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US4632074A
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Wear-resistant member for use in internal combustion engine and method for producing the same
Assignee: Nippon Piston Ring Co Ltd
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Filing: 1985-09-30
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Granted: 1986-12-30
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Expires: 2005-09-30
Abstract
Abstract A wear-resistant member and method for producing the same which member may form a movable member in an internal combustion engine which is subjected to high pressure such as a rocker arm, tappet, cam, valve or valve seat. The member is formed as a combination of a ferrous sintered body and a ferrous base body having a common surface. The sintered body is formed from a compressed powder body disposed in contact with the ferrous base body. The powder body, in a preferred embodiment, consists of 0.5 to 7.0% by weight carbon, 0.1 to 5.0% phosphorus, the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ. The combined powder body and ferrous base body are heated to a temperature higher than the liquid-phase temperature of the powder body but lower than the melting point of the ferrous body to sinter the powder body.
Inventors
- 👤 Kentaro Takahashi
- 👤 Takeshi Hiraoka
- 👤 Yoshikatsu Nakamura
- 👤 Masajiro Takeshita
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 18:13
CPC Classifications
F; F01; F01L; F01L3/00; B; B22; B22F; B22F7/00; B22F7/06; B22F7/062; C; C22; C22C; C22C33/00; C22C33/02; C22C33/0257; C22C33/0278; C22C33/0285; F01L1/00; F01L1/12; F01L1/14; F01L1/16; B22F2998/00; F01L2301/00; F05; F05C; F05C2203/00; F05C2203/04; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12028; Y10T428/12063; Y10T428/12139; Y10T74/00; Y10T74/20; Y10T74/20576; Y10T74/20882
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
265 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 7.0% by weight carbon, 0.1 to 5.0% by weight phosphorus, 8.0 to 30.0% by weight chromium, not more than 10% by weight of at least one material selected from the group consisting of nickel, copper, cobalt, tungsten and molybdenum, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing diffusion elements of said compressed powder body into said ferrous base body.
Claim 2
Independent Claim
265 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 7.0% by weight carbon, 0.1 to 5.0% by weight phosphorus, 8.0 to 30.0% by weight chromium, not more than 10% by weight of at least one material selected from the group consisting of nickel, copper, cobalt, tungsten and molybdenum, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing diffusion elements of said compressed powder body into said ferrous base body.
Claim 3
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 1, wherein said combination member is heated to a temperature of not more than 1250° C. in a sintering furnace.
Claim 4
Independent Claim
248 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 4.0% by weight carbon, 0.2 to 3.0% by weight phosphorus, 10.0 to 20.0% by weight chromium, 0.1 to 2.0 by weight tungsten, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing diffusion elements of said compressed powder body into said ferrous base body.
Claim 5
Independent Claim
248 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 4.0% by weight carbon, 0.2 to 3.0% by weight phosphorus, 10.0 to 20.0% by weight chromium, 0.1 to 2.0 by weight tungsten, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing diffusion elements of said compressed powder body into said ferrous base body.
Claim 6
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 3, wherein said combination member is heated to a temperature of not more than 1250° C. in a sintering furnace.
Claim 7
Independent Claim
280 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 4.0% by weight carbon, 0.2 to 3.0% by weight phosphorus, 10.0 to 20.0% by weight chromium, 0.1 to 2.0% by weight tungsten, at least one material selected from the group consisting of nickel, copper and cobalt, the amount of said at least one material plus said tungsten being not more than 10% by weight, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing diffusion elements of said compressed powder body into said ferrous base body.
Claim 8
Independent Claim
280 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 4.0% by weight carbon, 0.2 to 3.0% by weight phosphorus, 10.0 to 20.0% by weight chromium, 0.1 to 2.0% by weight tungsten, at least one material selected from the group consisting of nickel, copper and cobalt, the amount of said at least one material plus said tungsten being not more than 10% by weight, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing diffusion elements of said compressed powder body into said ferrous base body.
Claim 9
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 5, wherein said combination member is heated to a temperature of not more than 1250° C. in a sintering furnace.
Claim 10
Independent Claim
244 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of at least one powder selected from ferrous alloy powder or iron powder containing 0.5 to 7.0% by weight carbon and 0.1 to 5.0% by weight phosphorus, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing elements of said compressed powder body into said ferrous base body.
Claim 11
Independent Claim
244 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of at least one powder selected from ferrous alloy powder or iron powder containing 0.5 to 7.0% by weight carbon and 0.1 to 5.0% by weight phosphorus, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing elements of said compressed powder body into said ferrous base body.
Claim 12
Dependent Claim
34 words
A method for producing a wear-resistant member as defined in claim 7 wherein said ferrous base body has a surface roughness of 20μ or less and wherein said compressed powder body is liquid-phase sintered.
Claim 13
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 7 further comprising the step of disposing a flux layer between said compressed powder body and said ferrous base body.
Claim 14
Dependent Claim
47 words
A method for producing a wear-resistant member as defined in claim 7 further comprising the step of disposing a flux layer between said compressed powder body and said ferrous base body, the material of said flux layer being selected from the group consisting of boron and phosphorus.
Claim 15
Dependent Claim
34 words
A method for producing a wear-resistant member as defined in claim 7 wherein interfacing surfaces of said compressed powder body and said ferrous base body are provided with a mating groove and projection, respectively.
Claim 16
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 7 wherein flanges are provided on said ferrous base body and said compressed powder body is disposed between said flanges.
Claim 17
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 7, wherein said combination member is heated to a temperature of not more than 1250° C. in a sintering furnace.
Claim 18
Independent Claim
263 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 7.0% by weight carbon, 0.1 to 5.0% by weight phosphorus, 8.0 to 30.0% by weight chromium, not more than 10% by weight of at least one material selected from the group consisting of nickel, copper, cobalt and tungsten, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing elements of said compressed powder body into said ferrous base body.
Claim 19
Independent Claim
263 words
A method for producing a wear-resistant member formed of a combination of a ferrous sintered body and a ferrous base body for use in an internal combustion engine comprising the steps of: (a) compressing a ferrous powder mixture to provide a compressed powder body, said compressed body consisting of 0.5 to 7.0% by weight carbon, 0.1 to 5.0% by weight phosphorus, 8.0 to 30.0% by weight chromium, not more than 10% by weight of at least one material selected from the group consisting of nickel, copper, cobalt and tungsten, and the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300μ, (b) mounting said compressed powder body on said ferrous base body to provide a combination member, said ferrous base body having a melting point higher than that of said compressed powder body, (c) placing said combination member in a sintering furnace and heating said combination member to a temperature higher than the liquid-phase temperature of said compressed powder body and lower than the melting point of said ferrous base body so as to thus perform sintering of said compressed powder body, (d) continuously cooling said combination member to thereby produce a ferrous sintered body having a porosity of 0.2 to 10% by volume, at least 40% of which is sintering pores having a pore size of not more than 250μ, said sintered body being bonded to said ferrous base body by diffusing elements of said compressed powder body into said ferrous base body.
Claim 20
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 14, wherein said combination member is heated to a temperature of not more than 1250° C. in a sintering furnace.
Claim 21
Dependent Claim
34 words
A method for producing a wear-resistant member as defined in claim 14, wherein said ferrous base body has a surface roughness of 20μ or less and wherein said compressed powder body is liquid-phase sintered.
Claim 22
Dependent Claim
30 words
A method for producing a wear-resistant member as defined in claim 14 further comprising the step of disposing a flux layer between said compressed powder body and said ferrous body.
Claim 23
Dependent Claim
47 words
A method for producing a wear-resistant member as defined in claim 14 further comprising the step of disposing a flux layer between said compressed powder body and said ferrous base body, the material of said flux layer being selected from the group consisting of boron and phosphorus.
Claim 24
Dependent Claim
34 words
A method for producing a wear-resistant member as defined in claim 14, wherein interfacing surfaces of said compressed powder body and said ferrous base body are provided with a mating groove and projection, respectively.
Claim 25
Dependent Claim
31 words
A method for producing a wear-resistant member as defined in claim 14, wherein flanges are provided on said ferrous base body and said compressed powder body is disposed between said flanges.
Claim 26
Independent Claim
41 words
A method for producing a wear-resistant member as defined in any of claims 3, 5, 7, 8, or 14 wherein interfacing surfaces of said compressed powder body and said ferrous base body are provided with a mating projection and groove, respectively.
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| 3.5 Years (Year 4) | 1989-12-29 | 1990-06-30 | 1990-12-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-12-29 | 1994-06-30 | 1994-12-30 | $3760.00 | Window Closed / Lapsed |
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