Development of fabrication process of hard porous carbon materials RB ceramics using injection molding and their application to tribo-elements

本研究的目的是开发一种新的RB陶瓷的注射成型工艺，并将其应用于摩擦元件。研制了一种新型的注射成型RB陶瓷，并于2003年对其碳化减径率和力学性能进行了研究。制备RB陶瓷的新工艺有：采用注射成型方法对RB陶瓷与苯酚树脂的混合物进行成型，然后在900℃的氮气中进行炭化，制备出新型RB陶瓷。结果表明，新研制的RB陶瓷的尺寸减小率小于5%，是常规压制成型RB陶瓷（25%）的五分之一。结果表明，新制备的RB陶瓷的杨氏模量为15GPa，抗压强度为270MPa，比常规RB陶瓷的抗压强度提高了约4.5倍。2004年，研究了新开发的RB陶瓷在干润滑和油润滑条件下与氧化铝、轴承钢球和奥氏体不锈钢摩擦的摩擦学性能。结果表明，新开发的RB陶瓷在干润滑和油润滑条件下均表现出优异的摩擦学性能。因此，新开发的注射成型RB陶瓷有望在滑动轴承材料中得到实际应用。研究了温度对新开发的RB陶瓷摩擦学性能的影响。结果表明，新开发的RB陶瓷在高温干燥条件下具有优异的摩擦学性能。因此，新开发的RB陶瓷有望在干式离合器片材料中得到实际应用。

The Purpose of this study is to develop new fabrication process of RB ceramics by using injection molding, and to apply them to tribo-elements.New RB ceramics fabricated by using injection molding have been developed, and their size reduction rate during carbonization and mechanical properties were clarified in 2003. The new fabrication process of RB ceramics were as follows ; The form of the mixture of RB ceramics and phenol resin was molded by injection molding, and then the new RB ceramics were fabricated by carbonizing the form in nitrogen gas at 900 ℃. It was clarified that the size reduction rate of the newly developed RB ceramics was less than 5% which was one-fifth of that of conventional RB ceramics (25%) made by using press molding. Then, it was also clarified that young's modulus of the newly developed RB ceramics was 15GPa, and the compressive strength was 270MPa which was about 4.5 times higher than that of the conventional RB ceramics.Tribological properties of the newly developed RB ceramics sliding against alumina, bearing steel ball and austenitic stainless steel under dry and oil lubricated conditions were clarified in 2004. As a result, it was clarified that a newly developed RB ceramics showed superior tribological properties under dry and oil lubricated conditions. Therefore, the newly developed RB ceramics fabricated by using injection molding are expected to be practically applied to the materials of sliding bearing.The effect of temperature on tribological properties of the newly developed RB ceramics was clarified in 2005. As a result, it was clarified that the newly developed RB ceramics showed superior tribological properties under dry condition at high temperature. Therefore, the newly developed RB ceramics are expected to be practically applied to the materials of the dry type clutch plates.