EP1148147A1 - Wire for electric arc spraying process - Google Patents

Wire for electric arc spraying process Download PDF

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Publication number
EP1148147A1
EP1148147A1 EP01105650A EP01105650A EP1148147A1 EP 1148147 A1 EP1148147 A1 EP 1148147A1 EP 01105650 A EP01105650 A EP 01105650A EP 01105650 A EP01105650 A EP 01105650A EP 1148147 A1 EP1148147 A1 EP 1148147A1
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EP
European Patent Office
Prior art keywords
silicon
material wire
filling
wire according
weight
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Granted
Application number
EP01105650A
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German (de)
French (fr)
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EP1148147B1 (en
Inventor
Manfred Dr. Fischer
Peter Gödel
Werner Trübenbach
Reinhard Dr. Rosert
Markus Müller
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Drahtzug Stein Wire & Welding & Co K GmbH
Federal Mogul Friedberg GmbH
Original Assignee
Drahtwarenfabrik Drahtzug Stein GmbH and Co KG
Federal Mogul Friedberg GmbH
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Publication of EP1148147A1 publication Critical patent/EP1148147A1/en
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    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/131—Wire arc spraying
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/937—Sprayed metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063—Nonparticulate metal component
    • Y10T428/12097—Nonparticulate component encloses particles

Definitions

  • the present invention relates to a material wire for the production of moldings made of wear-resistant and tribologically favorable aluminum / silicon alloys thermal spraying process.
  • Alloys of this type are known per se, in particular as surface coatings. You will find in particular as cylinder liners of cylinder housings in Reciprocating machines or internal combustion engines use.
  • Coatings Aluminum / silicon alloys are known for example from US 50 22 455 A. In layers of molten aluminum and silicon particles are described, the be sprayed separately onto the surface to be coated. Although such Coatings can be applied in a variety of ways to surfaces of substrates thermal spray processes are particularly suitable, for example Plasma spraying or wire arc spraying. When plasma spraying is in the flame melted powdered starting material used in the Wire arc spraying is a metallic starting material in the form of a material wire. Wire arc spraying is particularly preferred because of its high cycle times a large application rate of the coating allows and with regard to the material as well is inexpensive with regard to the system.
  • the wire has a solid core conductive metal and a shell in which solid lubricant particles and wear-resistant Particles suspended homogeneously in a conductive metal corresponding to the solid core are.
  • a composite wire is relatively expensive to manufacture and expensive and not suitable for all applications.
  • the object of the present invention is therefore to provide a material wire of the above type to deliver, which has a good and precise eligibility and a uniform Distribution of the alloying elements and thus the wear and tear Corrosion-resistant molded body guaranteed.
  • a tube made of sheath material is filled with filler material and then subjected to drawing and / or rolling processes to the diameter of the Reduce wire.
  • Magnesium is preferably added to the aluminum alloy of the shell. Because by that is the surface of the shell of the during the drawing and rolling processes in the manufacture Cored wire solidified. This results in a good and precise eligibility of the Material wire.
  • Silicon is preferred as a component of the filling of the material wire, so that the Generating molded body consists of an aluminum / silicon alloy.
  • About the share of silicon in the filling can be the proportion of silicon in the molded body to be produced can be set and controlled.
  • the ratio of the proportions in the resulting alloy to that to be produced Shaped body can be adjusted and controlled.
  • Addition of boron as a component of the fill is preferred to improve fluidity to improve the molded body to be produced.
  • the filling is preferably composed such that the resulting proportion of the Silicon on the alloy of the molded body to be produced between about 12.5% by weight and is about 50% by weight.
  • the silicon content is more preferably about 15% by weight to about 40% by weight.
  • a silicon content of between approximately 20% by weight and approximately 30 is more preferred % By weight.
  • the proportion of silicon in the resulting Alloy of the molded body to be produced about 25 wt .-%.
  • the material wire is preferably composed of sheath and filling such that in addition to Aluminum and silicon together further portions of the molded body to be produced less than about 2% by weight.
  • the wire preferably has a filling, the components of which have a statistical average Grain size between 45 and 700 microns and particularly preferably between 300 and 600 microns exhibit.
  • This version relates in particular to fillings that are silicon or contain substantial silicon or at least a silicon portion.
  • the filling contains essentially silicon, while the casing in contains essential aluminum, the content of silicon based on the Total wire weight between 20 and 26, more preferably between 21 and 25 and am most preferred is between 22 and 24% by weight, the rest i.w. Is aluminum.
  • the silicon content due to enrichment by Al burnup, between 22 and 29, more preferably between 24 and 28 and most preferably between 25 and 27% by weight.
  • the filling preferably contains up to max. 1% by weight boron, up to max. 10% by weight A1 and the rest Silicon, while the shell up to max. 1 wt% Si, max. 2% by weight of Mg and max. to 4 % By weight of Mn and A1.
  • the material wire according to the invention is preferably used in wire arc spraying processes Use. And preferred here for the production of cylinder liners from Internal combustion engines.
  • FIG. 1 shows a schematic sketch of the material wire 10 according to the invention, the one Cover 12 and a filling 14 comprises.
  • the shell 12 comprises an alloy Aluminum with the alloy components silicon, magnesium, manganese. From the shell 12 includes the filling 14, the other powdery components for a resulting alloy of a molded body to be produced, which with the Material wire according to the invention by an arc spraying method on a substrate can be applied.
  • the filling contains the alloy components silicon, boron and Aluminum.
  • the manufacturing process provides for a closed seamless tube to be provided as a sheath 12.
  • the casing 12 comprises an aluminum-based alloy with at least one further alloy component.
  • magnesium, silicon and manganese are added to the aluminum.
  • the tube of the sheath 12 can be drawn, welded, or extruded.
  • the casing 12 is then filled with a filling material 14.
  • the components of the filling 14 are in the form of a coarse powder.
  • a powder mixture is used which has silicon, aluminum and boron. Even if a coarse powder is used, the maximum grain size is about 600 ⁇ m.
  • the silicon portion of the wire (from the filling) is about 23%, with the rest being aluminum.
  • the filling 14 is compressed by directional shaking when filling.
  • the powder of the filling 14 is crushed, which leads to a dense filling and has a positive effect on the uniform distribution in the layer. Therefore, no organic or inorganic binders have to be used in the production of the material wire according to the invention, which further has a positive effect on a low porosity in the layer. This represents a significant improvement compared to surface coatings produced by plasma spraying, since only fine agglomerated and therefore expensive powders can be used here.
  • the silicon portion of the spray layer formed is between 25 and 27% by weight due to an Si enrichment caused by Al erosion during the spraying process.
  • the diameter of the wire before drawing is about 10-11 mm, preferably about 10.4 mm, 6.4 mm for the filling and 4.0 mm for the casing. After pulling the wire has a diameter of 3.6 to 4 mm, of which about 2-3 mm on the filling omitted.
  • composition of the alloy of the spray layer or of the shaped body formed is max. 2% by weight B, max. 5% by weight Mn, max. 3% by weight of Mg, between 15-40% by weight Si and between 60-85 wt .-% Al.
  • the Mg content can be higher due to Al burnup preferred Al content is about 75%, the preferred Si content is about 25%.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Details Of Aerials (AREA)
  • Vending Machines For Individual Products (AREA)
  • Separation By Low-Temperature Treatments (AREA)
  • Nonmetallic Welding Materials (AREA)

Abstract

Wire comprises a filler wire (10) having a filling (14) made from one or more components and a sleeve (12) made from aluminum and a further alloying component. Preferred Features: The further alloying component is magnesium or manganese. The filling component is silicon, aluminum or boron.

Description

Die vorliegende Erfindung betrifft einen Werkstoffdraht für die Erzeugung von Formkörpern aus verschleißfesten und tribologisch günstigen Aluminium/Silizium-Legierungen mittels thermischer Spritzverfahren.The present invention relates to a material wire for the production of moldings made of wear-resistant and tribologically favorable aluminum / silicon alloys thermal spraying process.

Derartige Legierungen sind an sich bekannt, insbesondere als Oberflächenbeschichtungen. Sie finden insbesondere als Zylinderlaufflächen von Zylindergehäusen in Hubkolbenmaschinen bzw. Verbrennungskraftmaschinen Verwendung. Beschichtungen aus Aluminium/Silizium-Legierungen sind beispielsweise aus der US 50 22 455 A bekannt. In ihr werden Schichten aus geschmolzenen Aluminium und Siliziumpartikeln beschrieben, die separat auf die zu beschichtende Oberfläche gesprüht werden. Obwohl derartige Beschichtungen auf vielfältige Art auf Oberflächen von Substraten aufgebracht werden können, eignen sich hierfür besonders thermische Spritzverfahren, beispielsweise Plasmaspritzen oder Drahtlichtbogenspritzen. Beim Plasmaspritzen wird in der Flamme aufgeschmolzenes pulverförmiges Ausgangsmaterial verwendet, beim Drahtlichtbogenspritzen ein metallisches Ausgangsmaterial in Form eines Werkstoffdrahtes. Das Drahtlichtbogenspritzen ist dabei besonders bevorzugt, weil es durch hohe Taktzeiten eine große Auftragsrate der Beschichtung erlaubt und hinsichtlich des Werkstoffs sowie hinsichtlich der Anlage kostengünstig ist.Alloys of this type are known per se, in particular as surface coatings. You will find in particular as cylinder liners of cylinder housings in Reciprocating machines or internal combustion engines use. Coatings Aluminum / silicon alloys are known for example from US 50 22 455 A. In layers of molten aluminum and silicon particles are described, the be sprayed separately onto the surface to be coated. Although such Coatings can be applied in a variety of ways to surfaces of substrates thermal spray processes are particularly suitable, for example Plasma spraying or wire arc spraying. When plasma spraying is in the flame melted powdered starting material used in the Wire arc spraying is a metallic starting material in the form of a material wire. Wire arc spraying is particularly preferred because of its high cycle times a large application rate of the coating allows and with regard to the material as well is inexpensive with regard to the system.

Aus der DE 43 41 537 A1 ist ein Verbundwerkstoffdraht für das Drahtlichtbogenspritzen sowie ein Verfahren zu seiner Herstellung bekannt. Der Draht weist einen festen Kern aus leitfähigem Metall und eine Hülle auf, in der feste Schmiermittelpartikel und verschleißfeste Partikel homogen in einem dem festen Kern entsprechenden leitfähigen Metall suspendiert sind. Ein solcher Verbundwerkstoffdraht ist jedoch in seiner Herstellung relativ aufwendig und kostenintensiv und nicht für alle Anwendungen geeignet. DE 43 41 537 A1 describes a composite wire for wire arc spraying as well as a method for its production. The wire has a solid core conductive metal and a shell in which solid lubricant particles and wear-resistant Particles suspended homogeneously in a conductive metal corresponding to the solid core are. However, such a composite wire is relatively expensive to manufacture and expensive and not suitable for all applications.

In der DE 198 41 619 A1 ist ein Werkstoffdraht mit einer Hülle aus metallischen Aluminium und einer Füllung aus einer Silizium-Legierung offenbart, der der Erzeugung von Oberflächen-Beschichtungen aus übereutektischen Aluminium/Silizium-Legierungen dient. Dieser Werkstoffdraht ist einfach und kostengünstig herzustellen.DE 198 41 619 A1 describes a material wire with a sheath made of metallic aluminum and a filling made of a silicon alloy disclosed that the generation of Surface coatings made of hypereutectic aluminum / silicon alloys are used. This material wire is simple and inexpensive to manufacture.

Bei thermischen Spritzverfahren ist eine präzise Förderfähigkeit der verwendeten Werkstoffdrähte äußerst wichtig. Denn es müssen beim Drahtlichtbogenspritzverfahren zwei Drähte derart geführt werden, dass ein stabiler gemeinsamer Lichtbogen entstehen und gehalten werden kann.In the case of thermal spraying methods, the conveying capacity used is precise Material wires extremely important. Because there must be two in the wire arc spraying process Wires are guided in such a way that a stable common arc arises and can be held.

Aufgabe der vorliegenden Erfindung ist es daher, einen Werkstoffdraht der vorstehenden Art zu liefern, der eine gute und präzise Förderfähigkeit aufweist sowie eine gleichmäßige Verteilung der Legierungselemente besitzt und somit die Herstellung verschleiß- und korrosionsbeständiger Formkörper gewährleistet.The object of the present invention is therefore to provide a material wire of the above type to deliver, which has a good and precise eligibility and a uniform Distribution of the alloying elements and thus the wear and tear Corrosion-resistant molded body guaranteed.

Die Aufgabe wird durch einen Werkstoffdraht gemäß dem Anspruch 1 gelöst. Vorteilhafte Ausgestaltungen der Erfindung sind in den Unteransprüchen dokumentiert.The object is achieved by a material wire according to claim 1. Beneficial Embodiments of the invention are documented in the subclaims.

Bei der Herstellung des Fülldrahtes wird ein Rohr aus Hüllenmaterial mit Füllmaterial befüllt und anschließend Zieh- und / oder Walzprozessen unterworfen, um den Durchmesser des Drahtes zu reduzieren. Durch die Zugabe von weiteren Legierungskomponenten zum Aluminium im Material der Hülle können deren Materialeigenschaften verändert und den Erfordernissen angepasst werden.In the manufacture of the cored wire, a tube made of sheath material is filled with filler material and then subjected to drawing and / or rolling processes to the diameter of the Reduce wire. By adding further alloy components to the Aluminum in the material of the cover can change its material properties and the Be adapted to requirements.

Bevorzugt wird Magnesium der Aluminium-Legierung der Hülle zugegeben. Denn dadurch wird während der Zieh- und Walzprozesse bei der Herstellung die Oberfläche der Hülle des Fülldrahtes verfestigt. Dies bewirkt eine gute und präzise Förderfähigkeit des Werkstoffdrahtes.Magnesium is preferably added to the aluminum alloy of the shell. Because by that is the surface of the shell of the during the drawing and rolling processes in the manufacture Cored wire solidified. This results in a good and precise eligibility of the Material wire.

Bevorzugt ist Silizium als eine Komponente der Füllung des Werkstoffdrahtes, damit der zu erzeugende Formkörper aus einer Aluminium/Silizium-Legierung besteht. Über den Anteil von Silizium in der Füllung kann der Anteil von Silizium in dem zu erzeugenden Formkörper eingestellt und gesteuert werden.Silicon is preferred as a component of the filling of the material wire, so that the Generating molded body consists of an aluminum / silicon alloy. About the share of silicon in the filling can be the proportion of silicon in the molded body to be produced can be set and controlled.

Vorzugsweise kann durch eine entsprechende Zugabe von Aluminium als eine Komponente der Füllung das Verhältnis der Anteile in der resultierenden Legierung des zu erzeugenden Formkörpers eingestellt und gesteuert werden.Preferably, by appropriate addition of aluminum as a component of the filling, the ratio of the proportions in the resulting alloy to that to be produced Shaped body can be adjusted and controlled.

Eine Zugabe von Bor als eine Komponente der Füllung ist bevorzugt, um die Fließfähigkeit des zu erzeugenden Formkörpers zu verbessern.Addition of boron as a component of the fill is preferred to improve fluidity to improve the molded body to be produced.

Vorzugsweise ist die Füllung derart zusammengesetzt, dass der resultierende Anteil des Siliziums an der Legierung des zu erzeugenden Formkörpers zwischen etwa 12,5 Gew.-% und etwa 50 Gew.-% liegt. Bevorzugter beträgt der Siliziumanteil etwa 15 Gew.-% bis etwa 40 Gew.-%. Noch bevorzugter ist ein Siliziumanteil zwischen etwa 20 Gew.-% und etwa 30 Gew.-%. Am bevorzugsten jedoch beträgt der Anteil an Silizium an der resultierenden Legierung des zu erzeugenden Formkörpers etwa 25 Gew.-%.The filling is preferably composed such that the resulting proportion of the Silicon on the alloy of the molded body to be produced between about 12.5% by weight and is about 50% by weight. The silicon content is more preferably about 15% by weight to about 40% by weight. A silicon content of between approximately 20% by weight and approximately 30 is more preferred % By weight. Most preferably, however, the proportion of silicon in the resulting Alloy of the molded body to be produced about 25 wt .-%.

Bevorzugt ist der Werkstoffdraht aus Hülle und Füllung derart zusammengesetzt, dass neben Aluminium und Silizium weitere Anteile des zu erzeugenden Formkörpers zusammen weniger als etwa 2 Gew.-% betragen.The material wire is preferably composed of sheath and filling such that in addition to Aluminum and silicon together further portions of the molded body to be produced less than about 2% by weight.

Bevorzugt weist der Draht eine Füllung auf, deren Komponenten im statistischen Mittel eine Korngröße zwischen 45 und 700 µm und besonders bevorzugt zwischen 300 und 600 µm aufweisen. Diese Ausführung bezieht sich insbesondere auf Füllungen, die Silizium oder im wesentlichen Silizium oder zumindest einen Silizium-Anteil enthalten.The wire preferably has a filling, the components of which have a statistical average Grain size between 45 and 700 microns and particularly preferably between 300 and 600 microns exhibit. This version relates in particular to fillings that are silicon or contain substantial silicon or at least a silicon portion.

Vorzugsweise enthält die Füllung im wesentlichen Silizium, während die Hülle im wesentlichen Aluminium enthält, wobei der Gehalt des Siliziums bezogen auf das Gesamtgewicht des Drahtes zwischen 20 und 26, bevorzugter zwischen 21 und 25 und am bevorzugtesten zwischen 22 und 24 Gew.-% liegt, wobei der Rest i.w. Aluminium ist. In der gebildeten Spritzschicht des zu erzeugenden Formkörpers beträgt der Siliziumgehalt, aufgrund einer Anreicherung durch Al-Abbrand, zwischen 22 und 29, bevorzugter zwischen 24 und 28 und am bevorzugtesten zwischen 25 und 27 Gew.-%.Preferably, the filling contains essentially silicon, while the casing in contains essential aluminum, the content of silicon based on the Total wire weight between 20 and 26, more preferably between 21 and 25 and am most preferred is between 22 and 24% by weight, the rest i.w. Is aluminum. In the formed spray layer of the molded body to be produced is the silicon content, due to enrichment by Al burnup, between 22 and 29, more preferably between 24 and 28 and most preferably between 25 and 27% by weight.

Vorzugsweise enthält die Füllung bis max. 1 Gew.-% Bor, bis max. 10 Gew.-% A1 und Rest Silizium, während die Hülle bis max. 1 Gew.-% Si, max. 2 Gew.-% Mg und max. bis 4 Gew.-% Mn sowie als Rest A1 aufweist.The filling preferably contains up to max. 1% by weight boron, up to max. 10% by weight A1 and the rest Silicon, while the shell up to max. 1 wt% Si, max. 2% by weight of Mg and max. to 4 % By weight of Mn and A1.

Vorzugsweise findet der erfindungsgemäße Werkstoffdraht bei Drahtlichtbogenspritzverfahren Verwendung. Und hier bevorzugt zur Herstellung von Zylinderlaufbuchsen von Verbrennungskraftmaschinen.The material wire according to the invention is preferably used in wire arc spraying processes Use. And preferred here for the production of cylinder liners from Internal combustion engines.

Figur 1 zeigt eine schematische Skizze des erfindungsgemäßen Werkstoffdrahtes 10, der eine Hülle 12 und eine Füllung 14 umfasst. Die Hülle 12 umfasst hierbei eine Legierung aus Aluminium mit den Legierungskomponenten Silizium, Magnesium, Mangan. Von der Hülle 12 eingeschlossen ist die Füllung 14, die weitere pulverförmige Komponenten für eine resultierende Legierung eines zu erzeugenden Formkörpers enthält, die mit dem erfindungsgemäßen Werkstoffdraht durch ein Lichtbogenspritzverfahren auf ein Substrat aufgetragen werden kann. Die Füllung enthält die Legierungskomponenten Silizium, Bor und Aluminium.FIG. 1 shows a schematic sketch of the material wire 10 according to the invention, the one Cover 12 and a filling 14 comprises. The shell 12 comprises an alloy Aluminum with the alloy components silicon, magnesium, manganese. From the shell 12 includes the filling 14, the other powdery components for a resulting alloy of a molded body to be produced, which with the Material wire according to the invention by an arc spraying method on a substrate can be applied. The filling contains the alloy components silicon, boron and Aluminum.

Im folgenden wird anhand eines Ausführungsbeispieles die Erfindung und die Herstellung des erfindungsgemäßen Werkstoffdrahtes ausführlich erläutert. Der Herstellungsprozess sieht ein Bereitstellen eines geschlossenen nahtlosen Rohres als Hülle 12 vor. Die Hülle 12 umfasst eine Legierung auf Aluminiumbasis, mit mindestens einer weiteren Legierungskomponente. Im Ausführungsbeispiel wird dem Aluminium Magnesium,Silizium und Mangan beigefügt. Das Rohr der Hülle 12 kann gezogen, geschweißt oder stranggepresst sein. Anschließend wird die Hülle 12 mit einem Füllmaterial 14 befüllt. Die Komponenten der Füllung 14 liegen als grobes Pulver vor. Im Ausführungsbeispiel wird ein Pulvergemenge verwendet, das Silizium, Aluminium und Bor aufweist. Auch wenn ein grobes Pulver Anwendung findet, beträgt die maximale Korngröße etwa 600 µm. Bezogen auf das Gesamtgewicht beträgt der Siliziumanteil des Drahtes (aus der Füllung) etwa 23 %, wobei der Rest Aluminium ist. Die Füllung 14 wird durch gerichtetes Rütteln beim Einfüllen verdichtet. Im nachfolgenden Ziehvorgang, bei dem der Werkstoffdraht 10 auf den endgültigen Durchmesser reduziert wird, wird das Pulver der Füllung 14 zerkleinert, was zu einer dichten Füllung führt und sich positiv auf die gleichmäßige Verteilung in der Schicht auswirkt. Deshalb müssen bei der Herstellung des erfindungsgemäßen Werkstoffdrahtes keine organischen oder anorganischen Binder eingesetzt werden, was sich weiterhin positiv auf eine geringe Porosität in der Schicht auswirkt. Dies stellt eine wesentliche Verbesserung im Vergleich zu durch Plasmaspritzen erzeugte Oberflächen-Beschichtungen dar, da hier nur feine agglomerierte und damit teure Pulver verwendet werden können. Aufgrund der geringen Porosität ist es nicht erforderlich, dass feine Siliziumpartikel verwendet werden müssen, sondern die Füllung 14 kann, wie vorstehend erläutert, grobe Pulverpartikel aufweisen.
Der Siliziumanteil der gebildeten Spritzschicht beträgt aufgrund einer durch Al-Abbrand während des Spritzvorgangs bedingten Si-Anreicherung zwischen 25 und 27 Gew.-%.The invention and the production of the material wire according to the invention are explained in detail below using an exemplary embodiment. The manufacturing process provides for a closed seamless tube to be provided as a sheath 12. The casing 12 comprises an aluminum-based alloy with at least one further alloy component. In the exemplary embodiment, magnesium, silicon and manganese are added to the aluminum. The tube of the sheath 12 can be drawn, welded, or extruded. The casing 12 is then filled with a filling material 14. The components of the filling 14 are in the form of a coarse powder. In the exemplary embodiment, a powder mixture is used which has silicon, aluminum and boron. Even if a coarse powder is used, the maximum grain size is about 600 µm. Based on the total weight, the silicon portion of the wire (from the filling) is about 23%, with the rest being aluminum. The filling 14 is compressed by directional shaking when filling. In the subsequent drawing process, in which the material wire 10 is reduced to the final diameter, the powder of the filling 14 is crushed, which leads to a dense filling and has a positive effect on the uniform distribution in the layer. Therefore, no organic or inorganic binders have to be used in the production of the material wire according to the invention, which further has a positive effect on a low porosity in the layer. This represents a significant improvement compared to surface coatings produced by plasma spraying, since only fine agglomerated and therefore expensive powders can be used here. Because of the low porosity, it is not necessary that fine silicon particles have to be used, but the filling 14 can, as explained above, have coarse powder particles.
The silicon portion of the spray layer formed is between 25 and 27% by weight due to an Si enrichment caused by Al erosion during the spraying process.

Der Durchmesser des Drahtes vor dem Ziehen beträgt etwa 10-11 mm, bevorzugt etwa 10,4 mm, wovon 6,4 mm auf die Füllung und 4,0 mm auf die Hülle entfallen. Nach dem Ziehen hat der Draht einen Durchmesser von 3,6 bis 4 mm, wovon auf die Füllung etwa 2-3 mm entfallen.The diameter of the wire before drawing is about 10-11 mm, preferably about 10.4 mm, 6.4 mm for the filling and 4.0 mm for the casing. After pulling the wire has a diameter of 3.6 to 4 mm, of which about 2-3 mm on the filling omitted.

Die Zusammensetzung der Legierung der Spritzschicht bzw. des gebildeten Formkörpers beträgt max. 2 Gew.-% B, max. 5 Gew.-% Mn, max. 3 Gew.-% Mg, zwischen 15-40 Gew.-% Si und zwischen 60-85 Gew.-%Al. Der Mg-Gehalt kann wegen Al-Abbrand höher liegen, der bevorzugte Al-Gehalt liegt bei etwa 75 %, der bevorzugte Si-Gehalt bei etwa 25 %.The composition of the alloy of the spray layer or of the shaped body formed is max. 2% by weight B, max. 5% by weight Mn, max. 3% by weight of Mg, between 15-40% by weight Si and between 60-85 wt .-% Al. The Mg content can be higher due to Al burnup preferred Al content is about 75%, the preferred Si content is about 25%.

Claims (19)

Werkstoffdraht für die Erzeugung verschleißfester und tribologisch günstiger Formkörper aus Aluminium/Silizium-Legierungen durch thermisches Spritzen, wobei der Werkstoffdraht ein Fülldraht (10) ist, der eine Füllung (14) aus einer oder mehreren Komponenten und eine Hülle (12) aufweist, dadurch gekennzeichnet, dass die Hülle (12) eine Aluminium-Legierung umfasst, die Aluminium und mindestens eine weitere Legierungskomponente enthält.A material wire for producing wear-resistant and tribologically favorable shaped bodies of aluminum / silicon alloys by thermal spraying, wherein the material wire is a filler wire (10) having a filling (14) of one or comprising a plurality of components, and a shell (12), characterized that the shell (12) comprises an aluminum alloy which contains aluminum and at least one further alloy component. Werkstoffdraht nach Anspruch 1, dadurch gekennzeichnet, dass die weitere Legierungskomponente der Hülle (12) Magnesium umfasst.Material wire according to claim 1, characterized in that the further alloy component of the sheath (12) comprises magnesium. Werkstoffdraht nach Anspruch 1, dadurch gekennzeichnet, dass die weitere Legierungskomponente der Hülle (12) Mangan umfasst.Material wire according to claim 1, characterized in that the further alloy component of the sheath (12) comprises manganese. Werkstoffdraht nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass eine Komponente der Füllung (14) Silizium enthält.Material wire according to claim 1 or 2, characterized in that a component of the filling (14) contains silicon. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass eine Komponente der Füllung (14) Aluminium enthält.Material wire according to one of the preceding claims, characterized in that a component of the filling (14) contains aluminum. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass eine Komponente der Füllung (14) Bor enthält.Material wire according to one of the preceding claims, characterized in that a component of the filling (14) contains boron. Werkstoffdraht nach Anspruch 3, dadurch gekennzeichnet, dass der Anteil des Siliziums in der Füllung (14) derart bemessen ist, dass der Siliziumanteil in dem zu erzeugenden Formkörper etwa 12,5 Gew.-% bis etwa 50 Gew.-% beträgt.Material wire according to claim 3, characterized in that the proportion of silicon in the filling (14) is dimensioned such that the silicon proportion in the molded body to be produced is about 12.5% by weight to about 50% by weight. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Anteil des Siliziums in der Füllung (14) derart bemessen ist, dass der Siliziumanteil in dem zu erzeugenden Formkörper etwa 15 Gew.-% bis etwa 40 Gew.-% beträgt.Material wire according to one of the preceding claims, characterized in that the proportion of silicon in the filling (14) is dimensioned such that the proportion of silicon in the molded body to be produced is approximately 15% by weight to approximately 40% by weight. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Anteil des Siliziums in der Füllung (14) derart bemessen ist, dass der Siliziumanteil in dem zu erzeugenden Formkörper etwa 20 Gew.-% bis etwa 30 Gew.-% beträgt.Material wire according to one of the preceding claims, characterized in that the proportion of silicon in the filling (14) is dimensioned such that the proportion of silicon in the molded body to be produced is about 20% by weight to about 30% by weight. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Anteil des Siliziums in der Füllung (14) derart bemessen ist, dass der Siliziumanteil in dem zu erzeugenden Formkörper etwa 25 Gew.-% beträgt.Material wire according to one of the preceding claims, characterized in that the proportion of silicon in the filling (14) is dimensioned such that the proportion of silicon in the molded body to be produced is approximately 25% by weight. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Zusammensetzung der Hülle (12) und der Füllung (14) derart bemessen ist, dass neben Aluminium und Silizium weitere Anteile des zu erzeugenden Formkörper zusammen weniger als etwa 2 Gew.-% betragen.Material wire according to one of the preceding claims, characterized in that the composition of the sheath (12) and the filling (14) is dimensioned such that, in addition to aluminum and silicon, further proportions of the shaped body to be produced are less than about 2% by weight. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Zusammensetzung der Füllung (14) keine organischen oder anorganischen Binder aufweist.Material wire according to one of the preceding claims, characterized in that the composition of the filling (14) has no organic or inorganic binders. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß die Füllung (14) Komponenten aufweist, deren Teile eine Korngröße zwischen 45 und 700 µm, bevorzugter zwischen 300 und 600 µm aufweisen.Material wire according to one of the preceding claims, characterized in that the filling (14) has components, the parts of which have a grain size between 45 and 700 µm, more preferably between 300 and 600 µm. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß die Füllung im wesentlichen Silizium und die Hülle im wesentlichen Aluminium aufweist, wobei bezogen auf die Gesamtmasse der Siliziumgehalt zwischen 20 und 26, bevorzugter zwischen 21 und 25 und am bevorzugtesten zwischen 22 und 24 Gew.-% liegt, wobei der Rest im wesentlichen Aluminium ist.Material wire according to one of the preceding claims, characterized in that the filling essentially comprises silicon and the sheath essentially comprises aluminum, the silicon content being between 20 and 26, more preferably between 21 and 25 and most preferably between 22 and 24% by weight based on the total mass. -% is, the rest is essentially aluminum. Werkstoffdraht nach Anspruch 14, dadurch gekennzeichnet, daß der Siliziumgehalt des gebildeten Formkörpers bzw. der gebildeten Spritzschicht zwischen 22 und 29, bevorzugter 24 bis 28 und am bevorzugtesten zwischen 25 und 27 Gew.-% liegt, wobei der Rest im wesentlichen Aluminium ist.Material wire according to claim 14, characterized in that the silicon content of the molded body or spray layer formed is between 22 and 29, more preferably 24 to 28 and most preferably between 25 and 27% by weight, the remainder being essentially aluminum. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß die Füllung (14) max. 1 Gew.-% Bor und max. 10 Gew.-% Aluminium aufweist, wobei der Rest Silizium ist.Material wire according to one of the preceding claims, characterized in that the filling (14) max. 1% by weight boron and max. Has 10 wt .-% aluminum, the rest being silicon. Werkstoffdraht nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß die Hülle (12) max. 1 Gew.-% Si, max. 2 Gew.-% Mg und max. 4 Gew.-% Mn enthält, wobei der Rest Aluminium ist.Material wire according to one of the preceding claims, characterized in that the sheath (12) max. 1 wt% Si, max. 2% by weight of Mg and max. Contains 4 wt .-% Mn, the rest being aluminum. Verwendung eines Werkstoffdrahtes nach einem der vorstehenden Ansprüche für Lichtbogenspritzverfahren.Use of a material wire according to one of the preceding claims for Arc spraying process. Verwendung eines Werkstoffdrahtes nach einem der Ansprüche 1 bis 17 für die Herstellung von Zylinderlaufbuchsen von Verbrennungskraftmaschinen.Use of a material wire according to one of claims 1 to 17 for the Manufacture of cylinder liners for internal combustion engines.
EP01105650A 2000-04-20 2001-03-07 Wire for electric arc spraying process Expired - Lifetime EP1148147B1 (en)

Applications Claiming Priority (2)

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DE10019794 2000-04-20
DE10019794A DE10019794C2 (en) 2000-04-20 2000-04-20 Wire for wire arc spraying process and its use

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DE50102958D1 (en) 2004-09-02
DE10019794C2 (en) 2002-08-29
ATE272131T1 (en) 2004-08-15
EP1148147B1 (en) 2004-07-28
US20010033942A1 (en) 2001-10-25
DE10019794A1 (en) 2001-11-08
US6479165B2 (en) 2002-11-12

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