CA2039878A1 - Process for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine - Google Patents
Process for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engineInfo
- Publication number
- CA2039878A1 CA2039878A1 CA002039878A CA2039878A CA2039878A1 CA 2039878 A1 CA2039878 A1 CA 2039878A1 CA 002039878 A CA002039878 A CA 002039878A CA 2039878 A CA2039878 A CA 2039878A CA 2039878 A1 CA2039878 A1 CA 2039878A1
- Authority
- CA
- Canada
- Prior art keywords
- lining
- process according
- metal
- crankcase
- cast
- 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.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000002485 combustion reaction Methods 0.000 title claims abstract description 8
- 239000000463 material Substances 0.000 claims abstract description 34
- 238000005266 casting Methods 0.000 claims abstract description 30
- 229910052751 metal Inorganic materials 0.000 claims abstract description 29
- 239000002184 metal Substances 0.000 claims abstract description 29
- 238000000151 deposition Methods 0.000 claims abstract description 14
- 229910001092 metal group alloy Inorganic materials 0.000 claims abstract description 4
- 150000002739 metals Chemical class 0.000 claims abstract description 4
- 238000004381 surface treatment Methods 0.000 claims abstract description 4
- 239000002131 composite material Substances 0.000 claims description 16
- 230000002787 reinforcement Effects 0.000 claims description 13
- 239000011159 matrix material Substances 0.000 claims description 12
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 11
- 230000008021 deposition Effects 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 239000000843 powder Substances 0.000 claims description 8
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 7
- 239000000956 alloy Substances 0.000 claims description 7
- 239000000919 ceramic Substances 0.000 claims description 7
- 229910052749 magnesium Inorganic materials 0.000 claims description 7
- 239000011777 magnesium Substances 0.000 claims description 7
- 229910000838 Al alloy Inorganic materials 0.000 claims description 6
- 238000001764 infiltration Methods 0.000 claims description 6
- 230000008595 infiltration Effects 0.000 claims description 6
- 238000004544 sputter deposition Methods 0.000 claims description 6
- 238000001125 extrusion Methods 0.000 claims description 4
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 3
- 238000003754 machining Methods 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 238000004663 powder metallurgy Methods 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 239000011248 coating agent Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 238000004512 die casting Methods 0.000 claims description 2
- 238000005242 forging Methods 0.000 claims description 2
- 229910052741 iridium Inorganic materials 0.000 claims description 2
- 238000003475 lamination Methods 0.000 claims description 2
- 229910052750 molybdenum Inorganic materials 0.000 claims description 2
- 229910052759 nickel Inorganic materials 0.000 claims description 2
- 229910052758 niobium Inorganic materials 0.000 claims description 2
- 229910052755 nonmetal Inorganic materials 0.000 claims description 2
- 229910052763 palladium Inorganic materials 0.000 claims description 2
- 238000007750 plasma spraying Methods 0.000 claims description 2
- 229910052697 platinum Inorganic materials 0.000 claims description 2
- 229910052702 rhenium Inorganic materials 0.000 claims description 2
- 229910052703 rhodium Inorganic materials 0.000 claims description 2
- 229910052707 ruthenium Inorganic materials 0.000 claims description 2
- 229910052709 silver Inorganic materials 0.000 claims description 2
- 239000007787 solid Substances 0.000 claims description 2
- 238000009716 squeeze casting Methods 0.000 claims description 2
- 229910052715 tantalum Inorganic materials 0.000 claims description 2
- 238000002207 thermal evaporation Methods 0.000 claims description 2
- 229910052721 tungsten Inorganic materials 0.000 claims description 2
- 229910052726 zirconium Inorganic materials 0.000 claims description 2
- 229910052580 B4C Inorganic materials 0.000 claims 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims 3
- 229910052593 corundum Inorganic materials 0.000 claims 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims 3
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 3
- 229910052581 Si3N4 Inorganic materials 0.000 claims 2
- 238000005229 chemical vapour deposition Methods 0.000 claims 2
- 229910052681 coesite Inorganic materials 0.000 claims 2
- 229910052906 cristobalite Inorganic materials 0.000 claims 2
- 229910052682 stishovite Inorganic materials 0.000 claims 2
- 229910052905 tridymite Inorganic materials 0.000 claims 2
- 229910020489 SiO3 Inorganic materials 0.000 claims 1
- 238000005234 chemical deposition Methods 0.000 claims 1
- 238000004070 electrodeposition Methods 0.000 claims 1
- 238000005516 engineering process Methods 0.000 claims 1
- 229910003465 moissanite Inorganic materials 0.000 claims 1
- 229910052762 osmium Inorganic materials 0.000 claims 1
- 229910010271 silicon carbide Inorganic materials 0.000 claims 1
- 239000000377 silicon dioxide Substances 0.000 claims 1
- 235000012239 silicon dioxide Nutrition 0.000 claims 1
- 229910021364 Al-Si alloy Inorganic materials 0.000 description 7
- 229910052737 gold Inorganic materials 0.000 description 5
- 239000010931 gold Substances 0.000 description 5
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910001018 Cast iron Inorganic materials 0.000 description 3
- 230000005496 eutectics Effects 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 230000005484 gravity Effects 0.000 description 3
- 239000007769 metal material Substances 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229910001338 liquidmetal Inorganic materials 0.000 description 2
- 239000011156 metal matrix composite Substances 0.000 description 2
- 238000005272 metallurgy Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 238000005493 welding type Methods 0.000 description 2
- QIVUCLWGARAQIO-OLIXTKCUSA-N (3s)-n-[(3s,5s,6r)-6-methyl-2-oxo-1-(2,2,2-trifluoroethyl)-5-(2,3,6-trifluorophenyl)piperidin-3-yl]-2-oxospiro[1h-pyrrolo[2,3-b]pyridine-3,6'-5,7-dihydrocyclopenta[b]pyridine]-3'-carboxamide Chemical compound C1([C@H]2[C@H](N(C(=O)[C@@H](NC(=O)C=3C=C4C[C@]5(CC4=NC=3)C3=CC=CN=C3NC5=O)C2)CC(F)(F)F)C)=C(F)C=CC(F)=C1F QIVUCLWGARAQIO-OLIXTKCUSA-N 0.000 description 1
- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- 229910005091 Si3N Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000004581 coalescence Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- -1 e.g. Substances 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F7/00—Casings, e.g. crankcases or frames
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F1/00—Cylinders; Cylinder heads
- F02F1/004—Cylinder liners
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F7/00—Casings, e.g. crankcases or frames
- F02F7/0085—Materials for constructing engines or their parts
- F02F2007/009—Hypereutectic aluminum, e.g. aluminum alloys with high SI content
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
- Treatment Of Steel In Its Molten State (AREA)
- Non-Disconnectible Joints And Screw-Threaded Joints (AREA)
Abstract
"PROCESS FOR OBTAINING A CONTINUOUS METALLURGICAL BOND
BETWEEN THE LININGS OF THE CYLINDERS AND THE CAST WHICH
CONSTITUTES THE CRANKCASE OF AN INTERNAL-COMBUSTION
ENGINE"
Abstract A process for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine, which crankcase is made from a material different from the material uhich constitutes the linings, is disclosed, which process comprises carrying out a surface treatment by depositing a thin metal layer on the external surface of the lining, uhich metal is different from the metals which constitute the lining and the crankcase cast, and is capable of increasing the wettability of, and the heat transfer coefficient between, the materials which constitute the lining and the cast; and casting around tha same lining, positioned inside the mould, the metal or metal alloy from which the crankcase is made.
BETWEEN THE LININGS OF THE CYLINDERS AND THE CAST WHICH
CONSTITUTES THE CRANKCASE OF AN INTERNAL-COMBUSTION
ENGINE"
Abstract A process for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine, which crankcase is made from a material different from the material uhich constitutes the linings, is disclosed, which process comprises carrying out a surface treatment by depositing a thin metal layer on the external surface of the lining, uhich metal is different from the metals which constitute the lining and the crankcase cast, and is capable of increasing the wettability of, and the heat transfer coefficient between, the materials which constitute the lining and the cast; and casting around tha same lining, positioned inside the mould, the metal or metal alloy from which the crankcase is made.
Description
20398~8 PRûCESS FOR OBTAINING A CONTiNUOUS METALLURGICAL BûNG
., .
BETWEEN THE LININGS OF THE C`;LINDERS ANG THE CAST WHICH
CONSTITUTES THE CRAN~CASE OF AN INTERNAL-COMBUSTION
ENGINE
The present invention relates to a process for obtainin3 a continuous metaLlur3ical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine.
: 5 In an internal-com~ustion engine, each piston, made from an aluminum alloy, slides with precision inside a cylindrical hollow provided inside the crankcase of the engine, which is generally made from cast iron, but which can also be obtained from a cast made from an aluminum 1~ alLoy.
The precision of such a sliding is secured by segmentsor.~lastic piston r~made from steel or cast iron, arranged around the piston. In particular, in the crankcases made from aluminum alloys, the frictior. of the piston rings on the inner walls of the cylinder cause the latter to be worn and, over time, such a wear decreases the sliding precision, with the efficiency of the engine being consequently reduced.
In order to obviate this drawback, inside the hollow 2~ of the cylinders linings are inserted, which are made from high-wear-stren3th materials, such as, e.g., steel or other aluminum alloys.
These linings are inserted inside the engine crankca~e, after the latter is manufactured by casting, by heat-fitting or, during the same casting step, arranging the linings as inserts inside the casting mold.
In both cases, the coupling between the lining and the 2039~378 crankcas~ i5 achieved by n1echanical gripping, without material continuity, and this may cause drawbacks in tne cooling down of the internal surface of the cylinders by effect of poor heat conductivity due to the discontinuity between the materiaLs. Furthermore, owing to such a discontinuity, and to the difference between the coefficience of heat expansion of the different materials, in the mean time, following repeated termal cycles, the adhesion and the mechanical hooking between the crankcase and the lining decreases, with said crankcase and lining consequently getting detached from each other and undergoing mutual movements, causing, due to the effect of insufficient cooling, a rapid decay of the quality of the internal lining surface finish.
ihe present Applicant has found no~ that by means of a suitable surface treatment of the linings of the cylinders, a strong metallurgical bond can be obtained between said linings and the cast which constitutes the crankcase of an internal-combustion engine.
In particular, the process according to the present invention secures that the classic requirements of the welding operations are met: removal of surface impurities and oxides, intimate contact and coalescence of the materials to be bonded.
~5 However, this type of welding is very different from other methods in that no external energy sources are required te.s., heat, ultrasounds, and so forth) and the welding takes place during the course of the same casting.
3û Furthermore, metals which can be not easily coupled by means of other techniques can be bonded by means of 20398~8 ,.
' such a welding type.
The proces~ according to the present invention for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine, which crankcase is rnade from a materiaL different from the material which constitutes the linings, comprises carrying out a surface treatment by physically, chemically or electrochemically depositing a thin metal layer on the external surface of the lining, which metal is different from the metals which are containad in the materials of the lining and of the crankcase, and is capable of increasirg the wettability of, and the heat transfer coefficient between, the alloy which constitutes the crankcase and the material which constitutes the lining and the cast, and casting around the same lining, positioned inside the mou~d, the metal or metal alloy from which the crankcase is made.
The lining and the cast can be constituted by aluminum or magnesium or by aluminum or magnesium alloys:
however, they must have mutually different compositions.
The lining may also be made from a composite material having as its metal matrix, aluminum or magnesium or aluminum or magnesium alloys: such a type of material is constituted by a metal phase ~or a metal alloy phase), which surrounds and links other phases, which constitute the reinforcement (powders or ceramic fibres).
The reinforcement is endowed with high values of mechanical strength and hardness, and the stresses to which the matrix is submitted are transferred to it. The 203987~
matrix, on the other hand~ should be endowed with sui.aole characteristics as a function of the envisaged type of ap~lication.
The reinforcement can be constituted by long ceramic fibres or short ceramic fibres t~l~0~, SiC, âi~N~; BN, Si~) or by ceramic "whiskers" ~SiC, Si~N4, B~C, Al~0~) or by non-metal powders ~âiC, BN, Si3N~, ~4C, Siû~ or Al~0~).
The methods for preparing the composites can be the following:
- Dispersion of the reinforcement in the matrix on the molten state;
- Dispersion of the reinforcement in the matrix in a ' partially solid tatei ` 15 - Powder metallurgy;
- Fiber metallurgy;
- Layer compacting;
- Infiltration.
The composite material can be obtained either directly or by maans of a following mechanical machining/processing.
The metal which constitutes the thin layer, preferably ha~ing a thickness comprised within the range of from 10 to 100 nm, to be deposited onto the surface of the metal material or of the metal-matrix composite material, which should be different from those contained in the materials and in ` `. the cast, can be preferably selected from among Au, Ag, Cu, Ni, Pt, Pd, Cr, W, Ir, Mo, Ta, Nb, ûs, Re, Rh, Ru and Zr.
The deposition of said thin metal layer can be preferably carried out by "sputtering" or by 20;~98~8 5.
electrochen7ical deposition.
Also any other methods known in the art, of chemical, physical, and so forth, types, for surface coatiny can be used: for example, plasma-spraying, laser-assisted deposition, thermal-evaporation deposition, magneton-assisted deposition, CDV ("Chem;cal Vapour Deposition"), and so forth.
By using a suitable coating, the liquid to be cast will be capable of wetting the metal material or the metal-matrix composite to a sufficient extent to transfer heat to it, wash out the layer of oxide which is unavoidaoly formed on the surface of said material and directly binding to the material, in case a metal material ;s used, or to the metal matrix, if a composite is used.
Once that the material is adequately cleaned, coated and positioned inside the casting die, the casting operating parameters have to be so adjusted as to secure that a suitable stream of overheated liquid will lap the surfaces of the materials.
It is important that the position of the material inside the die is suitably selected and that the shape of the downward duct tingress duct) and of the upward duct (egress duct) inside the die is properly designed, so that the liquid metal will be obliged to lap, wet and wash out the walls of the material before said liquid metal is cooled down to a too low temperature.
Hence, the matter is of keeping under control the following three parameters: material pre-heating temperature, metal (or alloy) casting temperature, flux conditions. In such a way, an excellent metallurgical o 2039878 bond bet~eer, the material and the cast can be obtained.
The linings of the cyiinders can be obtained by means of techni4ues known in the art tfor example:
gravity casting or pressure casting or die-casting or squeeze-casting; or po~der metallurgy, or by infiltration or blending), and either directly or by a successive mechanical machining by tool machines or by plastic-working processes (such as extrusion, lamination or forging). Some examples are no~ given, ~hich have the purpose of better illustrating the invention, but which in no ~ay should be construed as being limitative of the same invention:
EXAMPLE_l 5Labo_ato y_te__3 - The lining is constituted by a tube made from a hypereutectic alloy of Al-Si ~ith a content of 17% of Si, with an outer diameter of 50 mm, a thickness of 5 mm and a height of 65 mm, obta;ned by gravity cast;ng.
- The outer surface of the lining is coated by sputtering ~ith a thin gold layer.
- The material ~hich constitutes the cast is an AL-Si alloy with a content of 9~of Si.
- The casting die i5 made of graphite tFigure ), ~herein:
(1) is the graphite die, (2) is the lining, and (3) is the casting channel.
- The lining and the die are pre-heated at ;500C.
- The temperature of the metal of the cast is of 7000C.
- The volume of cast material is of approximately 400 cm3.
7. 2()398~3 The casting is carried out in by bottom casting.
_`AArlPLE_2 ~LaDoratory tes ) The lin;ng is constituted by a tube made from a composite materiaL with an outer diameter oF S0 mm, a thickness of 5 mm and a height of 65 mm, obtained by gravity casting.
The composite material, ootained by infiltration, is constituted by a matrix of an eutectic Al-Si alloy, with a content of 13X, of Si, and with a reinforcement constituted by an SiC powder at 55X by volume (average diameter of po~der particles: 2ûym)~
The outer surface of the lining is coated by spu-ttering ~ith a thin gold layer~
The ma-t~rial ~hich constitutes the cast is an Al-Si alloy with a content of 9X of Si.
The casting die is made of graphite (Figure ), as in Example 1 The lining and the die are pre-heated at 3000C.
The temperature of the metal of the cast is of 6505C.
The volume of cast material is of approximately 400 cm3.
The casting is carried out by bottom casting _XA~PL__3 (I_du_t_ial_T___) The test was carried out on an industrial facility for casting crankcases for four-cylinder engines.
The linings, obtained by extrusion, are constituted by tubes made from a composite material, with an outer diameter of approximately 95 mm, a thickness of about 5 mm and a height of about 130 mm 8. 20~g878 - The composite mate,ia;, obtained by infiltration and dilution, i5 constituted by a matrix of an eutectic Al-Si alloy, ~ith a cor,tent of ~3^,' of Si, and with a reinforcement constituted by an SiC powder at 25^~ by volume (average diameter of the pohder 20~m).
- The outer surface of the lining is coated by sputtering with a thin gold layer.
- The material ~hich constitutes the cast is an Al-Si alloy with a content of 9% of Si.
- 10 - The industrial casting die is made of cast iron.
- The linings are pre-heated at 3000C.
- The temperature of the cast metal is of about 7ûO~C.
- The volume of cast material is of approximateLy 10 dm3.
- The casting is carried out by bottom casting.
ExAMpLE-4 ~Ingu~t_ial__est) - The test was carr;ed out on an industrial facility for casting crankcases for four-cylinder engines.
- The linings, obtained by extrusion, are constituted by tubes made from a composite material, with an outer diameter of approximately 95 mm, a thickness of about 5 mm and a height of about 130 mm.
- The composite material, obtained by mixing, is constituted by a matrix of an eutectic Al-Si alloy, with a content of 9% of Si, and with a reinforcement constituted by an SiC powder at 15% by volume (average diameter of the powder 20~m~.
- The outer surface oF the lining is coated by sputtering with a thin gold layer.
- The material which constitutes the cast i5 an Al-Si alloy with a content of 9% of Si.
- The ir,du 5 trial casting die is made of cast iror,.
- The linings are pre-heated at 3000C.
- The die is preheated at about 3700C.
- The tenperature of the cas. metal is of about 7000C.
- The volume of cast material is oF approximately 10 dm3.
- The casting i5 carried out by bottom casting~
., .
BETWEEN THE LININGS OF THE C`;LINDERS ANG THE CAST WHICH
CONSTITUTES THE CRAN~CASE OF AN INTERNAL-COMBUSTION
ENGINE
The present invention relates to a process for obtainin3 a continuous metaLlur3ical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine.
: 5 In an internal-com~ustion engine, each piston, made from an aluminum alloy, slides with precision inside a cylindrical hollow provided inside the crankcase of the engine, which is generally made from cast iron, but which can also be obtained from a cast made from an aluminum 1~ alLoy.
The precision of such a sliding is secured by segmentsor.~lastic piston r~made from steel or cast iron, arranged around the piston. In particular, in the crankcases made from aluminum alloys, the frictior. of the piston rings on the inner walls of the cylinder cause the latter to be worn and, over time, such a wear decreases the sliding precision, with the efficiency of the engine being consequently reduced.
In order to obviate this drawback, inside the hollow 2~ of the cylinders linings are inserted, which are made from high-wear-stren3th materials, such as, e.g., steel or other aluminum alloys.
These linings are inserted inside the engine crankca~e, after the latter is manufactured by casting, by heat-fitting or, during the same casting step, arranging the linings as inserts inside the casting mold.
In both cases, the coupling between the lining and the 2039~378 crankcas~ i5 achieved by n1echanical gripping, without material continuity, and this may cause drawbacks in tne cooling down of the internal surface of the cylinders by effect of poor heat conductivity due to the discontinuity between the materiaLs. Furthermore, owing to such a discontinuity, and to the difference between the coefficience of heat expansion of the different materials, in the mean time, following repeated termal cycles, the adhesion and the mechanical hooking between the crankcase and the lining decreases, with said crankcase and lining consequently getting detached from each other and undergoing mutual movements, causing, due to the effect of insufficient cooling, a rapid decay of the quality of the internal lining surface finish.
ihe present Applicant has found no~ that by means of a suitable surface treatment of the linings of the cylinders, a strong metallurgical bond can be obtained between said linings and the cast which constitutes the crankcase of an internal-combustion engine.
In particular, the process according to the present invention secures that the classic requirements of the welding operations are met: removal of surface impurities and oxides, intimate contact and coalescence of the materials to be bonded.
~5 However, this type of welding is very different from other methods in that no external energy sources are required te.s., heat, ultrasounds, and so forth) and the welding takes place during the course of the same casting.
3û Furthermore, metals which can be not easily coupled by means of other techniques can be bonded by means of 20398~8 ,.
' such a welding type.
The proces~ according to the present invention for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine, which crankcase is rnade from a materiaL different from the material which constitutes the linings, comprises carrying out a surface treatment by physically, chemically or electrochemically depositing a thin metal layer on the external surface of the lining, which metal is different from the metals which are containad in the materials of the lining and of the crankcase, and is capable of increasirg the wettability of, and the heat transfer coefficient between, the alloy which constitutes the crankcase and the material which constitutes the lining and the cast, and casting around the same lining, positioned inside the mou~d, the metal or metal alloy from which the crankcase is made.
The lining and the cast can be constituted by aluminum or magnesium or by aluminum or magnesium alloys:
however, they must have mutually different compositions.
The lining may also be made from a composite material having as its metal matrix, aluminum or magnesium or aluminum or magnesium alloys: such a type of material is constituted by a metal phase ~or a metal alloy phase), which surrounds and links other phases, which constitute the reinforcement (powders or ceramic fibres).
The reinforcement is endowed with high values of mechanical strength and hardness, and the stresses to which the matrix is submitted are transferred to it. The 203987~
matrix, on the other hand~ should be endowed with sui.aole characteristics as a function of the envisaged type of ap~lication.
The reinforcement can be constituted by long ceramic fibres or short ceramic fibres t~l~0~, SiC, âi~N~; BN, Si~) or by ceramic "whiskers" ~SiC, Si~N4, B~C, Al~0~) or by non-metal powders ~âiC, BN, Si3N~, ~4C, Siû~ or Al~0~).
The methods for preparing the composites can be the following:
- Dispersion of the reinforcement in the matrix on the molten state;
- Dispersion of the reinforcement in the matrix in a ' partially solid tatei ` 15 - Powder metallurgy;
- Fiber metallurgy;
- Layer compacting;
- Infiltration.
The composite material can be obtained either directly or by maans of a following mechanical machining/processing.
The metal which constitutes the thin layer, preferably ha~ing a thickness comprised within the range of from 10 to 100 nm, to be deposited onto the surface of the metal material or of the metal-matrix composite material, which should be different from those contained in the materials and in ` `. the cast, can be preferably selected from among Au, Ag, Cu, Ni, Pt, Pd, Cr, W, Ir, Mo, Ta, Nb, ûs, Re, Rh, Ru and Zr.
The deposition of said thin metal layer can be preferably carried out by "sputtering" or by 20;~98~8 5.
electrochen7ical deposition.
Also any other methods known in the art, of chemical, physical, and so forth, types, for surface coatiny can be used: for example, plasma-spraying, laser-assisted deposition, thermal-evaporation deposition, magneton-assisted deposition, CDV ("Chem;cal Vapour Deposition"), and so forth.
By using a suitable coating, the liquid to be cast will be capable of wetting the metal material or the metal-matrix composite to a sufficient extent to transfer heat to it, wash out the layer of oxide which is unavoidaoly formed on the surface of said material and directly binding to the material, in case a metal material ;s used, or to the metal matrix, if a composite is used.
Once that the material is adequately cleaned, coated and positioned inside the casting die, the casting operating parameters have to be so adjusted as to secure that a suitable stream of overheated liquid will lap the surfaces of the materials.
It is important that the position of the material inside the die is suitably selected and that the shape of the downward duct tingress duct) and of the upward duct (egress duct) inside the die is properly designed, so that the liquid metal will be obliged to lap, wet and wash out the walls of the material before said liquid metal is cooled down to a too low temperature.
Hence, the matter is of keeping under control the following three parameters: material pre-heating temperature, metal (or alloy) casting temperature, flux conditions. In such a way, an excellent metallurgical o 2039878 bond bet~eer, the material and the cast can be obtained.
The linings of the cyiinders can be obtained by means of techni4ues known in the art tfor example:
gravity casting or pressure casting or die-casting or squeeze-casting; or po~der metallurgy, or by infiltration or blending), and either directly or by a successive mechanical machining by tool machines or by plastic-working processes (such as extrusion, lamination or forging). Some examples are no~ given, ~hich have the purpose of better illustrating the invention, but which in no ~ay should be construed as being limitative of the same invention:
EXAMPLE_l 5Labo_ato y_te__3 - The lining is constituted by a tube made from a hypereutectic alloy of Al-Si ~ith a content of 17% of Si, with an outer diameter of 50 mm, a thickness of 5 mm and a height of 65 mm, obta;ned by gravity cast;ng.
- The outer surface of the lining is coated by sputtering ~ith a thin gold layer.
- The material ~hich constitutes the cast is an AL-Si alloy with a content of 9~of Si.
- The casting die i5 made of graphite tFigure ), ~herein:
(1) is the graphite die, (2) is the lining, and (3) is the casting channel.
- The lining and the die are pre-heated at ;500C.
- The temperature of the metal of the cast is of 7000C.
- The volume of cast material is of approximately 400 cm3.
7. 2()398~3 The casting is carried out in by bottom casting.
_`AArlPLE_2 ~LaDoratory tes ) The lin;ng is constituted by a tube made from a composite materiaL with an outer diameter oF S0 mm, a thickness of 5 mm and a height of 65 mm, obtained by gravity casting.
The composite material, ootained by infiltration, is constituted by a matrix of an eutectic Al-Si alloy, with a content of 13X, of Si, and with a reinforcement constituted by an SiC powder at 55X by volume (average diameter of po~der particles: 2ûym)~
The outer surface of the lining is coated by spu-ttering ~ith a thin gold layer~
The ma-t~rial ~hich constitutes the cast is an Al-Si alloy with a content of 9X of Si.
The casting die is made of graphite (Figure ), as in Example 1 The lining and the die are pre-heated at 3000C.
The temperature of the metal of the cast is of 6505C.
The volume of cast material is of approximately 400 cm3.
The casting is carried out by bottom casting _XA~PL__3 (I_du_t_ial_T___) The test was carried out on an industrial facility for casting crankcases for four-cylinder engines.
The linings, obtained by extrusion, are constituted by tubes made from a composite material, with an outer diameter of approximately 95 mm, a thickness of about 5 mm and a height of about 130 mm 8. 20~g878 - The composite mate,ia;, obtained by infiltration and dilution, i5 constituted by a matrix of an eutectic Al-Si alloy, ~ith a cor,tent of ~3^,' of Si, and with a reinforcement constituted by an SiC powder at 25^~ by volume (average diameter of the pohder 20~m).
- The outer surface of the lining is coated by sputtering with a thin gold layer.
- The material ~hich constitutes the cast is an Al-Si alloy with a content of 9% of Si.
- 10 - The industrial casting die is made of cast iron.
- The linings are pre-heated at 3000C.
- The temperature of the cast metal is of about 7ûO~C.
- The volume of cast material is of approximateLy 10 dm3.
- The casting is carried out by bottom casting.
ExAMpLE-4 ~Ingu~t_ial__est) - The test was carr;ed out on an industrial facility for casting crankcases for four-cylinder engines.
- The linings, obtained by extrusion, are constituted by tubes made from a composite material, with an outer diameter of approximately 95 mm, a thickness of about 5 mm and a height of about 130 mm.
- The composite material, obtained by mixing, is constituted by a matrix of an eutectic Al-Si alloy, with a content of 9% of Si, and with a reinforcement constituted by an SiC powder at 15% by volume (average diameter of the powder 20~m~.
- The outer surface oF the lining is coated by sputtering with a thin gold layer.
- The material which constitutes the cast i5 an Al-Si alloy with a content of 9% of Si.
- The ir,du 5 trial casting die is made of cast iror,.
- The linings are pre-heated at 3000C.
- The die is preheated at about 3700C.
- The tenperature of the cas. metal is of about 7000C.
- The volume of cast material is oF approximately 10 dm3.
- The casting i5 carried out by bottom casting~
Claims (16)
- c l a i m s -----------l. Process for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine, which crankcase is made from a material different from the material which constitutes the linings, comprising carrying out a surface treatment by depositing a thin metal layer on the external surface of the lining, which metal is different from the metals which are contained in the materials of the lining and of the crankcase, and is capable of increasing the wettability of, and the heat transfer coefficient between, the alloy which constitutes the cast and the material which constitutes the lining, and casting around the same lining, positioned inside the mould, the metal or metal alloy from which the crankcase is made.
- 2. Process according to claim 1, in which the crankcase is constituted by aluminum or magnesium, or by alloys of aluminum or magnesium.
- 3. Process according to claim l, in which the lining is constituted by aluminum or magnesium, or by alloys of aluminum or magnesium.
- 4. Process according to claim 1, in which the lining is constituted by a composite material having aluminum or magnesium, or aluminum or magnesium alloys as its matrix.
- 5. Process according to claim 4, in which the lining is constituted by a composite material containing non-metal powders selected from among SiC, BN, SiaN4, B4C, Si02 or Al203, as its reinforcement.
- 6. Process according to claim 4, in which the lining is constituted by a composite material having ceramic 11.
whiskers seiected fror,l among SiC, Si3N4, B4C, SiO2 or Al2O3, as its reinforcement. - 7. Process according to claim 4, in which the lining is constituted by a composite material having long or short ceramic fibres selected from among SiC,BN, Si3N4,B4C, SiO3 or Al2O3, as its reinforcement.
- 8. Process according to claims 5 or 6 or 7, in which the lining is constituted by a composite material containing powders, whiskers or lony or short ceramic fibres, in a concentration of from 10 to 60% by volume, as its re;nforcement.
- 9. Process according to claim 1, in which the metal to be deposited on the external surface of the lining is selected from among Au, Ag, Cu, Ni, Pt, Pd, Cr, W, Ir, Mo, Ta, Nb, Os, Re, Rh, Ru and Zr.
- 10. Process according to claim 1, in which the deposition of a thin layer of metal takes place by sputtering.
- 11. Process according to claim 1, in which the deposition of a thin layer of metal takes place by electrochemical deposition.
- 12. Process according to claim 1, in which the deposition of a thin layer of metal takes place by chemical deposition.
- 13. Process according to claim 1, in which the deposition of a thin layer of metal takes place by plasma-spraying or by thermal evaporation or by CVD
(Chemical Vapor Deposition), or by a laser-assisted or magnetron-assisted deposition technology. - 14. Process according to claim 1, in which the lining is obtained by gravity-casting; or pressure-12.
casting or die-casting or squeeze-casting, or by powder metallurgy or by infiltration or blending, either directly or with successive mechanical tool-machining or mechanical plastic processing, such as extrusion, lamination or forging. - 15. Process according to claim 4, in which the composite material is obtained by dispersing the reinforcement in the matrix in the molten state, or by dispersing the reinforcement in the matrix in a partially solid state, or by powder metallurgy, or by metal-coating the fibres, or by layer-compacting, or infiltration.
- 16. Process according to claim 1, in which the thin metal layer deposited on the outer surface of the lining is comprised within the range of from 10 nm to 100 nm.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IT19968A/90 | 1990-04-06 | ||
| IT19968A IT1240746B (en) | 1990-04-06 | 1990-04-06 | PROCEDURE FOR OBTAINING A CONTINUOUS METALLURGIC LINK BETWEEN CYLINDER BARRELS ID THE JET CONSTITUTING THE BASE OF AN INTERNAL COMBUSTION ENGINE |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2039878A1 true CA2039878A1 (en) | 1991-10-07 |
Family
ID=11162713
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002039878A Abandoned CA2039878A1 (en) | 1990-04-06 | 1991-04-05 | Process for obtaining a continuous metallurgical bond between the linings of the cylinders and the cast which constitutes the crankcase of an internal-combustion engine |
Country Status (11)
| Country | Link |
|---|---|
| EP (1) | EP0450722B1 (en) |
| JP (1) | JPH04251657A (en) |
| CN (1) | CN1027188C (en) |
| AT (1) | ATE116714T1 (en) |
| BR (1) | BR9101389A (en) |
| CA (1) | CA2039878A1 (en) |
| DE (1) | DE69106418T2 (en) |
| DK (1) | DK0450722T3 (en) |
| ES (1) | ES2066332T3 (en) |
| GR (1) | GR3015109T3 (en) |
| IT (1) | IT1240746B (en) |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4244502C1 (en) * | 1992-12-30 | 1994-03-17 | Bruehl Aluminiumtechnik | Cylinder crankcase and method for its manufacture |
| US5429173A (en) * | 1993-12-20 | 1995-07-04 | General Motors Corporation | Metallurgical bonding of metals and/or ceramics |
| DE102004007774A1 (en) * | 2004-02-18 | 2005-09-15 | Mahle Gmbh | Bushing for an internal combustion engine |
| JP4584058B2 (en) * | 2005-07-08 | 2010-11-17 | トヨタ自動車株式会社 | Cylinder liner and manufacturing method thereof |
| DE102010055162A1 (en) * | 2010-12-18 | 2012-06-21 | Mahle International Gmbh | Coating and coated casting component |
| BR102013005326A2 (en) * | 2013-03-05 | 2014-12-02 | Mahle Metal Leve Sa | CYLINDER SHIRT FOR ENGINING ON AN ENGINE BLOCK AND ENGINE BLOCK |
| CN107598485A (en) * | 2017-07-25 | 2018-01-19 | 中原内配集团安徽有限责任公司 | A kind of manufacture craft of screw thread process type cylinder sleeve |
| CN113999999A (en) * | 2021-10-29 | 2022-02-01 | 华中科技大学 | Preparation method of rare earth reinforced solid-liquid composite cast magnesium/aluminum bimetal and product |
| CN114046209A (en) * | 2022-01-13 | 2022-02-15 | 爱柯迪股份有限公司 | Silicon nitride fiber reinforced aluminum alloy engine cylinder sleeve and preparation method thereof |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1340869A (en) * | 1962-08-17 | 1963-10-25 | Willys Motors | Internal combustion engine and method for its manufacture |
| DE3837254A1 (en) * | 1988-11-03 | 1990-05-10 | Bayerische Motoren Werke Ag | Light alloy insert for the formation of an expansion joint in combustion chamber walls of internal combustion engines formed from cast light alloy, especially cylinder head bases of diesel internal combustion engines |
-
1990
- 1990-04-06 IT IT19968A patent/IT1240746B/en active IP Right Grant
-
1991
- 1991-03-29 ES ES91200747T patent/ES2066332T3/en not_active Expired - Lifetime
- 1991-03-29 EP EP91200747A patent/EP0450722B1/en not_active Expired - Lifetime
- 1991-03-29 DE DE69106418T patent/DE69106418T2/en not_active Expired - Fee Related
- 1991-03-29 DK DK91200747.3T patent/DK0450722T3/en active
- 1991-03-29 AT AT91200747T patent/ATE116714T1/en not_active IP Right Cessation
- 1991-04-05 CA CA002039878A patent/CA2039878A1/en not_active Abandoned
- 1991-04-05 BR BR919101389A patent/BR9101389A/en not_active IP Right Cessation
- 1991-04-05 JP JP3099724A patent/JPH04251657A/en active Pending
- 1991-04-06 CN CN91102700.9A patent/CN1027188C/en not_active Expired - Fee Related
-
1995
- 1995-02-17 GR GR950400334T patent/GR3015109T3/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| CN1027188C (en) | 1994-12-28 |
| ES2066332T3 (en) | 1995-03-01 |
| DE69106418T2 (en) | 1995-07-06 |
| GR3015109T3 (en) | 1995-05-31 |
| EP0450722B1 (en) | 1995-01-04 |
| DE69106418D1 (en) | 1995-02-16 |
| IT9019968A1 (en) | 1991-10-06 |
| ATE116714T1 (en) | 1995-01-15 |
| EP0450722A1 (en) | 1991-10-09 |
| DK0450722T3 (en) | 1995-05-15 |
| IT1240746B (en) | 1993-12-17 |
| CN1056923A (en) | 1991-12-11 |
| JPH04251657A (en) | 1992-09-08 |
| BR9101389A (en) | 1991-11-26 |
| IT9019968A0 (en) | 1990-04-06 |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Discontinued |