The present invention relates to a method for diffusing and permeating a creep reinforcement material into a heat-resistant metal member, and to a heat-resistant metal member with creep strength enhanced by such a method.
Hitherto, as a method for enhancing creep properties of a heat-resistant metal material, a method has been developed in which, for example, a grain boundary strengthening element that affects creep strength and/or fatigue strength is coated or thermally sprayed to form a film, and heated for a specific duration at a specific temperature (see Japanese Patent No.
An object of the present invention is to provide a method capable of efficiently diffusing and permeating a material that enhances creep strength (hereinafter referred to as a "creep reinforcement material") into a member manufactured using a heat-resistant metal material (hereinafter referred to as a "heat-resistant metal member"), and to provide a heat-resistant metal member with creep strength enhanced by such a method.
In order to address the above problem, according to the present invention, a method for diffusing and permeating a creep reinforcement material into a heat-resistant metal member, and a heat-resistant metal member with creep strength enhanced by such a method, as claimed in claims 1 and 3.
The present invention enables provision of a method capable of efficiently diffusing and permeating a creep reinforcement material into a heat-resistant metal member, and provision of a heat-resistant metal member with creep strength enhanced by such a method.
Detailed explanation follows regarding preferable embodiments of the present invention, with reference to the appended drawings. Note that the objects, features, advantages of the present invention will be clear to a person of ordinary skill in the art from the content of the present specification, and a person of ordinary skill in the art would easily be able to reproduce the present invention from the present specification. The following embodiments, drawings, and the like of the present invention illustrate preferable embodiments of the present invention, and are there to give examples and for the purpose of explanation; however, the present invention is not limited thereto. It will be obvious to a person of ordinary skill in the art that various modifications may be implemented based on the content of the present specification within the scope of the present invention disclosed in the present specification.
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As mentioned above, the heat-resistant metal member 10 coated or thermally sprayed with the creep reinforcement material is covered by the heat-resistant covering member 30 and is heated to a temperature of 1000°C or greater, and thus compressive force acts on the heat-resistant metal member as it thermally expands in a direction toward an outer periphery, restraining thermal expansion of the heat-resistant metal member in the direction toward the outer periphery, and enabling the creep reinforcement material on the surface of the heat-resistant metal member 10 to be efficiently diffused and permeated into the heat-resistant metal member 10. Thus, in cases in which the heat-resistant metal member 10 is a degraded member or an already installed member, by utilizing the force from thermal expansion in the direction toward the outer periphery of the heat-resistant metal member 10, creep voids and cracks in the heat-resistant metal member 10 and a weld 20 thereof are efficiently repaired, enabling regeneration of the heat-resistant metal member 10 and the weld 20 thereof to be achieved. Moreover, structural strengthening of the heat-resistant metal member 10 and the weld 20 thereof can be achieved accompanying restoration of the structure of the heat-resistant metal member 10 and the weld 20 thereof. The creep strength is accordingly enhanced, enabling the lifespan to be extended to that of a new member or greater. On the other hand, in cases in which the heat-resistant metal member 10 is an unused member, structural strengthening of the heat-resistant metal member 10 and the weld 20 thereof can be achieved, thereby enhancing the creep strength and enabling the lifespan to be extended to that of a new member or greater.
In the method for diffusing and permeating a creep reinforcement material into the heat-resistant metal member 10 according to the present invention, etching treatment, or shot peening and etching treatment, may be performed on the section 25 to be coated or thermally sprayed with the creep reinforcement material prior to coating or thermally spraying the creep reinforcement material on the surface of the heat-resistant metal member 10. Such processing enables work hardening of the surface layer of the heat-resistant metal member 10 to be performed by plastic deformation, enables residual compressive stress to be imparted to the surface of the heat-resistant metal member 10, and enables any oxidized film on the surface of the heat-resistant metal member 10 to be removed.
In the method for diffusing and permeating a creep reinforcement material into the heat-resistant metal member 10 according to the present invention, processing to remove (reduce) residual stress, such as stress relief or tension annealing processing, may be performed after the heat-resistant metal member 10 covered by the heat-resistant covering member 30 has been heated to a temperature of 1000°C or greater using the heater 40. More specifically, after the heat-resistant metal member 10 covered by the heat-resistant covering member 30 has been heated to a temperature of 1000°C or greater using the heater 40, the heat-resistant metal member 10 may be first cooled to room temperature, then reheated to a temperature of an A1 transformation point or greater (preferably from 10°C to 100°C above 1000°C) for a specific duration (for example, from approximately several hours to approximately 24 hours).
Moreover, in the method to diffuse and permeate a creep reinforcement material into the heat-resistant metal member 10 according to the present invention, in order to restrict thermal expansion of the heat-resistant metal member 10 toward the outside in the length direction thereof (in directions toward the ends of the heat-resistant metal member 10) occurring when the heat-resistant metal member 10, which has been coated or thermally sprayed with the creep reinforcement material, is covered by the heat-resistant covering member 30 and heated by the heater 40, the heat-resistant metal member 10 may be secured in sections not being heated by the heater 40, by, for example, two clamps so as to sandwich the section being heated by the heater 40.
In cases in which the section heated by the heater 40 is small compared to the overall heat-resistant metal member 10, there is no need to secure the heat-resistant metal member 10 in sections not being heated by the heater 40 with clamps or the like, since thermal expansion toward the outside in the length direction of the heat-resistant metal member 10 in the section being heated by the heater 40 is restricted by the sections not being heated by the heater 40.
According to the invention the heat-resistant metal of the member 10 is made of 0.3Mo steel, 0.5Mo steel, 0.5Cr-0.5Mo steel, 1Cr-0.2Mo steel, 1Cr-0.5Mo steel, 1.25Cr-0.5Mo steel, 2.25Cr-1Mo steel, 5Cr-0.5Mo steel, 7Cr-0.5Mo steel, 9Cr-1Mo steel, 0.3Cr-Mo-V steel, 0.5Cr-Mo-V steel, 9Cr-Mo-V steel, 12Cr-Mo-V steel, 1Cr-1.25Mo-0.25V steel, 9Cr-1Mo-W steel, SUS304, SUS304L, SUS316, SUS316L, SUS316TI, SUS317, SUS321, SUS347H, SUS310S, Super304, SUS904L, NCF600, NCF601, NCF800, and NCF800H.
The creep reinforcement material needs to contain an element which has a melting point of 1000°C or greater and in which precipitation strengthening and solid solution strengthening occur upon heating to a temperature of 1000°C or greater so as to enable creep strength to be enhanced. According to the invention, the heat-resistant metal member 10, the creep reinforcement material contains one or a plurality of elements appropriately selected from B (boron), W (tungsten), Cr (Chromium), Mo (molybdenum), Nb (niobium), V (vanadium), Hf (hafnium), Zr (zirconium), Ti (titanium), Cu (copper), and Co (cobalt). In cases in which the creep reinforcement material is coated on the surface of the heat-resistant metal member 10, powdered creep reinforcement material may be employed as it is, or a coating agent of the creep reinforcement material in a liquid form or paste form using a binder, solvent, adhesive or the like may be employed. In cases in which the creep reinforcement material is thermally sprayed on the surface of the heat-resistant metal member 10, for example, a known thermal spray method may be appropriately employed, such as a plasma spraying method using powdered creep reinforcement material. Note that coating or thermally spraying of the creep reinforcement material on the surface of the heat-resistant metal member 10 may be performed over the entire outer peripheral surface of the heat-resistant metal member 10 as in the present embodiment, or may be performed on a part of the surface of the heat-resistant metal member 10.
The heat-resistant covering member 30 needs to be capable of covering the section 25 coated or thermally sprayed with the creep reinforcement material so as to make contact with the section 25, as long as it is made from a heat-resistant material that restrains thermal expansion in the section 25 in the direction toward the outer periphery of the heat-resistant metal member 10 occurring when heated to the heating temperature mentioned above, and is able to maintain the approximate profile of the heat-resistant metal member 10 at the section 25. A material having a lower thermal expansion coefficient than the heat-resistant metal member 10 at temperatures of the heating temperature mentioned above or greater is preferably employed for the heat-resistant covering member 30. In cases in which the heat-resistant covering member 30 is configured from a heat-resistant material different from that of the heat-resistant metal member 10, yet having a thermal expansion coefficient of about the same as the heat-resistant metal member 10, or from a heat resistant material having a higher thermal expansion coefficient than the heat-resistant metal member 10, in order to restrain the thermal expansion of the heat-resistant covering member 30 occurring when heated to the heating temperature mentioned above, the outer periphery of the heat-resistant covering member 30 may be secured by a member of a heat-resistant material having a lower thermal expansion coefficient than the heat-resistant metal member 10 at or above the heating temperature mentioned above, so as to maintain the profile of the heat-resistant covering member 30.
According to the invention, the heat-resistant covering member 30 being a ceramic or an alloy, including ceramics such as alumina, zirconia, aluminum nitride, silicon carbide, silicon nitride, cordierite, sialon, zircon, and mullite, and alloys such as Alloy 903, Alloy 909, and HRA 929.
The heat-resistant covering member 30 is, for example, of a cord, plate, or clamp shape. Securing of the above may be performed by, for example, wrapping a cord-shaped or plate-shaped heat-resistant covering member 30 around the outer periphery of the heat-resistant metal member 10 at the section 25 coated or thermally sprayed with the creep reinforcement material, by attaching a clamp-shaped heat-resistant covering member 30 to the outer periphery of the heat-resistant metal member 10 at the section 25 coated or thermally sprayed with the creep reinforcement material, or by attaching a heat-resistant covering member 30 formed in a plate shape or the like to the outer periphery of a heat-resistant metal member 10 at the section 25 coated or thermally sprayed with the creep reinforcement material using fasteners, such as clamps or screws. In the present embodiment, the heat-resistant covering member 30 is made from fittings including two substantially semi-circular arc cross-section shapes. The heat-resistant covering member 30 is then secured to the surface of the heat-resistant metal member 10 using threaded members 35 attached to flanges of these fittings, such that the inner face of the fittings contact the outer periphery of the heat-resistant metal member 10 at the section 25 coated or thermally sprayed with the creep reinforcement material. The threaded members 35 are manufactured, for example, from the same material as the heat-resistant covering member 30.
The heating temperature of the heat-resistant metal member 10 coated or thermally sprayed with the creep reinforcement material is a temperature of 1000°C or greater. Preferably the heat-resistant metal member 10 is heated at a temperature of, or greater than, an A3 transformation point of the component of the heat-resistant metal material of the member 10 or the creep reinforcement material having the highest A3 transformation point (preferably from 10°C to 100°C above 1000°C) for a specific duration (for example, from approximately several hours to approximately 24 hours) . Note that although the present embodiment employs, as a heating device, the high frequency heater 40, which is capable of heating the heat-resistant metal member 10 coated or thermally sprayed with the creep reinforcement material, from the outer periphery thereof, there is no particular limitation thereto, as long as a heating device capable of heating the heat-resistant metal member 10 at the section 25 coated or thermally sprayed with the creep reinforcement material.
The product of diffusing and permeating the creep reinforcement material into the heat-resistant metal member 10 by the method described above is useful as a heat-resistant metal member with enhanced creep strength due to the creep strength being enhanced as described above.
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.