CN101983256B - 活塞环 - Google Patents

活塞环 Download PDF

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CN101983256B
CN101983256B CN2009801120775A CN200980112077A CN101983256B CN 101983256 B CN101983256 B CN 101983256B CN 2009801120775 A CN2009801120775 A CN 2009801120775A CN 200980112077 A CN200980112077 A CN 200980112077A CN 101983256 B CN101983256 B CN 101983256B
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CN101983256A (zh
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斯特芬·霍佩
曼弗雷德·菲舍尔
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Federal Mogul Burscheid GmbH
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
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    • C23C28/046—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material with at least one amorphous inorganic material layer, e.g. DLC, a-C:H, a-C:Me, the layer being doped or not
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    • F16J9/00—Piston-rings, e.g. non-metallic piston-rings, seats therefor; Ring sealings of similar construction
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Abstract

一种具有DLC涂层的活塞环，其在基体材料上从内部到外部包括粘合层、无定形金属碳氢化合物层和无定形非金属碳氢化合物层，其中主要地，sp2键在金属碳氢化合物层中占多数，并且非金属碳氢化合物层包括sp2键和sp3键，sp3键的分量高于在金属碳氢化合物层中sp3键的分量，从而产生了DLC涂层的电阻，所述电阻在大于5000Ohm、尤其是大于5000kOhm的范围内。

Description

活塞环
技术领域
本发明涉及一种具有新涂层的活塞环。
活塞环用在内燃机中以在上下移动的活塞和气缸壁之间提供尽可能理想的密封。此外，活塞环用于擦去位于活塞壁上的油，并保持上述油可以用于润滑。对于活塞环的基本要求是，在内燃机运行期间，在某种程度上极端的条件下，摩擦力尽可能最小并且使用寿命尽可能最长。这意味着满足要求的活塞环的磨损行为尽可能地长。
背景技术
WO 2007/020139A1描述了一种可以作为活塞环的基底，其具有粘合层、四面体碳的中间层和无定形碳的外层。
申请人的DE 102005063123B3与例如活塞环的滑动元件有关，其包括磨损层和磨合层。
WO 2006/125683A1涉及具有涂层的活塞环，其从内向外包括具有群组IVB、VB或者VIB中的至少一个元件的第一中间层，具有类似钻石的、纳米复合组合物的第二中间层以及类似钻石的碳层。
发明内容
本发明的目的在于提供一种活塞环，其能够以比现有技术中已知的活塞环更少的工时来制造并且同时满足与摩擦值和/或使用寿命有关的要求。
这个目的是通过一种具有DLC涂层的活塞环来实现的：
所述活塞环在基体材料上从内部到外部包括粘合层、含金属的无定形碳层和不含金属的无定形碳层，sp2键在所述含金属的碳层中占多数，而所述不含金属的碳层包括sp2键和sp3键并且sp3键的分量高于在所述含金属的碳层中的sp3键的分量，从而产生了DLC涂层的电阻，所述电阻在大于5000Ohm的范围内，
其中，所述基体材料是钢或者铸铁，
其中，所述粘合层包含铬，
其中，所述粘合层具有大约2μm的最大厚度，
其中，所述含金属的碳层具有朝外部减少的金属含量，
其中，所述含金属的碳层具有从大约1.5μm到大约17μm的厚度，
其中，所述含金属的碳层包含纳米晶碳化物相，
其中，所述含金属和/或所述不含金属的碳层包含氢，
其中，所述活塞环具有从1800到2800HV 0.002的表面硬度，
并且不需提供磨合层，使得经这样形成的层结构用作磨损保护层。
因此，上述活塞环从内向外包括涂覆在基体材料上的粘合层、含金属的无定形碳层和不含金属的无定形碳层。由于这种层结构，就不再需要现有技术中常见的具有磨合层和单独形成的磨损保护层的结构。已知的磨损保护层大多形成为氮化物层并且需要使用具有高铬含量的钢，其比较昂贵。与之相比，根据本发明不需要高含量的铬，因此可以低成本地生产上述新的活塞环。因此，也可以看出本发明的基本构思在于，基底上的新碳涂层仅设置有薄粘合层以促进基底和碳层之间的粘合，而未插入单独的磨损保护层。
如下文将详细描述的，测试已经表明，根据本发明的活塞环的摩擦系数是持续低的。在这个方面，新活塞环因此提供了长的使用寿命。这也适用于磨损，为此我们已经发现，磨损处于保证长的使用寿命的限度内。含金属的无定形碳层可以根据传统名称(cf.VDI Guideline 2840)表示为缩写a-C:H:Me。不含金属的无定形碳层的相应的表示为a-C:H。可以涂覆不含金属的碳层，例如作为在PACVD(离子加强化学气相沉积)方法内的单独处理步骤的部分。两个无定形碳层都是DLC(类似于钻石的碳)层。
在含金属的碳层中多数是sp2键。由于这个特性，可以发现根据本发明的活塞环具有活塞环所需要的特性。特别地，碳键的整个百分比的比例从20％到70％变化。
关于不含金属的碳层，sp3键的分量(fraction)高于含金属的碳层中sp3键的分量。当增强的电阻(Ohm)产生时，提供了优选的sp3键的分量。虽然传统的DLC涂层具有在小于100Ohm的范围内的电阻，但是根据本发明的层的优选增强电阻大于5000Ohm，尤其是大于5000kOhm并优选地小于10kOhm。
已经发现钢或者铸铁特别适于作为根据本发明的活塞环的基体材料。
优选地，粘合层包含铬并且特别地可以主要由铬构成。已经发现这种粘合层包括在基体材料和含金属的无定形碳层之间促进粘合的理想特性。
基于测试结果，目前对于粘合层有利的最大厚度为2μm，优选为大约0.5μm。
关于包含在含金属的碳层中的金属，目前有利的是钨。对此，在测试中发现了特别良好的特性。
类似地，这可以应用到含金属的碳层中的金属含量朝外部减少的优选实施例中。
关于厚度，优选地，含金属的碳层具有从大约1.5μm到17μm的厚度。特别地，已发现大约1.5μm的层厚度具有良好的表现。
此外，在含金属的碳层包含纳米晶碳化物相的实施例中，发现了特别良好的特性。
此外，如果不含金属的碳层具有从大约1μm到15μm的厚度，尤其是大约1μm时，已发现设置有该不含金属的碳层的活塞环具有良好的特性。
优选地，含金属和/或不含金属的碳层还包含氢。可用的氢对于碳的交联(cross-linking)程度具有影响，从而产生了特别硬的层。
关于涂覆到基体材料上的各个层的总厚度，目前优选为≥大约2.9μm并且优选为≤大约30μm。这有利地构成了与之前已知的大多更薄的DLC层的差别。由于根据本发明可以实现的厚度，可以获得如下益处：由于DLC层同时充当磨合与磨损保护层从而不需要单独的磨损保护层。
根据本发明设计的活塞环的表面硬度优选为从1800HV到2800HV，优选为等于2400HV 0.002。在这种情况下，使用具有HV pl 0.002的纳米压头来进行测量。缩写pl代表镀层精整，相应的方法对于本领域技术人员是已知的。在特别的应用中，使用具有HV pl 0.02的纳米压头进行测量也是可以的。
目前优选地由铬构成的粘合层优选为借助于金属气相沉积来涂覆。
目前优选地含金属和/或不含金属的碳层借助于PACVD(离子加强化学气相沉积)方法来涂覆。
此外，关于根据本发明的活塞环、设置于其上的涂层和优选地与之一起工作的滑动配合件的所有特征，参考了前面提到的DE 102005063123B3或者WO 2007/079834A1，对于所引用的特征，本申请是在其基础上作出了所公开的本申请的主题。
具体实施方式
生产根据本发明的具有总厚度大约为2.9μm的涂层的活塞环，其硬度确定为1935HV 0.002。上述活塞环与具有氮化物层作为磨损保护层的活塞环和大量生产的DLC-涂层活塞环一起经受磨损测试。这个测试是在190℃、50N的负载并使用Castrol VP1作为油来进行的。旭丽(Silitec)S260用于钻孔。相应的产品对于本领域技术人员是公知的。六小时之后，根据本发明的活塞环的磨损确定为大约1.0μm，而大量生产的DLC-涂层的活塞环的磨损确定为大约5.3μm。在涂层更耐磨的情形下，滑动配合件的磨损通常会增加。根据本发明的涂层出乎意料地没有显示出诸如汽缸的汽缸套筒等滑动配件的磨损增加。
用于根据本发明的活塞环的汽缸套筒的磨损是2.7μm，用于大量生产的DLC-涂层的活塞环的磨损是2.8μm。此外，已发现根据本发明的活塞环的摩擦系数显著地减小了。与传统的DLC-涂层的活塞环相比，发现摩擦系数减小了高达30％。
因此，已经显示出根据本发明的活塞环获得了有利特性。如上所述，尤其是从长远来看，这尤其适用于摩擦系数、磨合行为和耐磨强度，这些特性整体地导致了耐用的活塞环。

Claims (7)

1.一种具有DLC涂层的活塞环，其特征在于，所述活塞环在基体材料上从内部到外部包括粘合层、含金属的无定形碳层和不含金属的无定形碳层，sp2键在所述含金属的碳层中占多数，而所述不含金属的碳层包括sp2键和sp3键并且sp3键的分量高于在所述含金属的碳层中的sp3键的分量，从而产生了DLC涂层的电阻，所述电阻在大于5000Ohm的范围内，
其中，所述基体材料是钢或者铸铁，
其中，所述粘合层包含铬，
其中，所述粘合层具有2μm的最大厚度，
其中，所述含金属的碳层具有朝外部减少的金属含量，
其中，所述含金属的碳层具有从1.5μm到17μm的厚度，
其中，所述含金属的碳层包含纳米晶碳化物相，
其中，所述含金属和/或所述不含金属的碳层包含氢，
其中，所述活塞环具有从1800到2800HV 0.002的表面硬度，
并且不需提供磨合层，使得经这样形成的层结构用作磨损保护层。
2.根据权利要求1所述的活塞环，其特征在于，所述含金属的碳层包含钨。
3.根据权利要求1或2所述的活塞环，其特征在于，所述不含金属的碳层具有从1μm到15μm的厚度。
4.根据权利要求1或2所述的活塞环，其特征在于，各个层的总厚度为≥2.9μm且≤30μm。
5.根据权利要求1或2所述的活塞环，其特征在于，所述粘合层是借助于金属气相沉积来涂覆的。
6.根据权利要求1或2所述的活塞环，其特征在于，所述含金属的碳层和/或所述不含金属的碳层是借助于PACVD方法涂覆的。
7.根据权利要求1或2所述的活塞环，其特征在于，所述电阻在大于5000kOhm的范围内。
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