CA1089186A - Method of making an article having cast-in-place bearing - Google Patents

Method of making an article having cast-in-place bearing

Info

Publication number
CA1089186A
CA1089186A CA284,595A CA284595A CA1089186A CA 1089186 A CA1089186 A CA 1089186A CA 284595 A CA284595 A CA 284595A CA 1089186 A CA1089186 A CA 1089186A
Authority
CA
Canada
Prior art keywords
composite part
casting
die
metal element
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA284,595A
Other languages
French (fr)
Inventor
Richard A. Ritzenthaler
James H. Koch
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NL Industries Inc
Original Assignee
NL Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by NL Industries Inc filed Critical NL Industries Inc
Application granted granted Critical
Publication of CA1089186A publication Critical patent/CA1089186A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00Casting in, on, or around objects which form part of the product
    • B22D19/12Casting in, on, or around objects which form part of the product for making objects, e.g. hinges, with parts which are movable relatively to one another
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16CSHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C11/00Pivots; Pivotal connections
    • F16C11/02Trunnions; Crank-pins
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16CSHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C11/00Pivots; Pivotal connections
    • F16C11/04Pivotal connections
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16JPISTONS; CYLINDERS; SEALINGS
    • F16J1/00Pistons; Trunk pistons; Plungers
    • F16J1/10Connection to driving members
    • F16J1/14Connection to driving members with connecting-rods, i.e. pivotal connections
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16JPISTONS; CYLINDERS; SEALINGS
    • F16J1/00Pistons; Trunk pistons; Plungers
    • F16J1/10Connection to driving members
    • F16J1/14Connection to driving members with connecting-rods, i.e. pivotal connections
    • F16J1/22Connection to driving members with connecting-rods, i.e. pivotal connections with universal joint, e.g. ball-joint
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05CINDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2203/00Non-metallic inorganic materials
    • F05C2203/08Ceramics; Oxides
    • F05C2203/0865Oxide ceramics
    • F05C2203/0882Carbon, e.g. graphite

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Sliding-Contact Bearings (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Standing Axle, Rod, Or Tube Structures Coupled By Welding, Adhesion, Or Deposition (AREA)

Abstract

METHOD OF MAKING AN ARTICLE HAVING CAST-IN-PLACE BEARING

Abstract of the Disclosure A method for making a part of dissimilar metal elements as disclosed in which said metal elements are intended to be freely movable with respect to one another as in a piston and connecting rod insert. The parts are cast as a unit and freed by the disclosed heating and cooling process.

Description

1089~B6 ~`
This invention relates to a method of making a composite part of movably interconnected dissimilar metal elements, such as a piston and connecting rod insert.
U.S. Patent 3,763,535 discloses the method for fabricating an article such~as a piston which has a cap-tured connecti~g rod journaled therein. The piston is cast around the connecting rod insert end at a pressure selected to provide, upon cooling, a clearance between the insert and the piston. The selected casting pressures are well under 2~00 psi. Die casting pressures in the order of 3000 to 10,000 psi will produce a casting in which the connecting rod insert is irretrievably locked in place.
The present invention in its broadest aspect relates to a method for making a composite part of movably inter-connected dissimilar metal elements which comprises (a) introducing into a casting die a first metal element having a bearing surface thereon; (b) casting a second metal element having a lower melting point and a higher thermal conductivity than said first metal element in said castlng die to form a composite part in which said first metal element is captured at least in part in said ~;
second metal element; (c) thermally treating said composite part to provide a temperature differential between said first metal element and said second metal element whereby to free said first metal element and ~

bearing surface from said second metal element and ;
thereby establish a clearance thetebetween; and , (d) restoring the elements of said composite part to the same temperature at which no further significant contraction or expansion of said elements occurs.

. .

~...... -.' ' ' ' . ~ , ~

More particularly it provides a method for die casting a composite article such as a piston and connect-ing rod insert, for example, in which normal die casting pressures of, for example, from 3000 psi. and higher may be used. Die casting is highly advantageous in making articles of this nature because the process is faster and less expensive than other casting processes. Though the composite casting is ejected from the die with the parts frozen together, the present invention provides a method to free them one from the other. We have found that if a composite aluminum alloy-iron alloy casting is heat treated by the method of this invention, the initially frozen parts are freed and a very satisfactory product results. In more specific terms the procedure can be as ~ollows:
1. Die cast at normal high pressures.
2. Optionally quench in water as the part comes from the die casting machine if hardness is desired in the aluminum.
3. Reheat to 850F. to 950F.
.~
4. Hold the heat in step 3 for a period of ten to ~ -~

thirty minutes depending upon the clearance desired.
,~.
5. Quench in water to bring the casting back to room temperature.
6. Age or harden the aluminum alloy by hea~ing to ;

320F. to 350F. for about four hours.
7. Cool to room temperature.

Apart from the controlled temperature aspects of ~ ~

~ the invention, there is also provided, as a preferred ~;
,~ :.. , -.~.
30 embodiment, a step to obtain a long lasting lubricant ``

film between the working surfaces of the bearing and its ;:
. , .
~: ; , .
~ ., , . - , . , . , - . . , . ~,, . . ~

1089~8~

housing. This step includes the application of a coating of polytetrafluoroethylene ( hereinafter referred to by its trademark " Teflon " ) to the bearing surface prior to casting.
Certain preferred embodiments of the invention are illustrated by the attached drawings in which:
Figure l is a central, vertical, sectional view of a piston having a spherical connecting rod insert cast in place:
Figure 2 is a similar view showing a cylindrical insert configuration;
Figure 3 is a section on line 3-3 of Figure 2;
Figure 4 is a diagrammatic sectional view of a part having a cast-in-place conical insert; and Figure 5 is a diagrammatic sectional view of a part having a cast-in-place double cone insert.
The present invention constitutes a method for making any composite part such as those shown in the drawings wherein a first element such as a connecting rod is designated 10. The first ~element is received in a second element such as the body of a piston 12. The composite part need not be a piston-connecting rod com-bination, but this combination lends itself to an easily understandable description of our new method. ~ ;
In manufacturing a composite member, a first element such as a connecting rod lO is provided with a bearing ll which ultimately journals the elements of the combination ~-with respect to each other. The element is inserted into a die casting die having an appropriate configuration.
If desired, and such is usually the case, the bearing end 11 of the connecting rod is ~irst given a lubricant coating .

by swabbing the exposed end of the insert with, for example, a colloidal graphite suspension. In some instances a second lubricant such as a coating of " Teflon " is sprayed on. Coating may advantageously take place outside the die casting machine as well as after the insert has been placed in the die. The exterior of the "Teflon" coating as it is applied appears to be rough in texture, but after casting it appears that the coating has been transplanted to the surrounding casting and that the first element moves with respect to the coating which, of course, has a very low coefficient of friction.
It will be assumed that the first element of the composite part is a ferrous alloy of a composition conven-tionally used for the desired part. Such an alloy may have a melting point in the range of 2500F. to 2800F. and a coefficient of thermal expansion of 8.3 x 10-6 in. per in.
per degree F.

:;`",'i , After the first element has been properly coated and inserted into the die casting machine the die halves are closed and the shot made. The die casting pressure is normally from 3000 psi. to 10,000 psi. for an aluminum alloy. ;~-The aluminum alloy is prefera~ly of a characte~ of the alloy ¦~
known commercially as 380 alloy which has a nominal composition:
.. . .
Si................. ..9% Mg........................ .2% ~-Fe................. 1.0% Al........................ Balance Cu................. 3.5%

The melting point of such an alloy is in the range of 1000F.

-~ to 1100F. and its coefficicnt of thermal expansion is 11.7 x 10 6 in. per in. per degree F. -_ 5 _ ~

:.:. , .

1089~86 By inspection of the drawings it will be seen that the cast metal surrounds more th2n 180 of the bearing part 11 of the connecting rod so that the first element is captured by the second. The parts are ejected from the die casting machine in a locked condition and are incapable of relative movement because the cast metal has shrunk around the insert.

The composite casting is ejected from the die cast-ing machine while it is still at a tcmperaturc of about 700F.
to 800F. and i9 pre~erably quenched promptly in water to cool it to room temperature.

The composite casting is then placed in a furnace held at a temperature of between 850F. and 950~. where it will be rapidly reheated. The cast-ing remains in the furnace for a period of ten to ~ twenty minutes depending upon the final clearance de-; sired for the bearing. Longer reheat time gives greater clearance for the bearing in the final product~
, ~or example, in a part in which the bearing diameter was .565 inches and a clearance of 0.0005 inches was desired a reheat time of 25 minutes was preferred.

.
A~ter reheating, the composite part is again quenched in water. -At about 600F. the surrounding aluminum alloy has a greatly reduced tensile strength and yield point and reheating has carried the aluminum alloy above this temperature. Quenching now results in a rapid contraction of the aluminum alloy around the still hot ferrous alloy element. As the aluminum cools it appears to take a permanent set at the ex-.'-.

' . ' ~ . . . ~ , ~ .

panded dimension of the ferrous alloy part which i~cooled l~ter in the quenching cycle because it has been largely insulated rom the quenching liquid by the aluminum alloy. When the ferrous ~lloy element finally reaches thc t~mperature of the quenching medium a ~lear-ance exists between the elements and the bearing is now free in its socket.
A preferred final step in the process consists in hardening the aluminum alloy by soaking at a tempera-ture of from 320F. to 350~F. for a period of about four hours. This har~ening or aging of the aluminum alloy is known to improve its resistance to wear, and its hardness, and is known as a T-5 heat treatment.

After aging the parts are again cooled and are now ready for final assembly and the bearing surface 11 is fully operative to journal one part with respect to the -other. The graphite and"Teflon"coatings have not been destroyed by the successive heating and cooling steps but -are functional to serve as inplace lubricants. The har~
dening treatment has given the aluminum alloy a Brinell hardness of approximately 100 so that minimum wear occurs.

,.' ~-As'previously noted, the "Teflon" coating appears to be stationary with respect to the body 12 and the bearing -11 moves therein. This transplanting of the "Teflon" coating from the bearing 11 to the body 12 probably takes place during the die casting operation itself.

The configuration of the insert, whether it be spheric~l, cylindrical or conical is not important since the method can be employed with any of these confiourations and others.

It has been found that instead of reheating the casting as in steps3 and 4 ctated above, a clearance between the parts can be established by immersing the casting in liquid nitrogen for a period of 15 to 30 minutes. In this case the aluminum shrinks away from the ferrous alloy part due to its high heat conductivity After the shrinkagc step the heat treatment proceeds as before. This phenomenon would give rise to the proposition that it is only necessary to establish a temperature differ~
ential between the two alloys to bring about the desired ~ ;
clearance. The time required will depend on the relative mass of the parts being treated. ;-;, --' ' !`~

;i~, i'' ` ~
, ; ~

,' ~

; - 8 - ~

, :

Claims (11)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A method for making a composite part of movably interconnected dissimilar metal elements which comprises (a) introducing into a casting die a first metal element having a bearing surface thereon;
(b) casting a second metal element having a lower melting point and a higher thermal conductivity than said first metal element in said casting die to form a composite part in which said first metal element is captured at least in part in said second metal element;
(c) thermally treating said composite part to provide a temperature differential between said first metal element and said second metal element whereby to free said first metal element and bearing surface from said second metal element and thereby establish a clearance therebetween;
and (d) restoring the elements of said composite part to the same temperature at which no further significant contraction or expansion of said elements occurs.
2. The method of claim 1 including the additional step of hardening said second metal element by heating said composite part at a temperature and for a period of time sufficient to refine the grain structure and improve the hardness of said second metal element.
3. The method of claim 1 wherein the composite part is thermally treated by differential heating.
4. The method of claim 1 wherein the composite part is thermally treated by differential low temperature cooling.
5. The method defined in claim 1 or 2 wherein a coating of polytetrafluoroethylene is applied to the first element prior to casting the second element to form said composite part.
6. A method for making a composite part of dis-similar metal elements wherein each of said dissimilar metal elements is movable with respect to the other which comprises (a) introducing into a die casting die a first element having a bearing surface thereon and having a higher melting point and a lower thermal conductivity than the element finally surrounding it;
(b) casting a second element having a lower melting point and a higher thermal expansion coefficient in said die cast-ing die to form a composite in which said first element is captured at least in part in said casting;
(c) ejecting the composite part from the die;
(d) reheating the composite part to at least a temperature at which the tensile strength of said second element is greatly reduced;
(e) quenching said reheated com-ponent so that the second element shrinks around said first element while the tem-perature of said first element is still elevated and is thus still capable of shrinking away from said second element upon cooling to establish a clearance therebetween; and (f) hardening said second element by reheating said composite a second time for a period sufficient to refine the grain structure and improve the hardness of said second element.
7. The method defined by claim 6, and quenching the casting as it is removed from the die casting machine.
8. The method defined in claim 1, 2 or 6, in which said first element is an alloy of iron and said second element is an aluminum alloy.
9. The method defined in claim 6 in which said first reheating temperature is within the range of 850°F;. to 950
10. The method defined in claim 9 in which said first reheating time is from about seven minutes to about twenty minutes depending upon the ultimate clearance desired between the first and second elements of the composite part.
11. The method defined in claim 1, 2 or 6 in which said hardening step comprises reheating said composite part to between 320°F. and 350°F. for a period of from three hours to four hours.
CA284,595A 1976-08-18 1977-08-12 Method of making an article having cast-in-place bearing Expired CA1089186A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US71541876A 1976-08-18 1976-08-18
US715,418 1976-08-18

Publications (1)

Publication Number Publication Date
CA1089186A true CA1089186A (en) 1980-11-11

Family

ID=24873957

Family Applications (1)

Application Number Title Priority Date Filing Date
CA284,595A Expired CA1089186A (en) 1976-08-18 1977-08-12 Method of making an article having cast-in-place bearing

Country Status (7)

Country Link
JP (1) JPS5323821A (en)
AU (1) AU511168B2 (en)
CA (1) CA1089186A (en)
DE (1) DE2736702A1 (en)
FR (1) FR2361961A1 (en)
GB (1) GB1545688A (en)
IT (1) IT1083935B (en)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2463316A1 (en) * 1979-08-09 1981-02-20 Auboiroux Jean Inexpensive monolithic assemblies contg. parts free to rotate - where one part is used as insert in casting or moulding to make valves, ball joints, and many other mechanical assemblies
US4505016A (en) * 1983-06-30 1985-03-19 Borg-Warner Corporation Method of manufacturing a die-cast wobble plate assembly
DE19819082A1 (en) * 1998-04-29 1999-11-04 Bayerische Motoren Werke Ag Method for forming a split bearing arrangement in a cast machine housing, in particular plain bearings for reciprocating piston machines
DE102006036690A1 (en) * 2006-08-05 2008-02-07 Forschungszentrum Karlsruhe Gmbh Compound and a method for producing the same
CN114562499B (en) * 2022-03-14 2023-05-05 东莞职业技术学院 Reinforced aluminum alloy mortise and tenon structure

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5325290B2 (en) * 1973-08-30 1978-07-26

Also Published As

Publication number Publication date
AU511168B2 (en) 1980-07-31
FR2361961A1 (en) 1978-03-17
IT1083935B (en) 1985-05-25
DE2736702A1 (en) 1978-02-23
GB1545688A (en) 1979-05-10
FR2361961B1 (en) 1983-07-22
AU2798877A (en) 1979-02-22
JPS5323821A (en) 1978-03-04

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