by the fine grains of high speed steel particles themselves which are dispersed therein. Therefore, it has great advantages in utility as a material to form parts which are subjected to extreme striking or rubbing actions, such as valve seats for high speed rotary engines. In order to carry out the invention, any high speed steel particles can be used having a chemical composition which is prescribed in JIS G 4403. Different types of high speed steel in the JIS G 4403 specification can be used. Using more than one Mo type which speed steel which forms a liquid phase on a surface thereof at relatively low temperatures, however, is more preferable. The amount of high speed steel particles to add is determined in a range of 2 to 20 wt%. If the amount of the high speed steel to add is less than 2 wt%, no improvement for wear resistance is observed. On the other hand, when more than 20 wt% of high speed steel is added, there cannot be observed further enhancing of wear resistance corresponding to the amount of addition and which would justify the rising production cost when more than 20 wt% is added. Particle size is less than 100 mesh, preferably. If the size of the particles is larger, mixture of particles is easier to deflect and compacting becomes difficult. Chemical compositions of the sintered ferro alloy are as follows; C combines with Cr, Mo, V, W which are carbide elements. This results in the formation of a carbide which improves the wear resistance. The amount of C is determined inevitably in relation to the class and amount of carbides elements, hard alloy or high speed steel. In the case of this invention, it is preferably between the range of 0.5 and 2 wt%. It is preferable that the amount of C is not less than 0.5 wt% because the yield of carbide would be insufficient to prevent formation of soft ferrites causing low wear resistance. On the other hand, it is also preferable that the amount of C is not more than 2 wt% because the material becomes so hard and fragile. Cr, Mo, V, W, which are carbide elements, combine with C and improve the wear resistance by forming a carbide. This effect is evidenced by any of the above mentioned elements. Any one element or several of them mixed together may be used. The total amount of these elements present is preferrably between 1 and 25 wt% including elements present in the high speed steel. It is preferable that the total amount is not less than 1 wt% because the yield of a carbide would be insufficient to prevent formation of soft ferrites causing low wear resistance. On the other hand, it is also preferable that the total amount is not more than 25 wt% because the material becomes so hard and fragile, and production costs also become high. As for other Components, one of Co, Ni, Si, Mn or a mixture of them is preferrably included in the range of 1 to 15, wt% (including elements from the high speed steel) in order to improve the strength of the matrix or stabilize the mixture. It is preferable that the total amount of these other components is not less than 1 wt% because wear resistance would be insufficient and it is also preferable that the total amount of them is not more than 15 wt% because there is no improvement for wear resisting effects corresponding to the amount and raised production costs. Still further, a portion of the above mentioned elements is added in the form of one or more hard alloys having a hardness higher than HMV 500. Such alloys as Fe-Mo, Fe-Cr-Co-Mo-C, Fe-W-Co-Cr-C are preferably added in order to raise the wear resistance of the sintered ferro alloy. It is preferable that the amount of hard alloy is between 2 wt% and 15 wt%. It is preferable that the amount of it is not less than 2 wt% because the wear resisting effect would be insufficient, and it is also preferable that the amount of it is not more than 15 wt% because the material becomes hard and fragile, and production costs become high. Production steps such as compacting and sintering of the mixture, are not modified specifically compared with the prior art. About 0.5 wt% of zinc stearate is added to the mixed particles as a lubricant while compacting, conventionally. Therefore, when sintering, pre-heating is carried out so as to dewax at about 650°C. Temperature of sintering is preferably about 1000 to 1200°C. After sintering, portions of high speed steel particles remain as high alloy steels. EXAMPLE As a base material, particles were blended, each component having an amount as follows; 43.1 wt% of pure Fe having 150 to 200 mesh peak size of particle, 43.1 wt% of Fe-2 wt% Ni-0.5 wt% Mo-0.2 wt% Mn particles having same size as the pure Fe, 1 wt% of Ni particles having a size under 325 mesh, 1.3 wt% of graphite having same size as Ni, 2 wt% of Fe-55 wt% Cr-20 wt% Mo-10 wt% Co-1.2 wt% C as a hard alloy having 150 to 200 mesh peak size of particle, and 4 wt% of Fe-63 wt% Mo particles, 5 wt% of Fe-12.5 wt% Cr particles, 0.5 wt% of zinc stearate as a lubricant. Then a high speed steel classified as JISSKH 53 or 59 having a size of less than 100 mesh was added in a rate as shown in the notes below Table 1. The mixture of the base material and the high speed steel particles was compacted by pressing under a pressure of 7t/cm 2 , pre-heated 1 hour at 650°C for dewaxing and heated again 1 hour at 1130°C for sintering. By this procedure test piece materials were obtained. Table 1 shows the chemical composition of the test materials. The materials were cut to the desired size for testing and an aptitude test for valve seat material was carried out by a simple abrasion test machine which imitates a real engine. Tests were carried out assuming usage under conditions of an inlet valve seat as shown in Table 2. (weight %) No. C Cr Ni Mo Co W V Total alloy 1 1.37 1.89 1.75 3.38 0.36 0.15 0.08 7.71 2 1.38 1.89 1.75 3.47 0.52 0.06 0.04 7.83 3 1.38 1.89 1.75 3.29 0.19 0.24 0.12 7.59 4 1.33 1.91 1.64 3.25 0.18 0.48 0.24 7.70 5 1.32 2.00 1.57 3.33 0.18 0.72 0.36 8.16 6 1.32 2.09 1.50 3.40 0.17 0.96 0.48 8.62 7 1.31 2.18 1.42 3.48 0.16 1.20 0.60 9.08 10 1.25 4.00 - 5.00 - 6.00 3.00 18.00 11 1.36 3.36 1.74 4.61 0.50 - - 10.32 12 1.33 1.73 1.78 3.10 0.20 - - 6.90 Notes; (1) Total alloy: Cr+Mo+W+V+Ni+Co (2) Blending rate of a high speed steel particle No. 1 SKH 59 : 4% No. 2 SKH 59 : 2%, SKH 53 : 2% No. 3 SKH 53 : 4% No. 4 SKH 53 : 8% No. 5 SKH 53 : 12% No. 6 SKH 53 :16% No. 7 SKH 53 : 20% No. 10 SKH 53 : 100% Material of valve seat SUH-3 Surface temperature of valve head 300°C Temperature of valve seat 150°C Speed of cam rotation 2500rpm Period of test 5Hr No. Amount of wearing (µm/5H) Remarks Valve seat Valve Total 1 48 45 93 2 53 19 72 3 50 38 88 4 37 34 71 5 36 42 78 6 57 28 85 7 64 25 89 10 83 16 99 SKH 53 11 63 38 106 by Prior art -2 90 57 147 base material Note: Nos.1 to 7 are materials formed by this invention and are mixed with high speed steel particles at the rate shown in Table 1 with a base material No.12. The results of the test are shown in Table 3. Comparing each material's total wearing of valve seat and valve, it is apparent that materials which relate to this invention exceed in wear resistance in spite of a total amount of alloy (wt%) which is less than No. 11 formed by the prior art, and highly exceed in wear resistance compared with No.12 which is base material.

Claims: A process of forming a ferrous alloy, wherein a matrix-forming first base material powder of at least one selected from a group consisting of Fe, Ni, Co, Si and Mn, a carbide-forming second base material powder of at least one selected from a group consisting of Cr, Mo, W and V, and hard alloy particles having a hardness greater than HV 500 of at least one selected from a group consisting of Fe, Cr, Mo, Co, C and W, are mixed, compacted and then sintered, characterized in that 2 to 20 wt% of high speed tool steel powder in the meaning of Japanese Industrial Standard G 0203 No. 4403 is mixed with said first and second base material powders and said hard alloy powder before compaction and sintering. A process as claimed in claim 1, characterized in that said compaction is performed at a pressure of 70 N/mm 2 (7 ton/cm 2 ). A process as claimed in claim 1 or 2, characterized in that said sintering is performed at a temperature falling in a range from 1000°C to 1200°C. A valve seat formed of a ferro alloy made by the process of any one of claim 1, 2, and 3. A sintered ferrous alloy having a carbide-containing matrix which is formed by sintering a mixture of a matrix-forming first base material of at least one selected from a group consisting of Fe, Ni, Co, Si and Mn, and a carbide-forming second base material of at least one selected from a group consisting of Cr, Mo, W and V, and hard alloy particles of at least one selected from a group consisting of Fe, Cr, Mo, Co, C and W which are dispersed in the matrix, characterized in that said ferrous alloy comprises 2 to 20 wt.% high speed tool steel particles in the meaning of Japanese Industrial Standard G 0203 No. 4403, cooperating with said first and second base materials after sintering, whereby gaps between said hard alloy particles and said matrix are filled or at least reduced. A ferrous alloy as claimed in claim 5, characterized by the following chemical composition : 0.5 to 2.0 wt% of C; 1 to 25 wt% of at least one selected from a group consisting of Cr, Mo, V, and W; 1 to 15 wt% of at least one selected from a group consisting of Co, Ni, Mn, and Si; and a balance of Fe. A valve seat formed of a ferrous alloy as claimed in any one of claims 5 and 6.

Inventors: ABE MAKOTO, FUJIKI AKIRA, ISHIBASHI AKIYOSHI, ITO TAKAAKI, KISO KIMITSUGU, TAKEMURA KAZUTOSHI, ABE, MAKOTO, FUJIKI, AKIRA, ISHIBASHI, AKIYOSHI, ITO, TAKAAKI, KISO, KIMITSUGU, TAKEMURA, KAZUTOSHI
Applicants: NISSAN MOTOR, RIKEN KK, KABUSHIKI KAISHA RIKEN, NISSAN MOTOR CO., LTD.
Application year: 1989
Main classification: C22C33
IPC codes: C22C38, C22C33, F02F7