CN106102988A - 涂布衬底的方法，其中线状喷涂材料在电弧中熔化并作为层沉积在所述衬底上，以及电弧线材喷涂的层 - Google Patents
涂布衬底的方法，其中线状喷涂材料在电弧中熔化并作为层沉积在所述衬底上，以及电弧线材喷涂的层 Download PDFInfo
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Abstract
本发明涉及一种涂布衬底的方法，其中基于铁的线状喷涂材料在电弧中熔化并作为层沉积在所述衬底上，其中在所使用的喷涂材料中含有以下合金成分：碳：0.1wt％至0.3wt％，锰：1.5wt％至2.0wt％，硅：0.25wt％至0.4wt％，均相对总重量而言；且其中使用由铝合金构成的衬底，在涂布前对所述衬底的表面进行机械粗化，从而形成具有底切的粗糙度RZ，在所述涂布过程中用所述喷涂材料将所述底切填满，从而使得所述涂层与所述衬底机械夹紧在一起；且其中对所述涂层进行表面移除。本发明还涉及一种在衬底上相应制成的基于铁的电弧线材喷涂的层。
Description
技术领域
本发明涉及一种涂布衬底的方法，其中线状喷涂材料在电弧中熔化并作为层沉积在所述衬底上，以及一种在衬底上的电弧线材喷涂的层。
背景技术
制造内燃机时，出于节能和减排的考虑而需要实现尽可能小的摩擦以及较高的抗摩擦与抗磨损性。为此而为发动机构件(如气缸孔或其壁部)配设工作面层，或者将衬套插入配设有工作面层的气缸孔。多数情况下借助热喷涂(如电弧线材喷涂)来镀覆这种工作面层。实施电弧线材喷涂时，通过施加电压在两个线状喷涂材料之间产生电弧。在此过程中，线尖熔化且例如借助喷雾气体被输送至待涂布表面(如气缸壁)，并沉积下来。
由DE 102009061274 B3已知一种用于进行电弧线材喷涂的线状喷涂材料，主要包括铁，其特征在于，这种喷涂材料至少包含碳作为微合金，使得在该喷涂材料凝固时会产生贝氏体和马氏体。在该喷涂材料中含有0.1wt％至0.28wt％的碳，1.4wt％至2.1wt％的锰以及0.05wt％至0.3wt％的硅。
发明内容
本发明的目的是提供一种进行电弧线材喷涂的改进型方法，以便制造具有良好的附著度、强度、可加工性和导热性的涂层。
本发明的另一目的是提供一种改进型喷涂层，其能够通过电弧线材喷涂涂覆在衬底上且易于加工，并且具有良好的附著度、强度和导热性。
本发明用以达成上述目的的解决方案为具有权利要求1的特征的一种进行电弧线材喷涂的方法以及具有权利要求3的特征的一种电弧线材喷涂的层。
将铝合金用作供镀覆涂层之用的衬底，这一点对使用本发明的方法或本发明的层来制造内燃机的气缸曲轴箱而言特别有利，因为这样就能制成与过去常见的铸铁发动机相比轻得多的内燃机，且铝合金具有更好的导热性。后者能够更快地排出燃烧热，从而大幅降低油焦化的风险。但铝合金的摩擦学负荷能力远低于发动机构造中常用的铁合金或钢合金。因此，迄今为止通常将灰铸铁衬套插入或注入铝曲轴箱，以确保足够的摩擦学负荷能力。这类衬套的壁厚至少为数毫米，导热性极差，且并不完全结合在铝衬底上，从而影响了热传递。这样就基本上抵消了铝合金在散热效果良好方面的优点。
因而就热负荷相对较小的汽油发动机而言，这些注入式衬套已被形式为热喷涂层的磨损防护层所取代。这些热喷涂层具有类似于衬套的摩擦学负荷能力，但其壁厚仅为10μm至数百μm，且这些热喷涂层与衬底的结合程度明显增强。通过这种层就能将燃烧热排出至导热效果良好的铝衬底而不会造成严重影响。
但就负荷程度大得多的增压式柴油发动机而言，对磨损防护层及其制造方法的要求高得多。一方面必须排出更多热量，这就需要尽可能薄的层。另一方面这个层必须经受活塞所引起的摩擦负荷和冲击负荷，且特别是不允许从衬底上剥落。后一种情形可以通过将衬底相应粗化来克服，这种粗化主要借助所置入的被喷涂材料填满的底切，来在磨损防护层与衬底间产生良好的机械夹紧效果。但需要对粗化轮廓的总高度与喷涂层的总厚度间的适宜比例加以注意，以便根据需要迅速且均匀地散热至衬底。根据有利方案，10μm至150μm的范围内的平均粗糙度深度Rz与30μm至150μm的层厚是适宜的参数组合，该参数组合在具有足够的摩擦学负荷能力的同时，既能产生足够的夹紧效果，又能足够迅速且均匀地进行散热。粗糙度深度定义为在单个被测距离内，最大轮廓峰顶的高度与最大轮廓谷底的深度之和。平均粗糙度深度Rz由对5个单个被测距离的结果求平均值产生。层厚是从基准线沿衬底的表面轮廓的最大轮廓峰顶直至喷涂层的表面而被测定。在多数场合，最大平均粗糙度深度Rz达到100μm即可，许多场合下甚至仅需达到50μm。在汽缸壁的被所涂布的铝合金所取代的区域内，与注入式灰铸铁衬套相比，本发明的方法和本发明的层的导热效果提高了4倍。
在根据本发明的用于制造本发明的层的方法中，使用线状喷涂材料进行电弧线材喷涂，所述喷涂材料主要包含铁，亦即，该材料除明确列出的合金成分和无法避免的杂质外余下由铁构成，其是该合金的最大成分。
所述喷涂材料优选至少包含碳作为微合金，使得在所述喷涂材料凝固时至少会产生珠光体、贝氏体和极小比例的马氏体，其中可以额外设有用于形成抗磨损相以及用于提高摩擦学特性的微合金元素。这样就能制成并镀覆250至400HV 0.1范围内的硬度相对较小的磨损防护层。这种层在层的可加工性与其所需的摩擦学特性之间实现了合适的折衷。后者主要指纳米晶结构在硬度较小的同时具有较小的磨损。较小的硬度在针对冲击负荷时特别有利，例如活塞施加于气缸工作面的冲击负荷。硬度较大的层易于剥落(蛋壳效应)。
上述微合金指的是主要由某种成分构成的合金，该成分中与总质量相比仅添加有少量其他成分。由较硬的Fe3C构成的细条纹式珠光体以及铁氧体是在摩擦学上起积极作用的相。贝氏体是中等硬度和抗磨损性的转换相。马氏体是一种较硬且抗磨损的结构。可以通过喷涂材料的冷却方式以及通过选择该微合金的合金成分来针对性地影响马氏体的形成，特别是其在整个结构中的比例和分布。在借助电弧线材喷涂并使用所述喷涂材料进行沉积的过程中产生在铝衬底(如气缸工作面)上的层，优选包括贝氏体、由马氏体构成的抗磨损岛状物以及细条纹式珠光体。
特别是可以通过以下方式来实现这些优选特性：所述喷涂线材中存在以下的其他合金成分：
-铜0.05wt％至0.25wt％以及/或者
-铬0.001wt％至0.1wt％以及/或者
-钛0.001wt％至0.01wt％以及/或者
-磷0.001wt％至0.02wt％以及/或者
-硫0.001wt％至0.02wt％以及/或者
-钒0.0001wt％至0.001wt％以及/或者
-铝0.001wt％至0.02wt％以及/或者
-硼0.0001wt％至0.0004wt％以及/或者
-氮100ppm至200ppm。
除非另有说明，以上单位为重量百分比的含量信息均相对总重量而言。
在所述方法和层的特别有利的设计方案中，所述铝衬底至少局部地具有2至8mm范围内的厚度。这样就能(例如)制造既具有足够的强度又能非常迅速地将燃烧热排出至水套的气缸曲轴箱，该水套位于构建为气缸工作面的铝衬底的未经涂布的一侧上。
特别有利地，本发明的方法和本发明的层用来制造柴油发动机，其具有包含热涂布气缸工作面的由铝合金构成的气缸曲轴箱以及具有钢活塞。由于钢与铝的导热性有所不同，迄今为止只有采用非常复杂的结构和控制技术才能实现这种组合，举例而言，既需要在气缸工作面中设置注入式衬套，又需要在整个工作期间内通过喷油对活塞进行主动冷却。因此，现有技术中的这种解决方案能耗较高。而采用本发明的方法和本发明的层后，就能制造具有较高功率密度的高负荷能力的柴油发动机，该柴油发动机具有钢活塞以及包含热涂布工作面的由铝合金构成的曲轴箱，而不会在工作过程中造成已知的焦化以及与此相关的油、活塞和工作面受损现象。这样就能充分利用钢活塞-铝曲轴箱这一组合的能耗优点并消除或至少抑制负面效果，例如能耗较高的通过喷油嘴进行持续主动冷却或类似措施。
附图说明
无
具体实施方式
下面借助两个实施例对本发明进行进一步说明。
根据第一实施例，首先对由铝合金构成的待涂布衬底的表面进行机械粗化，从而形成具有底切的约为20μm的平均粗糙度深度RZ。
随后，借助电弧线材喷涂对所述衬底的粗化区域进行涂布，其中使用的是基于铁的线状喷涂材料，其含有如下其他合金成分：
-碳0.12wt％
-硅0.28wt％
-锰1.7wt％
-铜0.18wt％
-铬0.027wt％
-氮150ppm。
以上单位为重量百分比的含量信息均相对总重量而言。
在用喷涂材料进行涂布的过程中，用喷涂材料将粗化的衬底表面的谷底并且特别是底切填满，从而使得该涂层与衬底机械夹紧在一起。最后，通过珩磨将该涂布表面平滑化并将其移除(abgetragen)至约100μm的剩余厚度。
根据第二实施例，将柴油发动机中的由铝合金构成的气缸曲轴箱的工作面用作衬底，并根据该第一实施例为其涂布磨损防护层。这个曲轴箱在磨损防护层与位于其后面的水套之间的壁厚约为5mm。该曲轴箱中可动布置有钢活塞。
即使在柴油发动机负荷较大时，在发动机工作过程中产生的燃烧热也能足够迅速地通过磨损防护层和位于其后面的曲轴箱壁排出至位于水套中的水，因而即使在不持续实施主动油冷却的情况下，也能大幅降低油焦化以及活塞和/或工作面受损的风险。同时，所述磨损防护层具有足够的厚度和柔软度，且因其机械夹紧作用而足够稳固地与工作面壁连接，从而能够持续经受工作负荷，特别是钢活塞的横向力。
亦即，本发明的方法和本发明的层因其优异的摩擦学特性而特别适于制造高负荷柴油发动机。
Claims (6)
1.一种涂布衬底的方法，
其中基于铁的线状喷涂材料在电弧中熔化并作为层沉积在所述衬底上，
其中在所使用的喷涂材料中含有以下合金成分：
-碳：0.1wt％至0.3wt％
-锰：1.5wt％至2.0wt％，
-硅：0.25wt％至0.4wt％
均相对总重量而言，
其特征在于，
-使用由铝合金构成的衬底，其中在涂布前对所述衬底的表面进行机械粗化，从而形成具有底切的粗糙度RZ，在所述涂布过程中用所述喷涂材料将所述底切填满，从而使得所述涂层与所述衬底机械夹紧在一起，
-对所述涂层进行表面移除。
2.根据权利要求1所述的方法，
其特征在于，
所述衬底垂直于所述涂层的主涂覆方向至少局部地具有2至8mm范围内的厚度。
3.一种基于铁的电弧线材喷涂的层，
所述层位于衬底上，
其中在所述层中含有以下合金成分：
-碳：0.1wt％至0.3wt％，
-锰：1.5wt％至2.0wt％，
-硅：0.25wt％至0.4wt％
均相对总重量而言，
其特征在于，
-所述衬底由铝合金构成，其中所述衬底的表面具有包含底切的粗糙度RZ，所述底切被喷涂层的材料填满，从而使得喷涂层与所述衬底机械夹紧在一起，
-所述涂层受到表面移除。
4.根据权利要求3所述的层，
其特征在于，
所述衬底垂直于所述涂层的主涂覆方向至少局部地具有2至8mm范围内的厚度。
5.根据权利要求3或4所述的层，
其特征在于，
所述衬底构造为气缸曲轴箱的工作面。
6.根据权利要求5所述的层，
其特征在于，
所述层作为钢活塞的作用性配合件布置在所述气缸曲轴箱中。
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| DE201410003114 DE102014003114B3 (de) | 2014-03-11 | 2014-03-11 | Verfahren zum Beschichten eines Substrats, bei dem ein drahtförmiger Spritzwerkstoff in einem Lichtbogen aufgeschmolzen und als Schicht auf dem Substrat abgeschieden wird sowie lichtbogendrahtgespritzte Schicht |
| DE102014003114.4 | 2014-03-11 | ||
| PCT/EP2015/000252 WO2015135618A1 (de) | 2014-03-11 | 2015-02-06 | Verfahren zum beschichten eines substrats, bei dem ein drahtförmiger spritzwerkstoff in einem lichtbogen aufgeschmolzen und als schicht auf dem substrat abgeschieden wird sowie lichtbogendrahtgespritze schicht |
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| DE102014003114B3 (de) | 2014-12-31 |
| EP3116678A1 (de) | 2017-01-18 |
| WO2015135618A1 (de) | 2015-09-17 |
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| US20170016105A1 (en) | 2017-01-19 |
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Address after: Stuttgart, Germany Patentee after: Mercedes-Benz Group Co.,Ltd. Address before: Stuttgart, Germany Patentee before: DAIMLER AG |
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