CN101198712A - 气缸衬套涂敷涂层的方法 - Google Patents

气缸衬套涂敷涂层的方法 Download PDF

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CN101198712A
CN101198712A CNA200680021287XA CN200680021287A CN101198712A CN 101198712 A CN101198712 A CN 101198712A CN A200680021287X A CNA200680021287X A CN A200680021287XA CN 200680021287 A CN200680021287 A CN 200680021287A CN 101198712 A CN101198712 A CN 101198712A
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格哈德·布赫尔
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Abstract

本发明推荐一种给由一种铁基材料制成的气缸衬套涂敷涂层的方法，其中，运用热喷涂方法在气缸衬套的外表面上喷涂第一层涂层和由锌合金构成的第二层涂层。通过采用铜合金或非铜合金构成第一层涂层和采用一种锌铝合金构成第二层涂层，在气缸衬套与在其中铸入气缸衬套的气缸体之间实现良好的金属接合。

Description

气缸衬套涂敷涂层的方法
技术领域
本发明涉及一种根据权利要求1的上位概念给气缸衬套涂敷涂层的方法。
背景技术
气缸体通常是用轻金属，特别是用铝铸造的，由于轻金属的摩擦性能较差，因此在铸造时必须把由一种例如灰铸铁之类的铁基材料制成的气缸衬套铸入到气缸体中。在这种情况下，会产生把气缸衬套足够牢固地固定在气缸体上的问题，以保证在气缸衬套与气缸体之间实现充分的热传导。解决上述问题的办法可以是，使气缸衬套的外表面获得一种带有粗糙的铸造结构。但这样做的结果是，铸入气缸体中的气缸衬套之间的隔片太宽，因而气缸衬套的空间需求过大。
根据同等功率的内燃机小型化的发展趋势，必须缩小各气缸衬套之间的间距，并改善从燃烧室经过气缸衬套向气缸体冷却室的热量导出。以上问题可这样解决，即采用一种用灰铸铁制成的气缸衬套作为粗糙铸造衬套的替代品，这种气缸衬套带有光滑的或中等粗糙度的外表面，并涂敷一层涂层，以确保气缸衬套与气缸体的重铸材料连成一体。
在德国专利文献DE 197 29 017 C2中，对由灰铸铁构成的这样一种气缸衬套作了说明。这种气缸衬套在其外表面上，有一层用火焰喷涂方法或电弧喷涂方法涂敷的AlSi合金覆盖层，其含硅量小于15％。在所述覆盖层上涂敷了一层由锌合金构成的防氧化保护层，其功用是抑制AlSi覆盖层的氧化，因为氧化会破坏覆盖层与气缸体的重铸材料的金属接合。
这样做的缺点在于，AlSi合金在喷涂覆盖层的过程中已被氧化。由此而生成的氧化皮非常牢固地附着在AlSi覆盖层上。此外，其熔化温度高于重铸时所能达到的温度。虽然氧化皮可用很高的代价去除，但在去除后很快又生成新的氧化皮，因此，附加的锌或锌合金保护层不能保证AlSi覆盖层与气缸体的重铸材料之间的金属接合。
此外，AlSi覆盖层的热膨胀系数约为灰铸铁的热膨胀系数的1.7倍，因此当温度变化时在已有的层系中会产生应力，影响气缸衬套与气缸体之间的接合。
发明内容
本发明的任务是，避免原有技术水准的上述缺点，也就是改善气缸衬套与气缸体的重铸材料之间的金属接合，并从而改善气缸衬套与气缸体之间的热传导。上述任务利用在表述主专利权项要求中的各项特征加以解决。
本发明的优点在于，根据本发明在灰铸铁衬套、层系与气缸体的重铸材料之间层结构中的热膨胀系数的级差，明显降低了根据本发明的层结构中的热应力。此外，从气缸衬套开始，经过根据本发明的层系到气缸体的重铸材料的熔化温度的级差，使外层与重铸材料产生某种熔融或某种扩散性熔合，结果导致在气缸衬套与气缸体重铸材料之间形成稳定的金属接合。最后，由根据本发明的合金构成的涂层的优点在于，其在接合区的合金成分参与弥散硬化。
本发明适用的造型是各项分权利要求的目标。
具体实施方式
下面进一步阐述根据本发明给铸入气缸体中的气缸衬套涂敷涂层的方法。
本发明所使用的气缸衬套采用一种铁基材料制成，可以是合金，也可以是非合金。气缸衬套优先选用灰铸铁制成，这种灰铸铁可含有片状石墨、蠕虫状石墨或球状石墨。灰铸铁的基体可以为铁素体加珠光体、珠光体、贝氏体或奥氏体。气缸衬套的外表面可以加工成光滑的表面。气缸衬套也可以包括平整的粗铸表面在内的其它各种表面质量。除此之外，气缸衬套的外表面还可切削加工。
为了把气缸衬套铸入气缸体，可以使用各种常用的铸造方法，例如使用压力铸造方法、挤压铸造方法、重力铸造方法或低压铸造方法。
气缸体用一种常用的轻金属铸造材料，既可以使用铝基铸造材料，也可以是镁基铸造材料。
为了保证在气缸衬套铸入气缸体的过程中，气缸衬套与气缸体重铸材料之间实现金属接合，气缸衬套外表面用热喷涂方法喷上涂层。作为准备工作，要求清除外表面的污垢和氧化物，然后将表面打毛。合适的打毛方法是用刷子刷和/或进行喷射。为此，特别适合用大颗粒刚玉(即晶体Al2O3)喷射。
紧接着用热喷涂方法在气缸衬套的外表面上直接喷上第一层涂层。所述第一层涂层可用99.9％的铜，或一种CuAl8合金，或一种CuAl8Ni2合金，或一种CuP8合金，或一种CuSi3合金，或一种CuZn37合金(黄铜)构成。应力求达到一层少气孔和氧化物的涂层，其层厚在60μm至130μm之间。
为了改善涂敷到气缸衬套上的涂层的熔化温度级差，应当优先选择在第一层由纯铜构成的涂层上涂敷另一层由上述铜合金构成的涂层，后者的熔化温度应低于纯铜涂层的熔化温度，但纯铜涂层的熔化温度应高于构成下面称之为第二层涂层的外层材料的熔化温度。
由于在市场上容易买到用上述合金制成的丝，因此，作为热喷涂方法应优先采用丝火焰喷涂，喷涂时，丝状的喷涂添加材料在乙炔-氧火焰的中心熔化，并借助雾化气体(例如压缩空气或氮气)喷涂到气缸衬套的外表面上。
也适合采用电弧丝喷涂，在喷涂时，两根丝状的喷涂添加材料在电弧中熔化，并借助雾化气体喷涂到气缸衬套的外表面上。喷涂时有可能把不同的丝合在一起熔化，如此可以在广泛的范围内改变由此而生成的涂层的成分。如果采用例如铜丝和锌丝，则可以把一种含锌量高达45％的CuZn合金涂敷到气缸衬套的外表面上。当采用氮气或氩气作为雾化气体时，可在很大程度上抑制材料的氧化。
进一步减少喷涂材料的氧化和涂层中氧化物含量，一种可能性是采用冷气体喷涂方法，其中，未熔化的和仅被加热到几百度的粉末微粒被加速到300m/sec到1200m/sec的速度，并喷涂到气缸衬套的外表面上。由于粉末微粒的冲击造成微摩擦，使接触面上的温度升高，并导致粉末微粒与气缸衬套的外表面发生微焊合。
也可以采用高速火焰喷涂(HVOF喷涂)，其中，高压气体在一个燃烧室内连续燃烧，粉末状的喷涂添加物被输送到燃烧室的中心轴线上。在燃烧室内产生的燃气与氧气的混合气体的高压使微粒达到高速，可产生很厚的和附着性能很好的喷涂涂层。
第一层涂层的功能是保证第一层涂层很好地附着在气缸衬套的灰铸铁上，为第二层涂层创造良好的接合的前提，并实现一定的熔化温度级差，这就是说，使气缸衬套的灰铸铁的熔化温度逐级过渡，经过第一层涂层和第二层涂层，直到气缸体的重铸金属。此外，这样可使从气缸衬套开始，经过第一层和第二层涂层，直到气缸体的轻金属材料的热膨胀系数达到一定的级差。
为了避免第一层涂层氧化，在涂敷第一层涂层之后应紧接着使用上文所述热喷涂方法将第二层涂层喷涂到第一层涂层上。为此要优先选用锌含量为85％和含铝量为15％的Zn85Al15合金。在这种合金中，含铝量也可以在3％至20％之间变化。应力求达到一层少气孔和氧化物的涂层，其层厚在60μm至130μm之间。
第二层涂层的功能是保证很好地附着在第一层涂层上。另外，含铝量占重量15％的AlZn合金的熔点为450℃，这样可使第二层涂层在铸造气缸体时被其重铸材料熔化，从而保证在气缸衬套与气缸体的重铸材料之间实现金属接合。
这种情况下AlZn合金虽然形成一层很薄的氧化层，但不会妨碍气缸衬套与气缸体的接合。不过最好是在AlZn合金中掺入占重量百分之几的铜，这样可完全防止生成氧化层，从而进一步改善气缸衬套与气缸体的接合。

Claims (14)

1.一种给由铁基材料制成的气缸衬套涂敷涂层的方法，其中，运用热喷涂方法在气缸衬套的外表面上喷涂第一层涂层和由锌合金构成的第二层涂层，其特征在于，包含如下工序：
将铜或铜基合金喷涂到气缸衬套的外表面上作为第一层涂层，然后
将一种锌铝合金喷涂到第一层涂层上作为第二层涂层。
2.根据权利要求1所述的方法，其特征在于，喷涂99.9％的铜作为第一层涂层。
3.根据权利要求1所述的方法，其特征在于，喷涂一种CuAl8合金作为第一层涂层。
4.根据权利要求1所述的方法，其特征在于，喷涂一种CuAl8Ni2合金作为第一层涂层。
5.根据权利要求1所述的方法，其特征在于，喷涂一种CuP8合金作为第一层涂层。
6.根据权利要求1所述的方法，其特征在于，喷涂一种CuSi3合金作为第一层涂层。
7.根据权利要求1所述的方法，其特征在于，喷涂一种锌含量占重量15％的CuZn合金作为第一层涂层。
8.根据权利要求7所述的方法，其特征在于，喷涂一种CuZn37合金作为第一层涂层。
9.根据权利要求1至8的任一项所述的方法，其特征在于，第一层涂层的厚度在60μm至130μm之间。
10.根据权利要求1所述的方法，其特征在于，喷涂一种铝含量占重量3到20％的ZnAl合金作为第二层涂层。
11.根据权利要求10所述的方法，其特征在于，喷涂一种Zn85Al15合金作为第二层涂层。
12.根据权利要求10或11所述的方法，其特征在于，在第二层涂层中掺入铜。
13.根据权利要求1到12的任一项所述的方法，其特征在于，使用冷气体喷涂方法喷涂第一层和/或第二层涂层。
14.铜或铜基合金的用途，作为第一层涂层喷涂在由灰铸铁构成的气缸衬套上；锌铝合金的用途，作为第二层涂层喷涂在第一层涂层上。
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