CN102333903A - 具有可调节性质的滑动部件 - Google Patents

具有可调节性质的滑动部件 Download PDF

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CN102333903A
CN102333903A CN2009801577742A CN200980157774A CN102333903A CN 102333903 A CN102333903 A CN 102333903A CN 2009801577742 A CN2009801577742 A CN 2009801577742A CN 200980157774 A CN200980157774 A CN 200980157774A CN 102333903 A CN102333903 A CN 102333903A
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马库斯·肯尼迪
迈克尔·津拉博德
马克-曼纽尔·马兹
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Abstract

本发明涉及一种滑动部件，特别是内燃机的活塞环，包括衬底；和通过热喷涂包含下列元素比例的粉末获得的磨损保护层：2-50%重量百分比铁Fe、5-60%重量百分比钨W、5-40%重量百分比铬Cr、5-25%重量百分比镍Ni、1-5%重量百分比钼Mo、1-10碳C和0.1-2%重量百分比硅Si；和通过热喷涂包含下列元素比例的粉末获得的磨合层：60-95%重量百分比镍、5-40%重量百分比碳。

Description

具有可调节性质的滑动部件
技术领域
本发明涉及具有可调节性质(特别是磨损性能)的滑动部件(特别活塞环)，以及生产它的方法。
背景技术
现在，用户对活塞环和汽缸筒的磨损性能方面的要求不同。一方面，要求尽可能低的磨损，而另一方面，发动机制造商也需要较高的磨损率，以便获得他们认为的“活塞环/汽缸套”系统的尽可能最好的磨合(running-in)性能。这在2冲程发动机扇区(环直径>430 mm)中成为日益常见的问题。
通过热喷涂法施用的基于铁的涂层尚未用在活塞环上。迄今，汽缸筒上仅基于铁的涂层在曲轴传动扇区中是已知的，所述涂层通过电弧丝喷涂法生产( EP 1 055 351 B2)。通过热喷涂法生产抗磨层是已知方法。当前用于此目的的粉末材料是Mo、WC、NiCr和Cr3C2。
发明内容
因此，本发明解决下列问题。一方面，相比传统的基于Mo的涂层，利用至今未使用的材料体系作为涂层材料改进热喷涂活塞环的摩擦学性质。此外，生产满足用户要求的涂敷活塞环，它们根据各自的磨损性能和内应力定制，其中涂敷通过热喷涂完成。此外，将优化磨合性能。基本材料基体将优选表现出与下面的衬底相似的物理性能(热膨胀系数和导热率)和充分的力学性能(硬度、延展性)。
依据本发明的第一方面，提供一种滑动部件，特别是内燃机的活塞环，包括：
-衬底，
-磨损保护层，通过热喷涂包含下列元素比例的粉末获得：
2-50 %重量百分比铁Fe；
5-60 %重量百分比钨W；
5-40 %重量百分比铬Cr；
5-25 %重量百分比镍Ni；
1-5 %重量百分比钼Mo；
1-10 碳C和
0.1-2 %重量百分比硅Si；
和
-磨合层，通过热喷涂包含下列元素比例的粉末获得：
60-95 %重量百分比镍；
5-40 %重量百分比碳。
为了解决上述问题，必须生产包含基本体系的层体系，该基本体系具有与待涂敷衬底类似的物理性能和充分的强度连同抗磨损比例，其中环和套上的不同磨损率产生润滑状态，视所用比例而定。同样地，残余应力的性质和强度可通过加入限定量的抗磨损比例来调整。原则上，在热喷涂层中不期望有残余张力应力，因为它们不能够减少已有裂缝的裂缝扩展，或者甚至可能使其增加。解决方案是一种新的基于Fe的体系，其由碳化物加固，并与适合发动机制造商需要的磨合层联合。
至于物理性能(导热率、热膨胀系数)，通过含铁基本体系的最小比例25%重量百分比在衬底和涂层之间产生准均匀体系。这样，在混合摩擦过程中，特别是在上死点或下死点范围内产生的热能可更有效地消散，且通过发动机中存在的温度变化保证统一的热弛豫过程。应用基于Fe的合金连同碳化物体系和磨合层(分级或未分级)作为活塞环基本涂层材料得到新型活塞环。该情况下，待涂敷的活塞环可以是铸铁或钢活塞环。
依据一个实施方式，新材料体系由下列元素组成：铁(Fe)、钨(W，作为WC)、铬(Cr，作为Cr和Cr3C2)、镍(Ni)、钼(Mo)、硅(Si)和碳( C，部分作为碳化物结合在Fe、W和Cr中，或者以纯形式被电化学包裹在镍中)。
依据一个实施方式，碳化物的比例是10-75 %重量百分比，由0-60 %重量百分比钨碳化物WC和0-50 %重量百分比铬碳化物Cr3C2组成。
不推荐不含碳化物的基于铁的合金，因为耐磨性(按照下述测量)不满足今天的需要。总碳化物含量增加超过75 %重量百分比不推荐用于碳化物环涂层，因为如果碳化物比例过大，那么该层过分呈现陶瓷特性(弹性模数过高)，所以不能承受发动机中的温度变化应力。
依据一个实施方式，所述滑动部件还包括在所述磨损保护层和所述磨合层之间的过渡层，其中所述过渡层的化学成分相对所述磨损保护层和所述磨合层表现出20:80到80:20的渐变比(graduation ratio)。
对于单层类型的磨损保护层：磨合层，可调整渐变比中的化学成分为20:80到80:20。
附图说明
图1示出本发明一个实施方式的热喷涂磨损保护/磨合层的微观结构。
具体实施方式
实施例1：
第一层：磨损保护层；
第二层：在磨损保护层一侧上，过渡层的化学成分为80%如同磨损保护层的成分，20%如同磨合层，而接近磨合层一侧时，基本上线性地过渡到一种成分，该成分20%如同磨损保护层的成分且80%如同磨合层的成分；
第三层：磨合层。
实施例2：
第一层：磨损保护层；
第二层：化学成分20%如同磨损保护层、80%如同磨合层，线性过渡直到80%如同磨损保护层、20%如同磨合层；
第三层：磨合层。
依据一个实施方式，磨损保护层的层厚度在100-800μm范围内，优选200-600μm范围内，最优选300- 500μm范围内。
依据一个实施方式，磨合层的层厚度在100-500μm范围内，优选200-400μm范围内，最优选150-300μm范围内。
依据一个实施方式，过渡层的层厚度在0-600μm范围内，最优选0-250μm范围内，在过渡层中磨损保护层和磨合层以分级形式存在。
依据一个实施方式，所述衬底为环，其直径大于220mm，优选大于430mm且最大980mm。
依据一个实施方式，粉末的粒度在1-100μm范围内。
依据一个实施方式，碳化物嵌入镍-铬基体中，并表现出0.5-5μm的粒度。
进行的测试
 热喷涂粉末，并测试不同变体的化学成分(表1)、碳化物含量(表2)、微观结构(图1)、孔隙度和硬度(表3)。测试1和2的不同在于，在测试1中产生层类型1，而在测试2中产生层类型2。对于测试1.1-1.4和2.1-2.4，设定不同的碳化物浓度。在所有情况下，顶层不含碳化物，因为该层用作对照的磨合。
Figure 2009801577742100002DEST_PATH_IMAGE001
表1：磨损保护/磨合层类型1的化学成分。
Figure 2009801577742100002DEST_PATH_IMAGE002
表2：磨损保护/磨合层类型1的碳化物含量。
微观结构图片(图1)显示磨损保护层均匀分布的碳化物，磨损保护层无不熔化的颗粒，是具有< 2%的极低孔隙度的非常稠密的层。石墨沉淀在顶层中清楚可见。磨损保护层的层厚度是330μm，磨合层的层厚度是180μm。
Figure 2009801577742100002DEST_PATH_IMAGE003
表3：磨损保护/磨合层类型1的硬度/孔隙度。
如表3所示，最初的测试已表明，磨损保护层类型1具有<1-2%的孔隙度，以及大约520HV1的硬度(对于不含碳化物的基于铁的材料)和达到710HV1的厚度(对于具有60%重量百分比的碳化物含量的基于铁的材料)。磨合层的硬度由于高石墨含量而不能测定。
碳化物的加入使得能够选择对环和汽缸筒所设的硬度。此外，尽管磨损测试中的高负荷，仍基本上保持了微观结构，这原则上表明用本发明的涂层生产了“环/套润滑”系统的抗磨损活塞环，因为磨合过程是完美的。

Claims (9)

1.一种滑动部件，特别是内燃机的活塞环，包括：
-衬底，
-磨损保护层，通过热喷涂包含下列元素比例的粉末获得：
2-50 %重量百分比铁Fe；
5-60 %重量百分比钨W；
5-40 %重量百分比铬Cr；
5-25 %重量百分比镍Ni；
1-5 %重量百分比钼Mo；
1-10 碳C和
0.1-2 %重量百分比硅Si；
和
-磨合层，通过热喷涂包含下列元素比例的粉末获得：
60-95 %重量百分比镍；
5-40 %重量百分比碳。
2.根据权利要求1所述的滑动部件，还包括在所述磨损保护层和所述磨合层之间的过渡层，其中，所述过渡层的化学成分相对所述磨损保护层和所述磨合层表现出20:80到80:20的渐变比。
3.根据权利要求1或2所述的滑动部件，其中，碳化物的比例是10-75%重量百分比，由0-60%重量百分比钨碳化物WC和0-50%重量百分比铬碳化物Cr3C2组成。
4.根据前述权利要求中任一项所述的滑动部件，其中，所述磨损保护层的层厚度在100-800μm范围内，优选200-600μm范围内，最优选300-500μm范围内。
5.根据前述权利要求中任一项所述的滑动部件，其中，所述磨合层的层厚度在100-500μm范围内，优选200-400μm范围内，最优选150-300μm范围内。
6.根据权利要求2-5中任一项所述的滑动部件，其中，所述过渡层的层厚度在0-600μm范围内，最优选0-250μm范围内，在所述过渡层中所述磨损保护层和所述磨合层以分级形式存在。
7.根据前述权利要求中任一项所述的滑动部件，其中，所述衬底为环，其直径大于220 mm，优选大于430 mm且最大980 mm。
8.根据前述权利要求中任一项所述的滑动部件，其中，粉末的粒度在1-100μm范围内。
9.根据前述权利要求中任一项所述的滑动部件，其中，所述碳化物嵌入镍-铬基体中，并表现出0.5-5μm的粒度。
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