Method for manufacturing Fe-based sintered alloy member having excellent dimensional accuracy, strength and sliding performance

Abstract

In a method of manufacturing an Fe-based sintered alloy member having excellent dimensional accuracy, strength, and sliding performance, and having a composition comprising: Cu: 0.5 to 7 wt %; C: 0.1 to 0.98 wt %; oxygen: 0.02 to 0.3 wt %; as needed, Mn: 0.0025 to 1.05 wt % and/or Zn: 0.001 to 0.7 wt %; and a balance of Fe and inevitable impurities by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture, in which the Cu alloy powder blended as the base powder has a composition comprising: Fe: 1 to 10 wt %; oxygen: 0.2 to 1 wt %; as needed, Zn: 0.2 to 10 wt % and/or Mn: 0.5 to 15 wt %; and a balance of Cu and inevitable impurities.

1 . A method of manufacturing an Fe-based sintered alloy member, comprising: 
 producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising:    Fe: 1 to 10 wt %;    oxygen: 0.2 to 1 wt %; and    a balance of Cu and inevitable impurities.    
   
   
       2 . A method of manufacturing an Fe-based sintered alloy member comprising: 
 producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %;    Mn: 0.0025 to 1.05 wt %; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising one or two among 1 to 10 wt % of Fe, 0.2 to 1 wt % of oxygen, and 0.5 to 15 wt % of Mn; and a balance of Cu and inevitable impurities.    
   
   
       3 . A method of manufacturing an Fe-based sintered alloy member comprising: 
 producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %;    Zn: 0.001 to 0.7 wt %; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising:    Fe: 1 to 10 wt %;    oxygen: 0.2 to 1 wt %;    Zn: 0.2 to 10 wt %; and    a balance of Cu and inevitable impurities.    
   
   
       4 . A method of manufacturing an Fe-based sintered alloy member comprising: 
 producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %;    Mn: 0.0025 to 1.05 wt %;    Zn: 0.001 to 0.7 wt %; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising:    Fe: 1 to 10 wt %;    oxygen: 0.2 to 1 wt %;    Zn: 0.2 to 10 wt %;    Mn: 0.5 to 15 wt %; and    a balance of Cu and inevitable impurities.    
   
   
       5 . A method of manufacturing an Fe-based sintered alloy member comprising: 
 producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %;    one or both of Al and Si: 0.001 to 0.14 wt % in total; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising:    Fe: 1 to 10 wt %;    oxygen: 0.2 to 1 wt %;    one or both of Al and Si: 0.01 to 2 wt % in total; and    a balance of Cu and inevitable impurities.    
   
   
       6 . A method of manufacturing an Fe-based sintered alloy member having excellent dimensional accuracy, strength, and sliding performance, and comprising: 
 producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %;    Mn: 0.0025 to 1.05 wt %;    one or both of Al and Si: 0.001 to 0.14 wt % in total; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising:    one or two among 1 to 10 wt % of Fe, 0.2 to 1 wt % of oxygen and 0.5 to 15 wt % of Mn;    one or both of Al and Si: 0.01 to 2 wt % in total; and    a balance of Cu and inevitable impurities.    
   
   
       7 . A method of manufacturing an Fe-based sintered alloy member comprising: 
 producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %;    Zn: 0.001 to 0.7 wt %;    one or both of Al and Si: 0.001 to 0.14 wt % in total; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising:    Fe: 1 to 10 wt %;    oxygen: 0.2 to 1 wt %;    Zn: 0.2 to 10 wt %;    one or both of Al and Si: 0.01 to 2 wt % in total; and    a balance of Cu and inevitable impurities.    
   
   
       8 . A method of manufacturing an Fe-based sintered alloy member comprising: 
 Producing said Fe-based sintered alloy member having a composition comprising:    Cu: 0.5 to 7 wt %;    C: 0.1 to 0.98 wt %;    oxygen: 0.02 to 0.3 wt %;    Mn: 0.0025 to 1.05 wt %;    Zn: 0.001 to 0.7 wt %;    one or both of Al and Si: 0.001 to 0.14 wt % in total; and    a balance of Fe and inevitable impurities, by blending and mixing an Fe powder, a graphite powder, and a Cu alloy powder as a base powder and by forming and sintering the resultant mixture,    wherein the Cu alloy powder blended as the base powder has a composition comprising:    Fe: 1 to 10 wt %;    oxygen: 0.2 to 1 wt %;    Zn: 0.2 to 10 wt %;    Mn: 0.5 to 15 wt %;    one or both of Al and Si: 0.01 to 2 wt % in total; and    a balance of Cu and inevitable impurities.    
   
   
       9 . The method of manufacturing an Fe-based sintered alloy member according to  claim 1 , 
 wherein a blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows:    the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.    
   
   
       10 . The method of manufacturing an Fe-based sintered alloy member according to  claim 2 , wherein the blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows: 
 the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.    
   
   
       11 . The method of manufacturing an Fe-based sintered alloy member according to  claim 3 , wherein the blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows: 
 the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.    
   
   
       12 . The method of manufacturing an Fe-based sintered alloy member according to  claim 4 , wherein the blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows: 
 the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.    
   
   
       13 . The method of manufacturing an Fe-based sintered alloy member according to  claim 5 , wherein the blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows: 
 the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.    
   
   
       14 . The method of manufacturing an Fe-based sintered alloy member according to  claim 6 , wherein the blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows: 
 the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.    
   
   
       15 . The method of manufacturing an Fe-based sintered alloy member according to  claim 7 , wherein the blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows: 
 the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.    
   
   
       16 . The method of manufacturing an Fe-based sintered alloy member according to  claim 8 , wherein the blending ratio of the Fe powder, the graphite powder and the Cu alloy powder is as follows: 
 the graphite powder: 0.1 to 1.2 wt %;    the Cu alloy powder: 1 to 7 wt %; and    the Fe powder: the balance.