CA2479032C - Multifunctional composite coating and process - Google Patents

Multifunctional composite coating and process Download PDF

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Publication number
CA2479032C
CA2479032C CA002479032A CA2479032A CA2479032C CA 2479032 C CA2479032 C CA 2479032C CA 002479032 A CA002479032 A CA 002479032A CA 2479032 A CA2479032 A CA 2479032A CA 2479032 C CA2479032 C CA 2479032C
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Prior art keywords
composite coating
oxide
coating
graphite
lubricant
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CA002479032A
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French (fr)
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CA2479032A1 (en
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Jingzeng Zhang
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    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C30/00Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process

Abstract

This invention deals with an oxide/lubricant composite coating on lightweight materials (Al-, Mg and Ti-alloys) with multifunctionality in terms of high hardness, low friction, thermal barrier, and high corrosion resistance. The oxide coating matrix with certain porosity and roughness is synthesized by a plasma process in an electrolyte. The solid lubricant (graphite, MoS2) is incorporated into the oxide coating matrix said by rubbing the solid lubricant against the relatively porous and rough oxide coating surface during the coating growth. The composite coating finally consists of low frictional lubricant (graphite, MoS2) embedded in hard, low thermal conductive, and anti-corrosive oxide coating matrix. The present invention is particularly applicable for enhancement in wear and corrosion protections for lightweight metals and alloys used in said engine, transmission case, pulley, air condition compressor, and brake system.

Description

MULTIFUNCTIONAL COMPOSITE COATING AND PROCESS
TECHNICAL FIELD

This invention relates to surface modification of cylinder bore, piston, and pulley which are deposited with an oxide/lubricant composite coating for wear and corrosion protections. A number of substrate materials of the cylinder bore and piston are lightweight alloys such as aluminum, magnesium, and titanium alloys. The oxide/lubricant coating, deposited by a plasma process, consists of a hard oxide matrix embedded with low-friction lubricant particles (such as graphite and/or MoS2).
The present invention is particularly well applicable for enhancement in wear and corrosion protections for lightweight engine, transmission case, pulleyõ air condition compressor, and brake system.

BACKGROUND
The use of lightweight materials has become more prevalent as said car manufacturer strive to reduce vehicle weight in order to improve performance, lower fuel and oil consumption, and to reduce emissions. Cast iron engine cylinder liner and piston are being replaced by lightweight metals (for instance, said aluminum-silicon alloys and magnesium alloys). The current-used cast iron liner requires a specific wall thickness to avoid occurrence of potential cracking during the engine casting, which results in a relatively large web width between the individual cylinder bore, and increase the dimensions and weight of the engine. By removing the cast-iron liner from engine block and using aluminum alloy cylinder bore, the engine length and weight can be significantly reduced. However, the aluminum alloy bore and piston must have wear resistant surfaces.

The possible solutions to improve the wear characteristics of' aluminum cylinder bores are to form a nickel dispersion coating (Patent No.: US 6,684,844 Bl), graphite and thermosetting resin dispersion coating (Patent No.: DE 4,113,773), or ferrous coating deposited by plasma spraying (Patent Application No.: CA 2,296,155). Another solution is to form a hard ceramic coating on the outer surfaces of aluminum alloys (Patent No.:
EP 1,050,606A and US 6,365,028). The hard ceramic coating itself has a high wear resistance but unfortunately it also wear and damage the counterface for instance piston ring surface. To potentially overcome the problem, an additional polymer-based lubricant layer has been deposited on top of the ceramic layer (a duel-layered structure as described in Patent No. US 5,884,600). However, durability of such a polymer-based lubricant layer on the piston operating in a high load condition or high-temperature combustion and corrosion environment may not be high enough.

Accordingly, it may be critical to provide sliding/moving components of Al-, Mg-, or Ti-alloys with a multifunctional coating which has an improved wear resistance, friction coefficient, thermal barrier, and corrosion resistance. The multifunctional coating can be deposited on components said pistons, cylinders, pulleys, and others for applications under load, wear, heat, and/or corrosion environment.

SUMMARY OF THE INVENTION

The present invention is directed to plasma deposition of a multifunctional composite coating which consists of oxide matrix embedded with said graphite or MoS2 lubricant particles:

The plasma deposition process is conducted in an environmentally-friendly aqueous electrolytic passivating medium. The plasma process carried on the material surfaces is established by arranging the materials to form the anode of an electrolytic cell circuit in which the counter-electrode is the electrolyte and/or electrolytic jet head.
Between the electrodes is biased by an AC, DC or pulse DC voltage in excess of 100 V.
During the oxidizing process caused by plasma elec.trochemical reaction, solid lubricant additives (i.e., graphite and/or MoS2) are rubbed against the oxide surfaces, forming hard, low thermal conductive, anti-corrosive, and lubricant composite coatings.

In a first aspect the present invention provides a composite coating on piston ring groove, skirt, and top surfaces of a piston made from lightweight metals and alloys (e.g., Mg, Al and Ti). The lubricant additive, provided by rubbing said graphite (or MoS2) block during the oxide coating formation and growth, is embedded in oxide coating matrix, producing a hard, lubricant, and thermul barrier composite coating. Such a coating also has excellent compatibility to the counterface such as surfaces of a piston ring. The coating also benefits said an engine piston in reduction of piston temperature due to thermal barrier effects.

In a second aspect the present invention provides a composite coating on a cylinder bore or liner made fi-om lightweight metals and alloys (e.g., Mg, Al and Ti). The lubricaint additive, provided by rubbing said graphite (and/or MoS2) block during the oxide coating formation and growth, is embedded in oxide coating matrix, producing a. hard oxideJlubricant composite coating. Such a coataig has high hardness and low friction and also has excellent compatibility to the counterface such as a worldng surface of a piston ring.

In a third aspect the present invention provides a composite coating on cylinder, and piston ring groove and skirt surfaces made frorr.t lightweight metals and alloys (e.g., Mg, Al and Ti). And the lubricant additive, provided by rubbing said graphite (or MoS2) block during the oxide coating formation and growth, is embedded in oxide coating matrix, producing a hard, solid lubricant, and anti-corrosive coating. Such a coating can be applied onto any piston, air condition compressor, transfer case, brake cylinder, pulley, and others.

In a fourth aspect the present invention provides a uniform composite coating for cast Al-Si alloys (hypoeutectic, outectic, and liypereutectic) which is otherwise difficult to be
2 achieved by using conventional anodizing methods due to the high Si content effect in the alloys.

In a fifth aspect the present invention provides a benign coating process. No strong alkaline and no any acidic solution as well as no fine particle is involved in the coating process.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative and presently preferred embodiments of the invention are shown in the accompanying drawing in which:
FIG. 1 illustrates schematically a composite coating process on exterior surfaces in a immersing/spraying and rubbing mode according to the present invention.
FIG. 2 illustrates schematically a composite coating process on an interior surface in a spraying and rubbing mode according to the present invention.
FIG. 3 illustrates a typical composite coating surface morphology and graphite distribution.
FIG. 4 illustrates a cross-section of the composite coating and its graphite distribution.
FIG. 5 illustrates the tribological behavior of an oxide/graphite composite coating in a dry sliding wear test against a steel counterface.

Referring to FIG. 1 of the drawings, the graphite 1 is rubbed on the rotated exterior surface of said piston 2 during the oxidizing process as shown by the arrows, producing a composite coating 4 on exterior surfaces of said piston groove 3, skirt 5 and/or top surface 6. During the coating process, the component can be immersed in an electrolyte or the electrolytic is supplied by a jet/spraying head. The localized surfaces contacted with the electrolyte are oxidized and form a hard (> HV 1500) oxide coating with a certain amount of porosity and roughness which provide the rubbing solid lubricant said graphite and/or MoS2 with anchors. Finally, an oxide/lubricant composite coating forms on the exterior surface using this invented method.

Referring to FIG. 2 of the drawings, an interior surface said cylinder 7 is treated by plasma oxidizing where a rotary electrolytic spraying/jet head(s) 8 is used to spray/jet an electrolyte 9 with rubbing of solid lubricant 10 on the treated surface as shown by the arrows. The localized surfaces contacted with the electrolyte are oxidized and form a hard oxide coating with a certain amount of porosity and roughness which provide the rubbing solid lubricant said graphite and/or MoS2 with anchors. Finally, an oxide/lubricant composite coating 11 forms on the interior surface using this invented method.

Referring to FIG. 3 of the drawings, a typical composite coating in this invention consists of oxide 12 and solid lubricant 13. Volume ratio of graphite to oxide can be controlled from 5-90%, preferred 10-60%. While the dark area is graphite as lubricant 13, the bright area is oxide 12.

Referring to FIG. 4 of the drawings, solid lubricant graphite 13 also exists in the cross section of the typical composite coating (i.e., on surface, subsurface and near to interface).
3 The graphite 13 is embedded in the oxide matrix 12 of the coating. It is observed that coating can uniformly form on surfaces of Al-Si alloys 14 of even 20% Si content high.
The Si grains 15 on the component surface do not negatively affect the coating uniformity in the present invention. The coating thickness and roughness depends on the coating process parameters.

Referring to FIG. 5 of the drawings, tribological behavior of oxide (Curve I) and oxide/graphite composite (Curve II) coating under dry pin-on-disc sliding wear testing (at - 1 GPa Hertz contact stress) shows the oxide/graphite composite coating has 4 times lower coefficient of friction than the oxide ceramic coating. Negligible wear occurs on the composite coating.

The present invention will be further described with reference to the following examples.
Example 1 Piston (exterior surface) An exterior surface on a lightweight metallic component such as piston can be coated with an oxide/graphite/MoS2 composite coating. The volume percentage of graphite and/or MoS2 in the coating can be in range of 5-90%. The composite coating with 20-40% graphite (FIGS. 3 and 4) exhibits a coefficient of friction 0.2 under dry sliding wear testing against a steel counterface (FIG. 5). Under the same testing condition, an oxide coating without graphite and uncoated Al alloy contrastively have friction coefficient of 1.1 and 0.8, respectively. At an oil-starved boundary lubricant testing condition, coefficient of friction for the composite coating is less than 0.1.

High Si content in Al-Si alloy is not any more a barrier to deposition of a uniform coating on a piston in this invention.

The coating in this invention possesses multifunctional properties, i.e., high hardness (>
HV 1500), low friction, thermal barrier, and high corrosion resistance. The coated piston can increase resistance to heat, eliminate scuffing and wear, reduce friction, and improve cylinder sealing.

Example 2 Cylinder (interior surface) An interior surface on a lightweight metallic component such as cylinder or cylinder liner can be coated with the oxide/graphite/MoS2 composite coating. The volume percentage of graphite and/or MoS2 in the coating can be in range of 5-90%. The composite coating with 20-40% graphite exhibits a coefficient of friction 0.2 under dry sliding wear testing against a steel counterface. Under the same testing condition, an oxide coating without graphite/ MoS2 and uncoated Al alloy contrastively have friction coefficient of 1.1 and
4 0.8, respectively. At an oil-starved boundary lubricant testing condition, coefficient of friction for the composite coating is less than 0.1.

The coated cylinder can increase resistance to heat, eliminate scuffing and wear, reduce friction, and improve cylinder sealing.

Example 3 Pistons and cylinders for air condition compressor and brake system, transmission case, and others.

Lightweight metallic components such as piston and cylinder for air condition compressor and brake system, as well as transmission case, and others can be coated with the oxide/graphite/MoS2 composite coating. The volume percentage of graphite and/or MoS2 in the coating can be in range of 5-90%. The composite coating with 20-40%
graphite exhibits a coefficient of friction 0.2 under dry sliding wear testing against a steel counterface.

Example 4 Pulley Lightweight metallic components such pulleys can be coated with the oxide/graphite/MoS2 composite coating. The volume percentage of graphite and/or MoS2 in the coating can be in range of 5-90%. The coated components possess high hardness, wear and corrosion resistance, and low coefficient of friction as well.

Example 5 The oxide/graphite/MoS2 composite coating can be deposited on a sliding surface of lightweight metallic component. The volume percentage of graphite and MoS2 in the coating can be in range of 5-90%. The relative porous coating surface can be attractive to oil films as oil replenishing reservoirs.

Claims (7)

What is claimed is:
1. A process of forming an oxide and solid lubricant composite coating in which the oxide is produced by plasma oxidizing of a surface while the solid lubricants graphite and MoS2 are incorporated into the oxide by rubbing graphite and MoS2 blocks against the oxidized surface.
2. A composite coating process as claimed in claim 1, wherein the oxide has high hardness and corrosion resistance, and the solid lubricants with 5-90% volume in the coating provide the coating with low coefficient of friction.
3. A composite coating process as claimed in claims 1 or 2, wherein the oxide and lubricant composite coating is deposited and used for wear and corrosion prevention of engine piston, cylinder, transmission case, air condition compressor, brake system, and pulley.
4. A composite coating process as claimed in claims 1 or 2, wherein the oxide and lubricant composite coating is deposited on surfaces of lightweight Al, Mg, and Ti alloys for sliding wear and corrosion prevention.
5. A composite coating process as claimed in claim 1, wherein the composite coating is deposited on cast hypoeutectic, eutectic, and hypereutectic Al-Si alloys.
6. A composite coating process as claimed in claims 1, 2, and 5, wherein the composite coating deposited on an Al-Si alloy engine piston is to reduce the piston temperature, eliminate scuffing and seizing problem, and smoothen engine start-up and running.
7. A composite coating process as claimed in claim 1, wherein no hazardous and toxic materials and fine particles are involved.
CA002479032A 2004-09-13 2004-09-13 Multifunctional composite coating and process Expired - Fee Related CA2479032C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002479032A CA2479032C (en) 2004-09-13 2004-09-13 Multifunctional composite coating and process

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA002479032A CA2479032C (en) 2004-09-13 2004-09-13 Multifunctional composite coating and process

Publications (2)

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CA2479032A1 CA2479032A1 (en) 2006-03-13
CA2479032C true CA2479032C (en) 2009-04-21

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Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7569132B2 (en) 2001-10-02 2009-08-04 Henkel Kgaa Process for anodically coating an aluminum substrate with ceramic oxides prior to polytetrafluoroethylene or silicone coating
US7452454B2 (en) 2001-10-02 2008-11-18 Henkel Kgaa Anodized coating over aluminum and aluminum alloy coated substrates
US7578921B2 (en) 2001-10-02 2009-08-25 Henkel Kgaa Process for anodically coating aluminum and/or titanium with ceramic oxides
US9701177B2 (en) 2009-04-02 2017-07-11 Henkel Ag & Co. Kgaa Ceramic coated automotive heat exchanger components
US20110048958A1 (en) * 2009-09-02 2011-03-03 Gm Global Technology Operations, Inc. Methods of reducing surface roughness and improving oxide coating thickness uniformity for anodized aluminum-silicon alloys
EP3084048B1 (en) * 2013-12-17 2018-08-01 Meotec GmbH & Co. KG Method for producing a protective layer on a thermally stressed component and component having such a protective layer
CN106735225B (en) * 2016-12-26 2018-08-28 天津百恩威新材料科技有限公司 A method of being injected into shape forging aluminium alloy brake disc brake drum

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