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WO2018159091A1 - スチール製燃料圧送配管の製造方法 - Google Patents

スチール製燃料圧送配管の製造方法 Download PDF

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Publication number
WO2018159091A1
WO2018159091A1 PCT/JP2017/046980 JP2017046980W WO2018159091A1 WO 2018159091 A1 WO2018159091 A1 WO 2018159091A1 JP 2017046980 W JP2017046980 W JP 2017046980W WO 2018159091 A1 WO2018159091 A1 WO 2018159091A1
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WIPO (PCT)
Prior art keywords
pipe
pipe material
inner peripheral
peripheral surface
steel
Prior art date
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Ceased
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PCT/JP2017/046980
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English (en)
French (fr)
Inventor
剛人 池ノ谷
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Usui Co Ltd
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Usui Co Ltd
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Publication date
Application filed by Usui Co Ltd filed Critical Usui Co Ltd
Priority to EP17898798.8A priority Critical patent/EP3591213A4/en
Priority to CN201780084755.6A priority patent/CN110226032A/zh
Priority to RU2019130046A priority patent/RU2727419C1/ru
Priority to MX2019010024A priority patent/MX2019010024A/es
Priority to KR1020217011723A priority patent/KR102484816B1/ko
Priority to BR112019016757A priority patent/BR112019016757A2/pt
Priority to US16/485,787 priority patent/US20200047296A1/en
Priority to KR1020197028555A priority patent/KR20190121835A/ko
Publication of WO2018159091A1 publication Critical patent/WO2018159091A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
    • F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
    • F02M61/168—Assembling; Disassembling; Manufacturing; Adjusting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/1601—Process or apparatus
    • C23C18/1603—Process or apparatus coating on selected surface areas
    • C23C18/1614—Process or apparatus coating on selected surface areas plating on one side
    • C23C18/1616—Process or apparatus coating on selected surface areas plating on one side interior or inner surface
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/31—Coating with metals
    • C23C18/32—Coating with nickel, cobalt or mixtures thereof with phosphorus or boron
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M55/00—Fuel-injection apparatus characterised by their fuel conduits or their venting means; Arrangements of conduits between fuel tank and pump F02M37/00
    • F02M55/02—Conduits between injection pumps and injectors, e.g. conduits between pump and common-rail or conduits between common-rail and injectors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C1/00—Manufacture of metal sheets, wire, rods, tubes or like semi-manufactured products by drawing
    • B21C1/16—Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes
    • B21C1/22—Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes specially adapted for making tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/16—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass plates with holes of very small diameter, e.g. for spinning or burner nozzles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B3/00—Engines characterised by air compression and subsequent fuel addition
    • F02B3/06—Engines characterised by air compression and subsequent fuel addition with compression ignition
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
    • F02M2200/05—Fuel-injection apparatus having means for preventing corrosion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/02—Rigid pipes of metal

Definitions

  • the present invention relates to a method of manufacturing a pipe for supplying fuel to an engine in a gasoline direct injection engine system or a diesel engine system. For example, an inner surface treatment is performed by removing fine cracks and wrinkles generated on an inner surface by, for example, a drawing process.
  • the present invention relates to a method for producing a high-quality steel fuel pumping pipe excellent in corrosion resistance.
  • Patent Document 1 a fuel pumping pipe that employs a steel pipe such as low carbon steel, which is cheaper than the above-described stainless pipe, has been proposed (see Patent Document 1).
  • This steel fuel pumping pipe has been subjected to inner surface treatment and / or outer surface treatment excellent in resistance to corrosive fuel, in particular, in order to obtain high resistance to corrosive fuel.
  • a Ni plating layer is formed on the surface, and a rust preventive film layer made of a Zn plating layer or a Zn-based alloy plating layer is further provided on the Ni plating layer.
  • a Zn plating layer or a Zn-based alloy plating layer is formed on the outer surface of the steel pipe. Are formed.
  • the above-described steel fuel pressure delivery pipe has the following problems. That is, when using, for example, a drawn drawn pipe material for the steel fuel pumping pipe described above, there are initial defects (such as fine cracks and wrinkles) generated during drawing and drawing on the inner peripheral surface of the pipe. Has an initial flaw (welding defect portion or the like) generated due to poor welding or the like on the inner peripheral surface of the pipe.
  • the above-mentioned inner surface treatment for example, Ni plating
  • the plating solution does not penetrate into the inside of the part, and micro cracks, wrinkles, and parts of the weld defect are not subjected to surface treatment completely, resulting in defects, and in particular, resistance to corrosive fuel cannot be obtained and corrosion and rust are generated. There is a problem of being forced.
  • the present invention has been made in view of the above-described problems of the prior art.
  • steel piping for supplying fuel to an engine in a gasoline direct injection engine system or a diesel engine system an initial soot (fine fineness) generated on the inner peripheral surface of the pipe is provided.
  • the present invention intends to propose a method for manufacturing a high-quality steel fuel feed pipe having no resistance to cracking, wrinkles and weld defects and having high resistance to corrosive fuel.
  • a method for manufacturing a steel fuel pumping pipe according to the present invention is a method for manufacturing a steel fuel pumping pipe having a rust-proof coating layer on the inner peripheral surface of a steel pipe material, Pipes with initial wrinkles (fine cracks, wrinkles, weld defects, etc.) exceeding a preset threshold and pipes that do not exceed the same threshold are selected, and initial wrinkles on the inner peripheral surface of the pipe that does not exceed the threshold are mechanically cut. After the removal, the inner peripheral surface of the pipe material is subjected to a surface treatment (for example, Ni plating). Note that the pipe material exceeding the threshold is treated as a defective product.
  • a surface treatment for example, Ni plating
  • the maximum flaw depth assumed using a statistical method may be calculated, and the maximum flaw depth may be used as the threshold value.
  • the method by the mechanical cutting used as a method of removing the initial wrinkles (fine cracks, wrinkles, weld defects, etc.) on the pipe inner peripheral surface of the pipe material is preferably a method using a gun drilling machine used for deep hole machining. Is.
  • an ultrasonic flaw detection method is a preferred embodiment.
  • the method for manufacturing a steel fuel pressure delivery pipe of the present invention detection of initial defects (fine cracks, wrinkles, weld defects, etc.) of pipe inner peripheral surfaces of drawn pipes, semi-seamless pipes, welded pipes, etc. Or by predicting and removing the inner peripheral surface of the pipe material whose detected value does not exceed a predetermined threshold value by mechanical cutting, the initial wrinkles are completely removed and the smoothness of the inner peripheral surface of the pipe is increased.
  • the corrosion resistance of the surface treatment of the inner peripheral surface of the pipe is improved, and an excellent effect is obtained in that a high-quality steel fuel pumping pipe having high resistance to corrosive fuel is obtained.
  • FIG. 2 is a schematic diagram showing a gun drill processing machine used in an initial soot removal process of pipe material in the steel fuel pressure feed pipe manufacturing process shown in FIG. 1.
  • an example of the production process is as follows. First, a pipe material that is a pipe base material is produced in a pipe production process 1 as a pipe to be processed.
  • the pipe material manufacturing process 1 include a drawing and drawing pipe process, a welded pipe manufacturing process, and the like.
  • the pipe material manufactured in the pipe material manufacturing process 1 for example, low carbon steel and alloy steel such as carbon steel pipe STKM material, SCM material, STK material, and STS material for mechanical structure are used, and the outer diameter is 10 to 30 mm and the inner diameter is 5 to 20 mm. Steel pipe material.
  • the tube inner peripheral surface of the tube is detected by a flaw detector to detect initial defects (fine cracks, wrinkles, weld defects, etc.).
  • the pipe material sorting step 3 the pipe material having the detection value detected in the flaw detection step exceeds a predetermined threshold value, and the pipe material does not exceed the threshold value.
  • the threshold value of initial wrinkles fine cracks, wrinkles, weld defects, etc.
  • the reference value is set to a depth of 150 ⁇ m, for example, and pipe materials that exceed this threshold value are treated as defective, and pipe materials that do not exceed the threshold value. It sends to the next initial soot removal process 4.
  • the threshold is determined based on the type of pipe material, inner diameter, wall thickness, fine cracks and wrinkles, the size of a weld defect, and the like.
  • the initial wrinkles are removed by mechanically cutting the inner peripheral surface of the pipe material that does not exceed the threshold with a size equal to or larger than the threshold.
  • the mechanical drilling method used as a method for removing initial wrinkles (fine cracks, wrinkles, weld defects, etc.) on the pipe inner peripheral surface of the pipe material that does not exceed this threshold is a gun drilling machine used for deep hole machining shown in FIG.
  • the method according to 7 is used.
  • the gun drilling machine 7 used for the deep hole machining cuts the cutting tool 7-2 attached to the main body 7-1 by rotating the cutting tool 7-2 while pushing it into a tube fixed to a jig (not shown). It is a method. Since this processing is a so-called gun drill, which uses a tool that emphasizes the straightness of the hole, the gun drill processing machine 7 used for deep hole processing is suitable as a means for removing initial wrinkles on the inner peripheral surface of the pipe material. .
  • the pipe material that does not exceed the threshold value removed by the gun drilling machine 7 that uses the initial wrinkle on the inner peripheral surface of the pipe for deep hole machining in the initial wrinkle removal process 4 is then subjected to Ni plating or the like on the inner surface of the pipe material in the surface treatment process 5.
  • Surface treatment is applied. At that time, the surface treatment is performed along the inner surface of the pipe material.
  • the inner surface has fine cracks and wrinkles. Since there are no defects or weld defects, there is no portion where the plating solution does not adhere, and the entire inner surface is reliably subjected to surface treatment.
  • steel drawn drawn pipe materials (test Nos. 1 to 6) having an outer diameter of 15.6 mm and an inner diameter of 9.8 mm manufactured by a drawing and drawing apparatus are used as pipe base materials.
  • the flaw detection process 2 after detecting the initial flaws (fine cracks, wrinkles, weld defects, etc.) by flaw-detecting the pipe inner peripheral surface of the drawn drawn pipe material with a flaw detector, in the drawn drawn pipe material selecting step 3, the flaw detection
  • Each of the drawn tube materials whose detected value detected in step 2 exceeds a preset threshold value (150 ⁇ m) and a drawn tube material that does not exceed the threshold value are selected, and each threshold value does not exceed the threshold value in the next initial wrinkle removing step 4
  • the inner peripheral surface of the drawn drawn tube material was cut with a gun drilling machine 7 used for deep hole machining.
  • the cutting allowance of the inner peripheral surface at that time was 0.2 mm (one piece).
  • the pipe inner peripheral surface of each drawn drawn pipe material cut from the inner peripheral surface is subjected to electroless Ni plating treatment to form a Ni—P (electroless Ni) plating layer having a thickness of 3 to 5 ⁇ m. Formed.
  • Table 1 shows the results of the corrosion resistance test of the steel drawn drawn tube material in the present example as described below.
  • Corrosion resistance test Enclose corrosive fuel (20% alcohol mixed fuel (gasoline), 500 ppm organic acid, 5% moisture, 10 ppm chlorine) in each steel drawn drawn tube with Ni plating on the entire inner surface of the tube, The state of corrosion in the pipe when left at a temperature of 100 ° C. for 1000 hours was confirmed. Corrosion resistance evaluation was determined by checking the presence or absence of red rust visually and with a microscope. [Conventional Examples 1 to 3]
  • a steel welded pipe material (test Nos. 7 to 12) having an outer diameter of 15.9 mm and an inner diameter of 9.9 mm manufactured by a welded pipe manufacturing apparatus is used as a pipe base material, and the depth of welding defects.
  • Investigate the depth to be removed by statistical method in advance set the machining allowance on the inner surface of the pipe based on the expected maximum flaw depth, and the amount of machining with a preset machining allowance threshold (150 ⁇ m)
  • the inner peripheral surface was cut with a gun drilling machine 7 used for deep hole machining.
  • the cutting allowance of the inner peripheral surface at that time was 0.2 mm (one piece).
  • the inner circumferential surface of each welded pipe material cut from the inner circumferential surface is subjected to electroless Ni plating treatment to form a Ni—P (electroless Ni) plating layer having a thickness of 3 to 5 ⁇ m.
  • Table 2 shows the results of performing the corrosion resistance test of the steel welded pipe material in this example in the same manner as in Example 1.
  • each welded pipe material is not subjected to mechanical cutting of the pipe inner peripheral surface after the pipe material is manufactured.
  • the same electroless Ni plating treatment as in 7 to 12 was performed to form a Ni—P (electroless Ni) plating layer having a thickness of 3 to 5 ⁇ m, and the corrosion resistance test was performed in the same manner as in Examples 1 to 6. Is also shown in Table 2.
  • the depth of the weld defect after manufacturing the welded pipe is set in advance by a statistical method, and the inner peripheral surface of the welded pipe material is mechanically cut to a predetermined threshold or more. It was confirmed that none of the welded pipe materials of Examples 7 to 12 of the present invention, in which an electroless Ni plating layer was formed after removal by the above method, had excellent corrosion resistance because no red rust was observed inside the pipe. . On the other hand, in all of the conventional examples 4 to 6, red rust was observed on the inner peripheral surface of the welded pipe material, and it was found that the corrosion resistance was inferior to that of the steel welded pipe material of the present invention.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Fuel-Injection Apparatus (AREA)
  • Rigid Pipes And Flexible Pipes (AREA)
  • Metal Extraction Processes (AREA)

Abstract

腐食性燃料に対する高い耐性を有する高品質のスチール製の燃料圧送配管の製造方法の提供。　スチール製の管材の管内周面の初期疵（微細クラックやしわ疵、溶接欠陥部等）が予め設定した閾値を超える管材と同閾値を超えない管材とに選別し、閾値を超えない管材の内周面の初期疵を機械的切削によって除去した後、当該管材の内周面にＮｉめっき等の表面処理を施すことを特徴とする。

Description

スチール製燃料圧送配管の製造方法
　本発明は、ガソリン直噴エンジンシステムやディーゼルエンジンシステムにおける燃料をエンジンに供給する配管の製造方法に係り、例えば伸管加工等で内面に生じる微細クラックやしわ疵等を除去して内表面処理を施して、耐食性に優れた高品質のスチール製燃料圧送配管を製造する方法に関する。
　上記したガソリン直噴エンジンシステムやディーゼルエンジンシステムに使用される燃料圧送配管においては、耐圧性、気密性及び耐食性等の諸性能を有する仕様として、ステンレス系の材料に各種塑性加工（管末成形加工、曲げ加工等）や接合加工（ろう付け加工等）を施して製品とされたものが最も多く採用されている。
　さらに近年は、ガソリン直噴エンジンシステムにおいては、前記したステンレス系配管より安価な低炭素鋼等のスチール系配管を採用した燃料圧送配管が提案されている（特許文献１参照）。このスチール製の燃料圧送配管は、特に腐食性燃料に対する高い耐性を得るために、腐食性燃料への耐性に優れる内表面処理及び／又は外表面処理を施したもので、例えばスチール製配管内表面にＮｉめっき層を形成し、さらに前記Ｎｉめっき層上にＺｎめっき層又はＺｎ基合金めっき層からなる防錆皮膜層を設けたもの、スチール製配管外表面にＺｎめっき層又はＺｎ基合金めっき層を形成したもの等である。
　しかしながら、前記したスチール製の燃料圧送配管には、以下に示す問題点がある。
　即ち、前記したスチール製の燃料圧送配管に例えば引抜き伸管材を用いる場合、管内周面には引抜き伸管時に発生した初期疵（微細クラックやしわ疵等）が存在し、又、溶接管の場合には管内周面に溶接不良等により発生した初期疵（溶接欠陥部等）が存在している。このような管内周面の欠陥、特に微細クラックやしわ疵、溶接欠陥部が存在した状態で前記した内表面処理（例えばＮｉめっき等）が施された場合、その微細クラックやしわ疵、溶接欠陥部の内部までめっき液が浸透せず、微細クラックやしわ疵、溶接欠陥部の部位が完全に表面処理が施されず欠陥となり、特に腐食性燃料に対する耐性が得られなくなり腐食や錆の発生を余儀なくされるという問題がある。
特開２０１２－２６３５７号公報
　本発明は、前記した従来技術の問題点に鑑みなされたもので、ガソリン直噴エンジンシステムやディーゼルエンジンシステムにおける燃料をエンジンに供給するスチール製の配管において、管内周面に発生した初期疵（微細クラックやしわ疵、溶接欠陥部等）が存在せず、腐食性燃料に対する高い耐性を有する高品質のスチール製の燃料圧送配管の製造方法を提案しようとするものである。
　本発明に係るスチール製の燃料圧送配管の製造方法は、スチール製の管材の内周面に防錆皮膜層を有するスチール製の燃料圧送配管の製造方法であって、当該管材の管内周面の初期疵（微細クラック、しわ疵、溶接欠陥部等）が予め設定した閾値を超える管材と同閾値を超えない管材とに選別し、閾値を超えない管材の内周面の初期疵を機械的切削によって除去した後、当該管材の内周面に表面処理（例えばＮｉめっき等）を施すことを特徴とするものである。なお、閾値を超える管材は不良品として処理する。この閾値を決めるにあたり統計的手法を用いて想定される最大キズ深さを算出して、その最大キズ深さを閾値としてもよい。
　又、管材の管内周面の初期疵（微細クラック、しわ疵、溶接欠陥部等）を除去する方法として用いる機械的切削による方法は、深穴加工に用いるガンドリル加工機による方法を好ましい態様とするものである。
　さらに、管内周面の初期疵の検出手段としては、超音波探傷方法を好ましい態様とするものである。
　本発明のスチール製の燃料圧送配管の製造方法によれば、引抜き伸管材、セミシームレス管、溶接管等の管材の管内周面の初期疵（微細クラック、しわ疵、溶接欠陥部等）を検出又は予測し、該検出値が予め定めた閾値を超えない管材の内周面を機械的切削によって除去することにより、前記初期疵の除去が完全に行われると共に、管内周面の平滑度が高まり、管内周面の表面処理の耐食性が向上し、腐食性燃料に対する高い耐性を有する高品質のスチール製の燃料圧送配管が得られるという、優れた効果を奏する。
　又、管材の管内周面の初期疵（微細クラックやしわ疵、溶接欠陥部等）の除去手段に深穴加工に用いるガンドリル加工機を用いることにより、刃の直進性が良好であるため管材の管軸方向及び円周方向に均一に切削することが可能となり初期疵を完全に除去することができる。
本発明方法を実施するためのスチール製燃料圧送配管の製造工程の一例を示すブロック図である。 図１に示すスチール製燃料圧送配管製造工程における管材の初期疵除去工程で用いるガンドリル加工機を示す該略図である。
　本発明に係るスチール製の燃料圧送配管の製造方法は、図１にその製造工程の一例を示すように、先ず被加工パイプとして、管材製造工程１において配管母材である管材が製造される。管材製造工程１としては、例えば引抜き伸管工程、溶接管製造工程等である。管材製造工程１で製造される管材としては、例えば機械構造用炭素鋼管ＳＴＫＭ材、ＳＣＭ材、ＳＴＫ材、ＳＴＳ材等低炭素鋼や合金鋼が用いられて外径１０～３０ｍｍ、内径５～２０ｍｍのスチール製管材等である。
　次に、配管母材の受け入れ検査として、管材の探傷工程２において、探傷機により当該管材の管内周面を探傷して初期疵（微細クラック、しわ疵、溶接欠陥部等）を検出する。続いて、管材の選別工程３において、前記探傷工程で検出された検出値が予め定めた閾値を超える管材と、同閾値を超えない管材とに選別する。初期疵（微細クラック、しわ疵、溶接欠陥部等）の閾値については、その基準値を例えば深さ１５０μｍと設定し、この閾値を超える管材は不良品として処理し、同閾値を超えない管材を次の初期疵除去工程４へ送る。なお、閾値については、管材の種類、内径、肉厚、微細クラックやしわ疵、溶接欠陥部等の大きさ等に基づいて決定する。
　初期疵除去工程４では、閾値を超えない管材を閾値以上の大きさで内周面を機械的切削することで初期疵を除去する。この閾値を超えない管材の管内周面の初期疵（微細クラック、しわ疵、溶接欠陥部等）を除去する方法として用いる機械的切削による方法は、図２に示す深穴加工に用いるガンドリル加工機７による方法を用いる。この深穴加工に用いるガンドリル加工機７は、本体部７－１に取り付けられた切削工具７－２を回転させながら、治具（図面省略）に固定された管材に押し込むようにして切削加工する方式である。この加工はいわゆるガンドリルと言われる穴の直進性を重視した工具を使用した工法であることから、深穴加工に用いるガンドリル加工機７は管材の管内周面の初期疵の除去手段として好適である。
　初期疵除去工程４で管内周面の初期疵を深穴加工に用いるガンドリル加工機７によって除去された閾値を超えない管材は、続いて表面処理工程５において当該管材の内表面にＮｉめっき等の表面処理が施される。その際、表面処理は当該管材の内表面に沿って施されるが、前記初期疵除去工程４で管内周面の初期疵が除去されている管材の場合は、その内表面に微細クラックやしわ疵、溶接欠陥部等が無いことからめっき液が付かない部位が全く存在せず内表面全体に確実に表面処理が施される。したがって、表面処理工程５で管内周面にＮｉめっき等の表面処理が施された製品は、腐食性燃料に対する防錆力が十分保持されることにより腐食や錆の発生は皆無となり、耐食性に優れることが明らかである。
[実施例１～６]
　管材製造工程１において、引き抜き伸管装置により製造された外径１５．６ｍｍ、内径９．８ｍｍのスチール製引抜き伸管材（供試Ｎｏ．１～６）を配管母材として用い、各伸管材を探傷工程２において、探傷機により当該引抜き伸管材の管内周面を探傷して初期疵（微細クラックやしわ疵、溶接欠陥部等）を検出した後、引抜き伸管材の選別工程３において、前記探傷工程２で検出された検出値が予め設定した閾値（１５０μｍ）を超える引抜き伸管材と、同閾値を超えない引抜き伸管材とに選別し、次の初期疵除去工程４で前記閾値を超えない各引抜き伸管材の内周面を深穴加工に用いるガンドリル加工機７により切削した。その際の内周面の削り代は、０．２ｍｍ（片肉）であった。続いて、表面処理工程５において、前記内周面を切削した各引抜き伸管材の管内周面に無電解Ｎｉめっき処理を施して、膜厚３～５μｍのＮｉ－Ｐ（無電解Ｎｉ）めっき層を形成した。
　本実施例におけるスチール製引抜き伸管材の耐食性試験を下記要領で行った結果を表１に示す。
・耐食性試験：
　管内面全体にＮｉめっきが施された各スチール製引抜き伸管材内に、腐食性燃料（２０％アルコール混合燃料（ガソリン）、有機酸５００ｐｐｍ、水分５％、塩素１０ｐｐｍを含む）を封入して、温度１００℃で１０００時間放置した時の管内の腐食状況を確認した。耐食評価は、赤錆の有無を目視及び実態顕微鏡にて確認して判定した。
[従来例１～３]
　実施例１～６と同じ外径１５．６ｍｍ、内径９．８ｍｍのスチール製引抜き伸管材を用い、引抜き伸管後の管内周面の機械的切削を施さずに各引抜き伸管材の内周面に実施例１～６と同じ無電解Ｎｉめっき処理を施して、膜厚３～５μｍのＮｉ－Ｐ（無電解Ｎｉ）めっき層を形成し、耐食性試験を実施例１～６と同様の方法で行った結果を表１に併せて示す。
　表１の結果より、引抜き伸管後に管内周面を探傷し、予め設定した閾値を超えない引抜き伸管材の内周面を機械的切削によって除去した後、無電解Ｎｉめっき層を形成した実施例１～６の本発明のスチール製引抜き伸管材は、いずれも管の内部に赤錆の発生は確認されず、優れた耐食性を有することが認められた。
　一方、従来例１～３は、いずれも引抜き伸管材の内周面に赤錆の発生が見られ、本発明のスチール製引抜き伸管材に比べて耐食性が劣ることが判明した。
Figure JPOXMLDOC01-appb-T000001
 ［実施例７～１２］
　管材製造工程１において、溶接管製造装置により製造された外径１５．９ｍｍ、内径９．９ｍｍのスチール製溶接管材（供試Ｎｏ．７～１２）を配管母材として用い、溶接欠陥の深さは予め統計的手法にて除去すべき深さを調査し、その予想される最大キズ深さに基づき管内面の削り代を設定しておき、予め設定した削り代の閾値（１５０μｍ）の削り量について内周面を深穴加工に用いるガンドリル加工機７により切削した。その際の内周面の削り代は、０．２ｍｍ（片肉）であった。続いて、表面処理工程５において、前記内周面を切削した各溶接管材の管内周面に無電解Ｎｉめっき処理を施して、膜厚３～５μｍのＮｉ－Ｐ（無電解Ｎｉ）めっき層を形成した。
　本実施例におけるスチール製溶接管材の耐食性試験を実施例１と同じ要領で行った結果を表２に示す。
［従来例４～６］
　実施例７～１２と同じ外径１５．９ｍｍ、内径９．９ｍｍのスチール製溶接管材を用い、管材製造後の管内周面の機械的切削を施さずに各溶接管材の内周面に実施例７～１２と同じ無電解Ｎｉめっき処理を施して、膜厚３～５μｍのＮｉ－Ｐ（無電解Ｎｉ）めっき層を形成し、耐食性試験を実施例１～６と同様の方法で行った結果を表２に併せて示す。
　表２の結果より、本実施例においても、溶接管製造後の溶接欠陥部の深さを統計的手法により予め設定しておき、予め設定した閾値以上に溶接管材の内周面を機械的切削によって除去した後、無電解Ｎｉめっき層を形成した実施例７～１２の本発明の溶接管材は、いずれも管の内部に赤錆の発生は確認されず、優れた耐食性を有することが認められた。一方、従来例４～６は、いずれも、溶接管材の内周面に赤錆の発生が見られ、本発明のスチール製溶接管材に比べて耐食性が劣ることが判明した。
Figure JPOXMLDOC01-appb-T000002
　１　管材製造工程
　２　探傷工程
　３　選別工程
　４　初期疵除去工程
　５　表面処理工程
　６　製品
　７　ガンドリル加工機
　７－１　本体部
　７－２　切削工具

Claims (4)

  1. 　スチール製の管材の内周面に防錆皮膜層を有するスチール製の燃料圧送配管の製造方法であって、当該管材の初期疵が予め設定した閾値を超える管材と同閾値を超えない管材とに選別し、閾値を超えない管材の内周面の初期疵を機械的切削によって除去した後、当該管材の内周面に表面処理を施すことを特徴とするスチール製の燃料圧送配管の製造方法。
  2. 　スチール製の管材の内周面に防錆皮膜層を有するスチール製の燃料圧送配管の製造方法であって、当該管材の内周面を探傷して初期疵を検出し、該検出値が予め設定した閾値を超える管材と同閾値を超えない管材とに選別し、閾値を超えない管材の内周面の初期疵を機械的切削によって除去した後、当該管材の内周面に表面処理を施すことを特徴とするスチール製の燃料圧送配管の製造方法。
  3. 　前記管材の管内周面の初期疵は、深穴加工に用いるガンドリル加工機によって除去することを特徴とする請求項１又は２に記載のスチール製の燃料圧送配管の製造方法。
  4. 　前記表面処理はＮｉめっきとすることを特徴とする請求項１～３のいずれか１項に記載のスチール製の燃料圧送配管の製造方法。
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