Background technology
At present, highly-intensified diesel engine is all to the development of high-power, high loading, and aluminium piston is as the important reciprocation parts of oil engine, and its performance directly affects the Performance And Reliability of highly-intensified diesel engine.Aluminium piston is typically provided with inner-cooling oil recess in thick large part and piston is carried out cooling, adopts castingin high nickel cast iron abrasion-proof inserted ring, to improve the wear resistance of first ring groove location in the first ring groove location of piston.High reinforcing stimulus requires very high to castability with single-piece piston, do not allow to occur any casting flaw.Adopt conventional metal mold gravity casting and sand mold casting aluminium piston, be easy to produce the casting flaws such as pore, shrinkage porosite, crackle, slag inclusion, microtexture density difference, mechanical property can not meet service requirements, moreover, routine casting method, production efficiency is low, labour intensity is large.
Thus, high strengthening piston for engine has been done many improvement in manufacturing technology, see that the patent No. is Chinese invention patent < < aluminium-based composite material for piston of ZL02135972.5 and preparation method thereof > > (Granted publication number: CN1257299C), matrix material in this patent is comprised of matrix alloy and wild phase, in matrix alloy, the mass percent of each component is silicon 9 ~ 16%, copper 0.5 ~ 2.5, nickel 0.5 ~ 2.0, magnesium 0.2 ~ 1.5, titanium 0.2 ~ 2.0, all the other are aluminium; Wild phase is Al2O3 and the TiC particle that reaction in-situ generates, and products obtained therefrom strength ratio is larger.See that again the patent No. is Chinese invention patent < < composite aluminium alloy for piston and the production technique > > (Granted publication number: CN100467644C) thereof of ZL200710015700.8, this patent is by being used old piston as aluminium alloy major ingredient, preferential component proportion and production technique, reached cost-effective object.The thermal treatment process > > (publication number is CN101117679A) of the open < < high-performance aluminum silicon alloy material of the Chinese invention patent application that can also be similarly, 200710049894.3 referring to application number and piston thereof.
Domestic existing piston for diesel engine adopts high nickel cast iron edge circle to strengthen in first ring groove location conventionally, adopt gravity foundry technology moulding, piston exists Heavy Weight, high nickel cast iron edge ring and aluminum substrate bonding strength low, the defects such as top combustion chamber Burning corrosion resistance is poor, thus cause that piston work-ing life is short, work reliability is poor.
Abroad aspect the development of composite material piston, making progress, the composite material piston of Toyota Motor company development makes Toyota Motor's overhaul mileage extend to 300,000 kilometers by 100,000 kilometers, the output rating of engine improves 5%, and the consumption of fuel oil and lubricating oil all improves.The countries such as Cummins Corp, Britain AE PLC and France, Russia, Bulgaria have all carried out the research work of composite material piston, and start a large amount of use.The external manufacturing process adopting is that matrix material is first made in the enhancing position of piston, again by metal mold gravity casting or Extrution casting technique moulding, this technique mainly exists process period long, the shortcomings such as matrix material and body material bonding strength are high not, while adopting Extrution casting technique moulding, can not manufacture the limitation of the high-power engine piston of top band inner-cooling oil recess.
Summary of the invention
Technical problem to be solved by this invention be for the above-mentioned state of the art, provide a kind of first ring groove location edge ring with aluminum substrate bonding strength high and piston offend and disobey with rude remarks the good aluminium method for making piston of ablation ability.
Another technical problem to be solved by this invention is the preparation method that a kind of good reliability, lightweight aluminium piston are provided for the above-mentioned state of the art.
The present invention solves the problems of the technologies described above adopted technical scheme: a kind of aluminium method for making piston, is characterized in that comprising being prepared as follows processing step:
1. prepare aluminium alloys for pistons, this alloy by following component and mass percent thereof is:
All the other are Al;
2. melting processing, by the piston alloy of preparation, putting into smelting furnace melts, after fusing, alloy liquid carries out refining, rotten, refinement, refining treatment, by temperature of aluminum liquid control, it is 720 ~ 740 ℃, adopt refining agent to process, temperature of aluminum liquid control is 760 ~ 780 ℃, adopts alterant to process, and by temperature of aluminum liquid control, is 740 ~ 760 ℃, adopt fining agent to process, by temperature of aluminum liquid control, be 730 ~ 740 ℃, adopt refining agent place to manage, after static 15 ~ 30 minutes, and be 710 ~ 720 ℃ by temperature of aluminum liquid control, pour into a mould;
3. alumina-ceramic staple fibre prefabricated component is made, alumina-ceramic staple fibre is pulverized with liquid fiber shredding unit, remove the non-fibrosis impurity such as slag ball, make first piston ring groove alumina-ceramic staple fibre prefabricated component and top combustion chamber alumina-ceramic staple fibre prefabricated component;
4. alumina-ceramic staple fibre prefabricated component preheating, the electrothermal oven of the first annular groove alumina-ceramic staple fibre prefabricated component of having prepared and top combustion chamber alumina-ceramic staple fibre prefabricated component being put into 690 ℃ ~ 710 ℃ of temperature carries out preheating;
5. mould and die preheating, is preheating to 200 ℃ ~ 250 ℃ to mold cavity before extrusion casting;
6. extrusion casting, preheated alumina-ceramic staple fibre prefabricated component is fixed on the corresponding site of mould, and prefabricated component < transfer time 30 seconds pours into processed good aluminum alloy melt in mold cavity, aluminum alloy melt teeming temperature is 710 ℃ ~ 720 ℃, matched moulds pressurization;
7. solidify pickup, aluminum alloy melt is under the mechanical pressure action of 100MPa ~ 120MPa, be penetrated in the hole of the first annular groove alumina-ceramic staple fibre prefabricated component 2 and top combustion chamber alumina-ceramic staple fibre prefabricated component 3, pressurize 60S ~ 90S, after aluminum alloy melt solidifies completely, release is taken out, and can obtain the composite material piston blank of annular groove, the enhancing of combustion chamber employing ceramic fiber;
8. piston blank 1 is heat-treated, solid solution temperature is 490 ~ 500 ℃, insulation 6h, in 60 ℃ ~ 100 ℃ water, carry out quench treatment, piston blank is less than 30s the transfer time from aluminium alloy quenching furnace to tank, and piston blank solution treatment is less than 2h to the holding time of ageing treatment, and aging temperature is 205 ± 5 ℃, insulation 8h, air cooling after coming out of the stove;
9. piston blank part 1 is carried out to mechanical workout and surface treatment, obtain aluminium piston finished product.
As preferably, step 2. described alterant is phosphor copper, (or microcosmic salt alterant of the model ZSABP of Sichuan Lan De high-tech industry company limited production), to add quality be aluminium alloy quality 0.2% ~ 0.4%, described fining agent is al-ti-b refiner, to add quality be aluminium alloy quality 0.1% ~ 0.2%, described refining agent is that the model that Sichuan Lan De high-tech industry company limited produces is JA04C aluminum refining agent, and to add quality be aluminium alloy quality 0.3% ~ 0.5%;
As preferably, in described alumina-ceramic staple fibre prefabricated component, the volume fraction of alumina-ceramic staple fibre is 10% ~ 12%, and porosity is 88 ~ 90%.
Compared with prior art, the invention has the advantages that:
First, at first piston ring groove position, adopt ceramic alumina fiber reinforced aluminum matrix composites to replace traditional high nickel cast iron edge circle, hot strength and the thermal fatigue resistance of material have been improved, wear resistance is better than high nickel cast iron edge circle, piston loss of weight approximately 5 ~ 10%, exceed more than 5 times than high nickel cast iron edge circle with the bonding strength of piston matrix, it is very approaching that piston strengthens thermal conductivity and the piston aluminum matrix alloy at position, effectively prevents from that the first annular groove from strengthening under the effect of the stress that colds and heat succeed each other at position to cause strengthening the disengagement that position edge encloses;
Secondly, the employing alumina-ceramic staple fibre strongthener at first piston ring groove, bowl in piston position, be prepared into the fiber preform with certain porosity, in piston extrusion casting forming technology, aluminum alloy melt under the effect of mechanical pressure to the diffusion of alumina-ceramic staple fibre prefabricated component, solidify, crystallization, local enhancement first piston ring groove position and top combustion chamber, mechanical property significantly improves;
Again, at position, top land combustion chamber, adopt alumina-ceramic staple fibre to strengthen, effectively improved mechanical behavior under high temperature and the Burning corrosion resistance energy at this position;
Again secondly, adopt alumina-ceramic staple fibre Al
2o
3reinforced aluminum matrix composites is compared with conventional aluminium piston material, and linear expansivity is low, and hot strength, wear resistance and heat-resistant anti-fatigue performance are high, can strengthen the positions such as piston ring groove, bank portion, top combustion chamber;
Finally, by the one-time formed single-piece piston blank of Extrution casting technique, material inside organization densification, without casting flaw, mechanical property significantly improves, and process efficiency is high, low cost of manufacture.
Embodiment
Below in conjunction with accompanying drawing, embodiment is described in further detail the present invention.
Embodiment 1: aluminium piston preparation process is as follows:
1. prepare novel piston alloying constituent, its material is comprised of following component and mass percent: Si:11.0%; Mg:0.6%; Cu:2.6%; Ni:1.8%; Fe:0.1%; Ti:0.1%; Mn:0.1%; Zn:0.1%; Cr:0.001%; Pb:0.001%; Sn:0.001%; All the other are Al;
2. by the novel piston alloy of preparation, putting into smelting furnace melts, after fusing, by temperature of aluminum liquid control, it is 720 ℃, adopt refining agent refining, to add quality be aluminium alloy 0.3%, the control of aluminium liquid deterroration is 760 ℃, adopt the processing of phosphor copper alterant, to add quality be aluminium alloy quality 0.2%, by temperature of aluminum liquid control, it is 740 ℃, adopt al-ti-b refiner processing, to add quality be aluminium alloy quality 0.1%, by temperature of aluminum liquid control, it is 730 ℃, adopt the processing of JA04C refining agent, to add quality be aluminium alloy quality 0.3%, after static 15 minutes, and it is 710 ℃ by temperature of aluminum liquid control, to be cast,
3. alumina-ceramic staple fibre prefabricated component is made, alumina-ceramic staple fibre is pulverized with liquid fiber shredding unit, remove the non-fibrosis impurity such as slag ball, make piston 1 first annular groove alumina-ceramic staple fibre prefabricated component 2 and top combustion chamber alumina-ceramic staple fibre prefabricated component 3;
4. alumina-ceramic staple fibre prefabricated component preheating, the electrothermal oven that the first annular groove alumina-ceramic staple fibre prefabricated component 2 of having prepared and top combustion chamber alumina-ceramic staple fibre prefabricated component 3 are put into 690 ℃ of temperature carries out preheating, wherein, in alumina-ceramic staple fibre prefabricated component, the volume fraction of alumina-ceramic staple fibre is controlled at 10% ~ 12%;
5. mould and die preheating, is preheating to 200 ℃ to mold cavity before extrusion casting;
6. extrusion casting, is fixed on preheated alumina-ceramic staple fibre prefabricated component on the corresponding site of mould, 15 seconds transfer time of prefabricated component, in mold cavity, pours into processed good aluminum alloy melt, and aluminum alloy melt teeming temperature is 710 ℃, matched moulds pressurization;
7. solidify pickup, aluminum alloy melt is under the mechanical pressure action of 100MPa, be penetrated in the hole of the first annular groove alumina-ceramic staple fibre prefabricated component 2 and top combustion chamber alumina-ceramic staple fibre prefabricated component 3, pressurize 60S, after aluminum alloy melt solidifies completely, release is taken out, and can obtain the composite material piston blank of annular groove, the enhancing of combustion chamber employing ceramic fiber;
7. piston blank is heat-treated, solid solution temperature is 495 ± 5 ℃, insulation 6h, in 60 ℃ of water, carry out quench treatment, the transfer time 15s of piston blank from aluminium alloy quenching furnace to tank, piston blank solution treatment is less than 2h to the holding time of ageing treatment, and aging temperature is 205 ± 5 ℃, insulation 8h, air cooling after coming out of the stove
8. piston blank part is carried out to mechanical workout and surface treatment, obtain aluminium piston finished product.
The piston obtaining in the present embodiment, concrete structure as shown in Figure 1, aluminium internal piston dense structure, without casting flaw, more than piston body room temperature tensile strength reaches 260MPa, the first annular groove 2, top combustion chamber 3 adopt ceramic fiber to strengthen position and detect in conjunction with good through fluorescent penetrant, and bonding strength is greater than 110MPa, and heat-resisting and wear resisting property is better than high nickel cast iron ring-mounted piston.
Embodiment 2
1. prepare novel piston alloying constituent, its material is comprised of following component and mass percent: Si:12.0%; Mg:0.9%; Cu:3.2%; Ni:2.3%; Fe:0.2%; Ti:0.15%; Mn:0.2%; Zn:0.2%; Cr:0.01%; Pb:0.01%; Sn:0.005%; All the other are Al;
2. by the novel piston alloy of preparation, putting into smelting furnace melts, after fusing, by temperature of aluminum liquid control, it is 730 ℃, adopt refining agent to add JA04C refining agent, to add quality be aluminium alloy 0.4%, the control of aluminium liquid deterroration is 770 ℃, adopt the processing of phosphor copper alterant, to add quality be aluminium alloy quality 0.3%, by temperature of aluminum liquid control, it is 750 ℃, adopt al-ti-b refiner processing, to add quality be aluminium alloy quality 0.15%, by temperature of aluminum liquid control, it is 735 ℃, adopt the processing of JA04C refining agent, to add quality be aluminium alloy quality 0.4%, after static 20 minutes, and it is 715 ℃ by temperature of aluminum liquid control, to be cast,
3. alumina-ceramic staple fibre prefabricated component is made, alumina-ceramic staple fibre is pulverized with liquid fiber shredding unit, remove the non-fibrosis impurity such as slag ball, make piston 1 first annular groove alumina-ceramic staple fibre prefabricated component 2 and top combustion chamber alumina-ceramic staple fibre prefabricated component 3;
4. alumina-ceramic staple fibre prefabricated component preheating, the electrothermal oven that the first annular groove alumina-ceramic staple fibre prefabricated component 2 of having prepared and top combustion chamber alumina-ceramic staple fibre prefabricated component 3 are put into 700 ℃ of temperature carries out preheating; Wherein, in alumina-ceramic staple fibre prefabricated component, the volume fraction of alumina-ceramic staple fibre is controlled at 10% ~ 12%;
5. mould and die preheating, is preheating to 230 ℃ to mold cavity before extrusion casting;
6. extrusion casting, is fixed on preheated alumina-ceramic staple fibre prefabricated component on the corresponding site of mould, 20 seconds transfer time of prefabricated component, in mold cavity, pours into processed good aluminum alloy melt, and aluminum alloy melt teeming temperature is 715 ℃, matched moulds pressurization;
7. solidify pickup, aluminum alloy melt is under the mechanical pressure action of 110MPa, be penetrated in the hole of the first annular groove alumina-ceramic staple fibre prefabricated component 2 and top combustion chamber alumina-ceramic staple fibre prefabricated component 3, pressurize 70S, after aluminum alloy melt solidifies completely, release is taken out, and can obtain the composite material piston blank of annular groove, the enhancing of combustion chamber employing ceramic fiber;
7. piston blank is heat-treated, solid solution temperature is 495 ± 5 ℃, insulation 6h, in 60 ℃ of water, carry out quench treatment, the transfer time 20s of piston blank from aluminium alloy quenching furnace to tank, piston blank solution treatment is less than 2h to the holding time of ageing treatment, and aging temperature is 205 ± 5 ℃, insulation 8h, air cooling after coming out of the stove;
8. piston blank part is carried out to mechanical workout and surface treatment, obtain aluminium piston finished product.
The aluminium internal piston dense structure obtaining in the present embodiment, without casting flaw, more than piston body room temperature tensile strength reaches 265MPa, annular groove, combustion chamber adopt ceramic fiber to strengthen position and detect in conjunction with good through fluorescent penetrant, bonding strength is greater than 115MPa, and heat-resisting and wear resisting property is better than high nickel cast iron ring-mounted piston.
Embodiment 3:
1. prepare novel piston alloying constituent, its material is comprised of following component and mass percent: Si:13.0%; Mg:1.2%; Cu:4.0%; Ni:2.8%; Fe:0.3%; Ti:0.2%; Mn:0.3%; Zn:0.3%; Cr:0.05%; Pb:0.05%; Sn:0.01%; All the other are Al;
2. by the novel piston alloy of preparation, putting into smelting furnace melts, after fusing, by temperature of aluminum liquid control, it is 740 ℃, adopt refining agent to add JA04C refining agent, to add quality be aluminium alloy 0.5%, the control of aluminium liquid deterroration is 780 ℃, adopt the processing of phosphor copper alterant, to add quality be aluminium alloy quality 0.4%, by temperature of aluminum liquid control, it is 760 ℃, adopt al-ti-b refiner processing, to add quality be aluminium alloy quality 0.2%, by temperature of aluminum liquid control, it is 740 ℃, adopt the processing of JA04C refining agent, to add quality be aluminium alloy quality 0.5%, after static 20 minutes, and it is 720 ℃ by temperature of aluminum liquid control, to be cast,
3. alumina-ceramic staple fibre prefabricated component is made, alumina-ceramic staple fibre is pulverized with liquid fiber shredding unit, remove the non-fibrosis impurity such as slag ball, make piston 1 first annular groove alumina-ceramic staple fibre prefabricated component 2 and top combustion chamber alumina-ceramic staple fibre prefabricated component 3;
4. alumina-ceramic staple fibre prefabricated component preheating, the electrothermal oven that the first annular groove alumina-ceramic staple fibre prefabricated component 2 of having prepared and top combustion chamber alumina-ceramic staple fibre prefabricated component 3 are put into 710 ℃ of temperature carries out preheating; Wherein, in alumina-ceramic staple fibre prefabricated component, the volume fraction of alumina-ceramic staple fibre is controlled at 10% ~ 12%;
5. mould and die preheating, is preheating to 250 ℃ to mold cavity before extrusion casting;
6. extrusion casting, is fixed on preheated alumina-ceramic staple fibre prefabricated component on the corresponding site of mould, 20 seconds transfer time of prefabricated component, in mold cavity, pours into processed good aluminum alloy melt, and aluminum alloy melt teeming temperature is 720 ℃, matched moulds pressurization;
7. solidify pickup, aluminum alloy melt is under the mechanical pressure action of 120MPa, be penetrated in the hole of the first annular groove alumina-ceramic staple fibre prefabricated component 2 and top combustion chamber alumina-ceramic staple fibre prefabricated component 3, pressurize 90S, after aluminum alloy melt solidifies completely, release is taken out, and can obtain the composite material piston blank of annular groove, the enhancing of combustion chamber employing ceramic fiber;
7. piston blank is heat-treated, solid solution temperature is 495 ± 5 ℃, insulation 6h, in 60 ℃ of water, carry out quench treatment, the transfer time 30s of piston blank from aluminium alloy quenching furnace to tank, piston blank solution treatment is less than 2h to the holding time of ageing treatment, and aging temperature is 205 ± 5 ℃, insulation 8h, air cooling after coming out of the stove;
8. piston blank part is carried out to mechanical workout and surface treatment, obtain aluminium piston finished product.The aluminium internal piston dense structure obtaining in the present embodiment, without casting flaw, more than piston body room temperature tensile strength reaches 260MPa, annular groove, combustion chamber adopt ceramic fiber to strengthen position and detect in conjunction with good through fluorescent penetrant, bonding strength is greater than 105MPa, and heat-resisting and wear resisting property is better than high nickel cast iron ring-mounted piston.