JP2002004063A - Method of forming metallic film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a film by a technique simple and excellent in workability and to further improve workability and cost reduction effects when the film is formed by using the technique. SOLUTION: The film is formed on a slanted plate 22 by friction welding so that an aluminum rod 45 formed by a continuous casting method and an extruding method is rotated to be brought into pressure contact with the surface 40 (41) of the slanted plate 22 to be processed, while the slanted plate is rotated as well. At this time, the aluminum rod is used in the friction welding in a state in which a black film of the surface formed at the time of forming the aluminum rod is left. At the time of friction welding, a wound part 52 is formed at the outer peripheral part of the tip end of the aluminum rod 45, thereby the black film is not almost mixed into the film.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a metal film on a surface of a base material.

[0002]

2. Description of the Related Art In a compressor of a swash plate type, for example, lubrication of sliding parts of parts is ensured by supplying mist-like lubricating oil to refrigerant gas and supplying lubricating oil to each sliding part. . However, for example, when the operation of the compressor is in an initial state at a low temperature, lubricating oil adhering to the sliding portion is washed away by the refrigerant gas, and the sliding portion tends to be in a dry state. Therefore, the sliding members are subjected to a surface treatment so that each sliding member has sliding characteristics excellent in seizure resistance and wear resistance. As one of the techniques, a thermal spraying technique is used in which a metal material such as a copper-based or aluminum-based alloy in a powdered state is melted and sprayed onto a processing surface together with a flame.

[0003]

However, when using this thermal spraying method, it is necessary to perform a roughening process by shot blasting or the like on a processing surface before performing thermal spraying. There is also a problem that the cost for the roughening treatment is additionally required. Further, there is a problem that considerable noise is generated during the roughening treatment, and the operator must work under such bad conditions.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has as its object to form a film by a simple and excellent workability method, and to further improve the workability at the time of film formation using the method. Another object of the present invention is to provide a method for forming a metal film which can further improve the cost reduction effect.

[0005]

According to the first aspect of the present invention, a metal film is formed on a surface of a substrate by friction welding a welding material formed by casting. A method of friction-welding the welding material to the surface of the base material while leaving the black scale formed on the outer surface when casting the welding material.

According to the present invention, when friction welding is performed, the outer periphery of the welding material is curled up as it softens, and the welding material is deformed into a substantially mushroom shape. Therefore, since black scale is unlikely to be mixed in the film due to this deformation action, there is no problem even if friction welding is performed using a welding material with black scale remaining on the outer surface. Therefore, if the welding material with the black scale left is used for friction welding, the work of removing the black scale of the welding material by machining or the like is omitted, and the operation up to forming a film on the surface of the base material is simplified. become. In addition, the use of friction welding eliminates the need for special processing, for example, required at the time of thermal spraying, thereby reducing manufacturing costs and improving the working environment.

According to a second aspect of the present invention, in the first aspect of the invention, the welding material is formed by a continuous casting method. According to this invention, in addition to the effect of the invention described in claim 1, the productivity of the welding material is improved as compared with, for example, a case where the welding material is cast individually one by one, and thus the film forming operation is further simplified. Become.

According to a third aspect of the present invention, in the first or second aspect of the invention, the welding material is made of an aluminum material. According to this invention, claim 1 or 2
In addition to the effects of the invention described in (1), by using an aluminum-based material for the film, high sliding characteristics of the sliding portion can be secured.

According to the fourth aspect of the invention, the first to third aspects are provided.
In the invention described in any one of the above, the base material is a swash plate for a compressor, and the coating is formed on a surface of the swash plate.

According to this invention, in addition to the operation of the invention described in any one of the first to third aspects, a swash plate having good sliding characteristics can be efficiently manufactured.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention embodied in a method for forming a swash plate film used in a variable capacity swash plate compressor will be described below with reference to FIGS.

As shown in FIG. 5, the swash plate type compressor 11 comprises:
The cylinder block 12 includes a front housing 13 joined to a front end thereof, and a rear housing 15 joined to a rear end of the cylinder block 12 via a valve body 14. These members 11 to 15 are provided with a plurality of through bolts. (Not shown), they are joined and fixed to each other to form a compressor housing.

A crank chamber 16, a suction chamber 17, and a discharge chamber 18 are defined in the housing. A plurality of cylinder bores (only one is shown) 19 are formed in the cylinder block 12, and a single-headed piston 20 is housed in each cylinder bore 19 so as to be able to reciprocate. Inhalation chamber 1
The discharge chamber 7 and the discharge chamber 18 are selectively communicated with the respective cylinder bores 19 via various flapper valves of the valve body 14.

A drive shaft 21 is rotatably provided through the housing. A swash plate 22 as a base material is provided on the drive shaft 21.
Are supported in a state accommodated in the crank chamber 16.
The swash plate 22 includes a hinge mechanism 23 and a lug plate 2.
The drive shaft 21 is operatively connected to the drive shaft 21 via the drive shaft 4 and is rotatable in synchronization with the drive shaft 21 and tiltable with respect to the drive shaft 21 while sliding in the axial direction of the drive shaft 21.

The ends of the swash plate 22 are slidably anchored to the ends of the pistons 20 via a pair of front and rear shoes 25 and 26, so that all the pistons 20 are operatively connected to the swash plate. ing. When the swash plate 22 inclined at a predetermined angle rotates together with the drive shaft 21, each piston 20 reciprocates with a stroke corresponding to the inclination angle of the swash plate 22, and in each cylinder bore 19, suction and suction of refrigerant gas from the suction chamber 17 is performed. The compression of the refrigerant gas and the discharge of the compressed refrigerant gas to the discharge chamber 18 are sequentially repeated.

The tilt angle of the swash plate 22 includes the moment of the rotational motion based on the centrifugal force when the swash plate rotates, the moment due to the spring force due to the urging action of the tilt reduction spring 27, the moment due to the reciprocating inertial force of the piston 20, the gas pressure. Is determined based on the mutual balance of various moments such as the moment by Here, the moment due to the gas pressure is a moment determined based on the internal pressure of the cylinder bore 19 and the internal pressure of the crank chamber 16 corresponding to the back pressure of the piston 20, and acts on the inclination decreasing direction and the increasing direction in accordance with the crank pressure. I do.

The variable displacement type swash plate type compressor 11 has a control valve 28 in the rear housing 15, and the control valve 28 communicates with the crank chamber 16 and the discharge chamber 18 through a pressure supply path 29.
Intervening above. Also, the crank chamber 16 and the suction chamber 17
Are communicated by a pressure release passage (throttle passage) 30.
In the variable displacement type swash plate type compressor 11 as in this example, the moment due to the gas pressure is appropriately changed by adjusting the crank pressure by adjusting the opening of the control valve 28. And
If the crank pressure is increased, the inclination angle of the swash plate 22 becomes smaller, the stroke of the piston 20 becomes smaller, and the discharge capacity decreases. If the crank pressure is reduced, the inclination angle of the swash plate 22 becomes larger, and the stroke of the piston 20 becomes larger. And the discharge capacity increases.

Next, the configuration of the swash plate 22 will be described with reference to FIGS. As shown in FIG. 5, the swash plate 22 has a land portion 31 on the center side and an outer peripheral portion 32 formed on the outer periphery of the land portion 31 with a small thickness. A pair of shoes 25 and 26 are engaged with the outer peripheral portion 32 of the swash plate 22 on both surfaces thereof.

As shown in FIG. 3, each shoe 25, 26 has flat portions 33, 34 and spherical portions 35, 36.
3, 34 are the front surface 37 and the rear surface 38 of the swash plate 22.
, And the spherical portions 35 and 36 are in contact with the shoe seat 39 of the piston 20. On the outer peripheral portion 32 of the swash plate 22, coatings 42, 4 are provided on both the front side and the rear side, respectively.
3 is formed over the entire circumferential direction. Shoe 25,
The flat portions 33 and 34 of the 26 abut against the surfaces (the front surface 37 and the rear surface 38) of the films 42 and 43, respectively.
Reference numerals 2 and 43 function as sliding surfaces for the shoes 25 and 26.

As the base material (base material) 44 of the swash plate 22, an iron-based material (for example, cast iron such as FCD700) is used. This is to make the swash plate 22 relatively heavy in order to appropriately generate a moment of rotational movement based on the centrifugal force when the swash plate 22 rotates. The shoes 25 and 26 are also made of an iron-based material (for example, bearing steel) in consideration of the mechanical strength and the like. In the outer peripheral portion of the base material 44, the coating 4
The surfaces on which the surfaces 2 and 43 are formed are the processing surfaces 40 and 41.

Each of the films 42 and 43 has, for example, A390
Systems, A390-5 systems, AS-1 systems and other aluminum-based materials (hereinafter simply referred to as aluminum-based materials). These aluminum-based materials contain S
i, Fe, Cu, Mn, and Mg are contained.
More specifically, in the A390-based material, the content of each component with respect to Al is 16 to 18 for Si, 0.5 or less for Fe,
Is 4 to 5, Mn is 0.1 or less, and Mg is 0.45 to 0.6.
5 (all units are% by weight). The A390-5 material has a Si content of 14 to 16% by weight and the same content of other components. The AS-1 material has a Si content of 1
The content of other components is the same at 3.5 to 14.5% by weight. In particular, as the aluminum material, hypereutectic aluminum having a Si content of 11.7% by weight or more is preferable, and preferably 13.5 to 1
It is preferably 8% by weight. The sliding effect is improved by the primary crystal silicon present in this hypereutectic aluminum, and the use of a film made of this hypereutectic aluminum ensures excellent sliding characteristics such as wear resistance and high strength. This is because that.

Next, a procedure for forming a film on the swash plate 22 will be described with reference to FIGS. 1, 2 and 4. As shown in FIGS. 1 and 2, an aluminum rod 45 as a welding material is friction-welded to the processing surfaces 40 and 41 of the swash plate 22, respectively.
First, the procedure for forming the aluminum rod 45 will be described with reference to FIG.

The material of the aluminum rod 45 is, for example, an A390-based aluminum material. Then, the columnar bar 46 shown in FIG. 4A is cast by the continuous casting method.
By the way, in the continuous casting method, there is a limit to the fineness of the diameter of a bar to be manufactured. Therefore, when a diameter smaller than the diameter of the bar 46 that can be formed by the continuous casting method is formed, the bar 46 is extruded with a die (not shown) to reduce the diameter. A bar 47 having a small diameter as shown in FIG. 4B is formed. The diameter of the bar 46 is equal to the swash plate 2.
The bar 46 may be used if it fits the width of the processing surface of No. 2.
Here, the bar 47 formed by the continuous casting method and the extrusion method has a black scale (shown in a stripe shape in FIG. 4) on the entire surface.
Are formed. The diameter of the bar 47 is set to be substantially the same as the width W (shown in FIG. 2) of the processing surfaces 40 and 41 of the swash plate 22.

Then, the rod material 47 is subjected to T6 heat treatment (solution treatment + age hardening treatment), whereby the adhesion effect of the aluminum material during friction welding is enhanced, and the hardness and strength of the aluminum rod 45 are improved. This T6 heat treatment is a treatment in which the material of the welding material is limited to an aluminum-based material. If the material is other than an aluminum-based material, the T6 heat treatment is not performed, or another predetermined processing for improving the adhesion efficiency is performed. You. Next, as shown in FIG. 4C, the bar 47 is cut into a predetermined number, and a plurality of aluminum bars 45 are formed from one bar 47. Accordingly, since the surface (outer peripheral surface) of the aluminum rod 45 is not machined (for example, cut), black scale remains on the surface. Also, aluminum rod 4
The cut end face 48 of No. 5 has no black scale.

Using the aluminum rod 45, a film 43 is first formed on the rear processing surface 41 side of the two processing surfaces 40 and 41. As shown in FIG. 1, the substrate 44 of the swash plate 22 is set on the rotation holding mechanism 49, and the aluminum rod 45 is set on the slide / rotation holding mechanism 50. At this time, the aluminum bar 45 is set so that the cut end face 48 faces the base material 44 side. The rotation holding mechanism 49 is operatively connected to the first motor M1, and the driving force of the first motor M1 causes the substrate 44 to rotate about the axis L1.

The slide / rotation holding mechanism 50 is operatively connected to the front / rear slide means 51 and the second motor M2. The aluminum rod 45 is approached, pressed and separated from the base material 44 by the front and rear sliding means 51, and rotates about the axis L2 of the aluminum rod 45 by the driving force of the second motor M2. Further, as shown in FIG. 2, the aluminum rod 45 and the base material 44 when set in the mechanisms 49 and 50 are provided.
Is set at a position where the end surface 48 is joined within the processing surface 41 when pressed against the substrate 44.

After the base member 44 and the aluminum rod 45 are set in the mechanisms 49 and 50, respectively, the aluminum rod 45 is operated at a predetermined rotation speed (for example, 1500 rpm) by the operation of the second motor M2 and the slide / rotation holding mechanism 50. Rotate (rotate). Then, while the rotation of the aluminum rod 45 is maintained, the slide / rotation holding mechanism 5
After the aluminum rod 45 moves toward the substrate 44 together with 0, and even after the end surface 48 of the aluminum rod 45 comes into contact with the processing surface 41, the aluminum rod 45 is pressed against the processing surface 41 to hold the aluminum rod 45 at a predetermined position. Pressure contact (for example, 18 Mpa) is performed.

While the aluminum rod 45 is pressed against the substrate 44, the substrate 44 is rotated at a predetermined rotation speed (for example, 1 rpm) by the operation of the first motor M1 and the rotation holding mechanism 49. Then, mainly due to the high speed rotation of the aluminum rod 45, frictional heat is generated between the end face 48 of the aluminum rod 45 in the pressed state and the processing surface 41. The frictional heat softens the vicinity of the end surface 48 of the aluminum rod 45, and the aluminum material is transferred to the processing surface 41.

At this time, the aluminum rod 45 is deformed from the cylindrical state before the friction welding shown in FIG. 1 into a substantially mushroom shape having a winding part 52 which is wound outward at the end thereof. Therefore, at the time of friction welding, the black scale is rolled up successively without hitting the base material 44 together with the winding upper portion 52. Even if the outer periphery is used for friction welding with the black scale state, black scale (impurities, etc.) is formed on the film 43. Almost no mixture, even if mixed, film 4
There is no problem in the characteristics of No. 3.

When the base material 44 makes at least one rotation, the aluminum material is transferred to the entire processing surface 41 and the coating 43 is formed.
Is formed. After the film 43 is formed on the processing surface 41, the aluminum rod 45 retreats (separates) from the base material 44 together with the slide / rotation holding mechanism 50. Thereafter, the film 43 is subjected to a processing such as a polishing process or a finishing process, so that the film thickness is adjusted to a required film thickness (for example, 50 μm). Then, friction welding is similarly performed on the processing surface 40 on the back surface side, and a film 42 is formed on the processing surface 40.

Therefore, in this embodiment, the following effects can be obtained. (1) In the present embodiment, since the friction welding is used as the film forming method, the films 42 and 43 can be formed in a short time in a simple procedure. Further, since the aluminum rod 45 has a characteristic of winding up the outer periphery during friction welding, even if the aluminum rod 45 is used in a black skin state, impurities such as black skin are hardly mixed in the films 42 and 43. Therefore, in this example, since the aluminum bar 45 is used for friction welding in a black scale state, the work of processing the outer periphery of the aluminum bar 45 becomes unnecessary, and the film forming operation can be further simplified. Also, by using friction welding, processing required at the time of thermal spraying (for example, surface roughening processing)
Is unnecessary, and the cost can be reduced. Further, since no loud noise or the like is generated, it is possible to work in a favorable environment.

(2) The productivity of the bar 46 (47) is improved by using the continuous casting method, and the productivity of the aluminum bar 45 is also improved. If the extrusion method is used, an aluminum rod 45 having a relatively small diameter can be formed.

(3) Since hypereutectic aluminum is used for the material of the aluminum rod 45, the coatings 42 and 43 of the swash plate 22 formed by friction welding the aluminum rod 45 have high sliding characteristics. Therefore, the reliability of components that can slide, such as the swash plate 22 and the shoes 25 and 26, is improved, and the reliability of the compressor 11 is also improved.

(4) The aluminum rod 45 is subjected to a T6 heat treatment consisting of a solution treatment and an age hardening treatment, so that the adhesion efficiency of the aluminum material to the base material 44 during friction welding is improved. Therefore, the films 42 and 43 can be formed efficiently.

(5) The films 42 and 43 are coated only on the surface layer of the swash plate 22 by friction welding. Incidentally, the swash plate preferably has a relatively high weight so that the tilt angle can be smoothly returned to "0" during high-speed rotation.
Therefore, if a structure in which only the surface layer is coated with an aluminum-based material is used, even if a heavy iron-based material is used as the material of the base material 44 of the swash plate 22, the surface thereof has high sliding characteristics. High responsiveness of the swash plate 22 can be maintained, and high sliding characteristics can be secured.

(6) Swash plate 2 using the film forming method of this embodiment
2, the coatings 42 and 43 can be easily formed, and the swash plate 22 can be manufactured efficiently. Note that the embodiment is not limited to the above, and for example, may be changed as follows.

The welding material is not limited to the aluminum rod 45. For example, an iron-based material or a copper-based material may be used. Also in this case, there is black scale on the surface of the welding material made of these materials, but there is no problem when the friction welding is performed in the same manner, since the outer periphery is wound up and the winding top is formed. Further, the material of the swash plate 22 may be, for example, an aluminum-based material instead of the iron-based material. Therefore, for example, a film made of an iron or copper material can be formed on the swash plate 22 made of an aluminum material, or a film made of a copper material can be formed on the swash plate 22 made of an iron material.

The welding material is not limited to hypereutectic aluminum even if it is an aluminum rod 45. That is, the aluminum rod 45
May be non-hypereutectic aluminum having a Si content of less than 11.7% by weight. Aluminum rod 45 is A390 series, A
The material is not limited to those of 390-5 type and AS-1 type, but may be of aluminum type material.

Although the bars 46 (47) are formed by the continuous casting method, the present invention is not limited to this, and the bars 46 (47) may be cast individually one by one. Although the T6 heat treatment was performed when forming the aluminum rod 45, this heat treatment may be omitted.

The shape of the aluminum rod 45 may be, for example, a square or triangular cross section instead of a column. In the present embodiment, the film formation is performed sequentially on each side of the base material 44. Alternatively, the rotation holding mechanism 4 for mounting the base material 44 may be used.
The slide / rotation holding mechanism 50 may be arranged on both sides of the substrate 9, and the films 42 and 43 may be simultaneously formed on both sides of the base material 44.
In this embodiment, the film was formed using only one aluminum rod 45. However, the film 42, 4 was formed using two or more aluminum rods 45.
3 may be formed. According to the above, the time for forming a film on the swash plate 22 can be reduced.

The coatings 42 and 43 were formed on both sides of the swash plate 22, but the coatings 42 and 43 were
8 may be formed only on one of them. Also, in consideration of the fact that a relatively large value of the compression reaction force is applied to the rear side of the swash plate 22, films of different materials may be formed on the front surface 37 and the rear surface 38. For example, the rear surface 3 to which a compression reaction force is applied
For example, a material having high sliding properties (for example, hypereutectic aluminum) may be used for the coating 43 and a copper-based material may be used for the coating 42 on the front surface 37.

The substrate is not limited to the swash plate 22, and the film forming method of the present embodiment may be applied to other components (for example, pistons) constituting the compressor. The compressor is not limited to the swash plate type, but may be, for example, a scroll type. Further, the base material is not limited to the components of the compressor 11 but other mechanical components.
When forming a film on the surface, the film forming method of this example may be adopted. In short, the present invention can be applied to the formation of a metal film that forms a film made of a metal material on the surface of a substrate. Further, the substrate is not limited to metal, and may be, for example, ceramic as long as the adhesion of the film is ensured.

The technical ideas other than the claims that can be grasped from the embodiment and the other examples will be described below together with their effects. (1) In Claims 1 to 4, in the welding material, a portion that comes into contact with the surface of the base material is machined. In this case, during friction welding, a portion without black scale comes into contact with the surface of the base material, so that a film can be formed without any trouble. it can.

(2) In Claims 1 to 4, the welding material is formed by an extrusion method for forming a cast raw material into a small diameter. In this case, a welding material having a relatively small diameter can be formed.

(3) In Claims 1 to 3, the base material is a component constituting a compressor. In this case, the sliding characteristics of the sliding part in the compressor are improved. (4) In claim 3, a hypereutectic aluminum material is used as the welding material made of the aluminum-based material. In this case, if a hypereutectic aluminum material is used, a metal film having high sliding characteristics can be obtained.

(5) In claim 3 or 4, the welding material made of the aluminum-based material is subjected to a solution treatment and an age hardening treatment. In this case, the adhesion efficiency when friction welding the welding material is improved.

[0047]

As described in detail above, according to the present invention, a metal film can be formed by a simple and excellent workability method, and the welding material used in the method can be used while leaving black scale. In addition, the workability and cost reduction effect during film formation can be further improved.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram illustrating a film forming method according to an embodiment.

FIG. 2 is a perspective view of an aluminum bar and a front view of a base material showing a contact relationship.

FIG. 3 is an enlarged cross-sectional view of the vicinity where a shoe is located.

4 (a) to 4 (c) are explanatory views until an aluminum rod is formed.

FIG. 5 is a sectional view of a variable displacement type swash plate type compressor.

[Explanation of symbols]

11: swash plate compressor as compressor, 22: swash plate, 4
2, 43: film, 44: base material, 45: aluminum rod as welding material.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Takashi Yoshida 2-1-1 Toyota-cho, Kariya-shi, Aichi Pref. Inside the Toyota Industries Corporation (72) Inventor Naohiko Isomura 2-1-1 Toyota-cho, Kariya-shi, Aichi Pref. Inside the Toyota Industries Corporation (72) Inventor Kazuaki Iwama 2-1-1 Toyota-machi, Kariya City, Aichi Prefecture F-term in the Toyota Industries Corporation (Reference) 3H076 AA06 BB26 CC20 CC34 4K044 AA04 AB10 BA10 BB01 BC01

Claims (4)

[Claims] 1. A method for forming a metal film on a surface of a base material by friction welding a welding material formed by casting, wherein a black scale formed on an outer surface when the welding material is cast. A method for forming a metal film, wherein the welding material is friction-welded to the surface of the substrate while leaving the material. 2. The method according to claim 1, wherein the welding material is formed by a continuous casting method. 3. The method according to claim 1, wherein the welding material is an aluminum-based material. 4. The swash plate for a compressor, wherein the base material is formed on a surface of the swash plate.
The method for forming a metal film according to any one of the above.