CN109072810A - 无通道的钢制活塞绝缘层 - Google Patents

无通道的钢制活塞绝缘层 Download PDF

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Publication number
CN109072810A
CN109072810A CN201780023921.1A CN201780023921A CN109072810A CN 109072810 A CN109072810 A CN 109072810A CN 201780023921 A CN201780023921 A CN 201780023921A CN 109072810 A CN109072810 A CN 109072810A
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Prior art keywords
barrier coatings
thermal barrier
ceramic material
piston
thermal
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CN201780023921.1A
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CN109072810B (zh
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N·G·施耐德
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Tenneco Co ltd
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Federer - Moguer LLC
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F02F3/10—Pistons  having surface coverings
    • F02F3/12—Pistons  having surface coverings on piston heads
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F02F3/10—Pistons  having surface coverings
    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
    • C04B35/486—Fine ceramics
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/62222—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining ceramic coatings
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
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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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    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/36—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including layers graded in composition or physical properties
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
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    • C23C4/11—Oxides
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/126—Detonation spraying
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    • C23C4/129—Flame spraying
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    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • F02F3/0084—Pistons  the pistons being constructed from specific materials
    • F02F3/0092—Pistons  the pistons being constructed from specific materials the material being steel-plate
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    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
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    • F05C2251/00—Material properties
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F05C2253/00—Other material characteristics; Treatment of material
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  • Chemical & Material Sciences (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
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  • Ceramic Engineering (AREA)
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Abstract

提供了一种无通道钢制活塞(10，1)，旨在提高发动机的热效率、燃油消耗和性能。活塞(10，1)包括钢主体部分和施加在上部燃烧表面(16)和/或环形带(32)的热障层(12，32)，以减少从燃烧室传递到主体部分的热量。热障层(12，32)的导热率低于钢主体部分的导热率。热障层(12，32)通常包括陶瓷材料，例如二氧化铈、二氧化铈稳定的氧化锆、和/或二氧化铈稳定的氧化锆和氧化钇稳定的氧化锆的混合物，其量为基于陶瓷材料的总重量的90至100重量％。热障层(12，32)还可以具有梯度结构，该梯度结构从100重量％的金属粘结材料逐渐过渡到100重量％的陶瓷材料。

Description

无通道的钢制活塞绝缘层
相关申请的交叉引用
本申请要求2016年2月22日提交的美国临时专利申请号62/298,024和2017年2月20日提交的美国发明专利申请号15/436,966的权益，其全部内容通过引用整体而并入本文。
技术领域
本发明总体上涉及用于内燃机的活塞，以及制造活塞的方法。
背景技术
发动机制造商遇到了日益增长的提高发动机效率和性能的需求，包括但不限于改善燃料经济性、减少油耗、改进燃料系统、增加缸膛内的压缩载荷和工作温度、减少通过活塞的热损失、改善零部件的润滑、降低发动机重量并使发动机更紧凑，同时降低与制造相关的成本。
虽然希望增加燃烧室内的压缩载荷和工作温度，但仍然需要将活塞的温度保持在可工作的限度内。因此，尽管希望增加燃烧室内的压缩载荷和工作温度，但是实现这一目标需要进行权衡，因为这些希望的“增加”限制了活塞压缩高度以及整体活塞尺寸和质量可以降低的程度。这对于具有封闭或部分封闭的冷却通道的典型活塞结构来说，降低活塞的工作温度尤其麻烦。由于用于将上部和下部结合在一起的连接工艺，制造具有沿着接合连接结合在一起以形成封闭或部分封闭的冷却通道的上部和下部的活塞，其成本通常增加。此外，发动机重量可以降低的程度受到用钢制造上述“含冷却通道(cooling gallery-containing)”活塞的需求的影响，因此它们能够承受施加在活塞上的机械载荷和热载荷的增加。
最近，已经开发出没有冷却通道的单件式钢制活塞，并且可以将其称为“无通道”活塞。这种活塞可减轻重量、降低制造成本并降低压缩高度。无通道活塞由冷却油喷嘴喷雾冷却、轻微喷雾仅用于润滑或者不喷洒任何油。由于没有冷却通道，这种活塞通常比具有传统冷却通道的活塞承受更高的温度。高温会导致钢制活塞的上部燃烧表面氧化或过热，这会导致连续的活塞破裂并可能导致发动机故障。高温还会导致沿着活塞的顶部底面区域的油劣化，例如在喷洒冷却或润滑油的燃烧碗下面。由于高温引起的另一个潜在问题是冷却油可以在冷却或润滑油与活塞顶部底面接触的区域中产生厚的碳层。该碳层可能导致活塞过热而可能发生破裂，从而可能导致发动机故障。然而，还认识到活塞的高表面温度可以提高发动机的热效率，从而允许发动机的更好的燃料消耗。
发明内容
本发明的一个方面提供了一种用于内燃机的无通道钢制活塞，其设计用于提高发动机的热效率、燃料消耗和性能。活塞包括由钢制成的主体部分。主体部分包含包括顶部底表面的上壁，当从活塞的下侧观察时顶部底表面暴露，并且上壁包括与顶部底表面相对的上部燃烧表面。环形带从上壁悬垂并围绕活塞的中心纵向轴线周向延伸，一对活塞销凸台从上壁悬垂，并且一对裙板从环形带悬垂并连接到活塞销凸台。将热障层施加到上部燃烧表面的至少一部分和/或环形带的至少一部分上，以防止来自燃烧室的热量进入活塞的钢主体部分，并且热障层的导热率低于主体部分的钢的导热率。
本发明的另一方面提供一种制造无通道活塞的方法。该方法包括将热障层施加到活塞的主体部分的上部燃烧表面的至少一部分和/或环形带的至少一部分上。活塞的主体部分由钢制成，并且热障层的导热率低于主体部分的钢的导热率。主体部分包括上壁和顶部底表面，上壁包括上部燃烧表面，顶部底表面从活塞的下侧暴露。环形带从上壁悬垂并围绕活塞的中心纵向轴线周向延伸，一对活塞销凸台从上壁悬垂，并且一对裙板从环形带悬垂并连接到活塞销凸台。
附图说明
当结合以下详细描述和附图考虑时，将更容易理解本发明的这些和其他方面、特征和优点，其中：
图1是根据本发明的示例性实施例构造的活塞的仰视透视图；
图2是本发明的示例性实施例的大致横向于活塞的销孔轴线截取的横截面图；
图3是图2的一部分的放大视图，示出了施加到活塞的上部燃烧表面的热障层；以及
图4是根据本发明的另一个实施例构造的活塞的示例，其中活塞不包括顶部底面凹穴。
具体实施方式
图1和2示出了根据本发明的示例性实施例构造的活塞10的视图，活塞10用于在内燃机(例如现代的、紧凑的、高性能的车辆发动机)的缸膛或腔室(未示出)中往复运动。如图3所示，热障层12(也称为绝缘层)施加到活塞10的上部燃烧表面16，以提高发动机的热效率、燃料消耗和性能。
活塞10构造成具有由单件钢材料形成的整体式主体，例如通过机械加工、锻造或铸造，如果需要，之后可以进行精加工，以完成构造。因此，活塞10不具有结合在一起的多个部件，例如彼此连接的上部件和下部件，这对于具有由冷却通道底板限定或部分限定的封闭或部分封闭的冷却通道的活塞是常见的。相反，活塞10是“无通道的”，因为它没有限定或部分限定冷却通道的冷却通道底板或其他特征。由钢制成的主体部分坚固且耐用，以满足现代高性能内燃机的高性能要求，即升高的温度和压缩载荷。用于构造主体的钢材料可以是诸如SAE4140等级的合金或不同的合金，这取决于特定发动机应用中活塞10的要求。由于活塞10是无通道的，最小化活塞10的重量和压缩高度(CH)，从而允许其中部署有活塞10的发动机实现减轻的重量并且使其更紧凑。此外，即使活塞10是无通道的，活塞10在使用期间也可以充分冷却以承受最严苛的工作温度，或者可选地在没有油冷却的情况下使用。
活塞10的主体部分具有提供上壁14的上部头部或顶部部分，这提供了上部燃烧表面16，其从活塞10的下侧直接暴露于内燃机的缸膛内的燃烧气体。在示例性实施例中，上部燃烧表面16包括环形第一部分18和第二部分20，环形第一部分18形成为沿上壁14的外周延伸的基本上平坦的表面，第二部分20形成燃烧碗。形成燃烧碗的上部燃烧表面16的第二部分20通常具有从平坦的第一部分18悬垂的非平坦的、凹入的或起伏的表面。
活塞10还包括顶部底表面24，顶部底表面24形成在上壁14的下侧，与上部燃烧表面16的第二部分20直接相对并且在环形带32的径向内侧。顶部底表面24优选地位于距燃烧碗的最小距离处，并且基本上是位于燃烧碗直接相对侧的表面。当从底部直接观察活塞10时，顶部底表面24在此限定为除了销孔40之外可见的表面。顶部底表面24也从活塞10的下侧暴露。顶部底表面24通常形成为与上部燃烧表面16的燃烧碗配合。从活塞10的下侧观察，顶部底表面24也是敞开暴露的，并且它不受封闭或部分封闭的冷却通道、或者倾向于在顶部底表面24附近保留油或冷却液的任何其他特征所限界。由于活塞10沿着顶部底表面24没有冷却通道，因此相对于包括封闭的冷却通道的活塞，活塞10的重量和相关成本降低。
在示例性实施例中，其中活塞10设计用于柴油发动机，上壁14的环形第一部分18形成上壁14的外周并围绕形成燃烧碗的第二部分，其由此悬垂。因此，在示例性实施例中，包括燃烧碗的第二部分20凹入上部燃烧表面16的最上面的第一部分18的下方。第二部分20的燃烧碗也在环形第一部分18的相对侧之间连续地延伸穿过中心轴线30并且横跨活塞10的整个直径。在示例性实施例中，燃烧碗包括在环形第一部分18的相对侧之间连续延伸的凹表面。或者，燃烧碗壁可以是波状外形的，例如为了提供上顶点，也称为中心顶点(未示出)，其可以沿着活塞10的中心轴线30同轴地放置，或者可以相对于活塞中心轴线30轴向偏移。根据另一个实施例，第一部分18位于第二部分20下方，第二部分20向上鼓起并凸出。该设计可用于天然气发动机或任何其他类型的发动机。
活塞10的顶部部分还包括环形带32，环形带32从上部燃烧表面16悬垂以提供上部平台17和一个或多个环形槽34，用于容置一个或多个相应的活塞环(未示出)。上部平台17从上部燃烧表面16延伸到环形槽34中的最上面的一个。在示例性实施例中，在上壁14的环形第一部分18中形成至少一个具有弯曲轮廓的阀囊29。
活塞10还包括底部部分，该底部部分包括一对大致从上壁14悬垂的活塞销凸台38。活塞销凸台38每个都具有销孔40，在给定钢结构的情况下优选地是无套管的，其中销孔40沿着销孔轴线42彼此同轴地横向间隔开，销孔轴线42大致横向于中心纵向轴线30延伸。活塞销凸台38具有大致平坦的径向最外表面，称为外表面43，它们沿销孔轴线42彼此间隔开距离PB，示出为彼此大致平行。PB尺寸被最小化，从而最大化凹陷的、通常为杯形的区域的暴露区域，在下文中称为顶部底面凹穴50。顶部底面凹穴50位于活塞销凸台38的径向外侧，并且每个凹穴50的至少一部分形成顶部底表面24的一部分。在示例性实施例中，形成顶部底表面24的一部分的顶部底面凹穴50的部分位于上部燃烧表面16的第二部分20的对面并且在环形带32的径向内侧。顶部底面凹穴50还在顶部底表面24上方沿着上部燃烧表面16的环形第一部分18的下侧表面径向向外延伸，并且沿着环形带32的内表面从上壁14悬垂。
在最大化凹穴50的2维和3维表面积的情况下，至少部分地由于最小化的距离PB，可以增强由油飞溅或从曲轴箱向上喷洒到顶部底面凹穴50的暴露表面引起的冷却，从而有助于进一步冷却上部燃烧表面16、顶部底表面24以及环形带32的一部分。
尽管图1和2的示例性实施例的活塞10包括顶部底面凹穴50，但是活塞10可替代地设计成没有顶部底面凹穴50。图4中示出了没有顶部底面凹穴50的活塞10的示例。
每个销孔40都具有凹入的最上面的承载表面，在下文中称为最上表面44，设置在环形带32附近。这样，压缩高度CH最小化(压缩高度是从销孔轴线42延伸到上部燃烧表面16的环形第一部分18的尺寸)。活塞销凸台38通过外板(也称为支柱46)连接到径向相对的裙板，也称为裙板48。
活塞销凸台38、裙板48和支柱46限定内部顶部底面区域，该内部顶部底面区域沿着顶部底表面24并且从支柱46和裙板48的最下部或底部表面51延伸到顶部底表面24。在图1和2的示例性实施例中，没有肋沿着顶部底表面24、沿着活塞销凸台38、沿着裙板48或沿着敞开区域中的支柱46定位。此外，在敞开区域中没有形成封闭或部分封闭的冷却通道。然而，如图1和图2中所示，活塞10可以包括沿着每个裙板48的最下边缘的邻近顶部底表面24的阶梯区域54。
与具有封闭或部分封闭的冷却通道的相当的活塞相比，活塞10的顶部底表面24具有更大的总表面积(遵循表面轮廓的3维区域)和更大的投影表面积(2维区域，平面，如平面图所示)。沿着活塞10下侧的这个敞开区域提供了直接进入油溅或从曲轴箱内直接喷洒到顶部底表面24上，从而允许整个顶部底表面24直接被来自曲轴箱内的油溅射到，同时还允许油围绕腕销(未示出)自由地飞溅，并且进一步显著减小活塞10的重量。因此，尽管没有典型的封闭或部分封闭的冷却通道，但是无通道活塞10的大致敞开的构造允许顶部底表面24的最佳冷却和对销孔40内的腕销接头的润滑，同时减少燃烧碗附近表面上的油停留时间，这是一定体积的油保留在表面上的时间。减少的停留时间可以减少焦化油的多余积聚，例如可以在具有封闭或基本封闭的冷却通道的活塞中发生。这样，在某些应用中，活塞10可以在长时间使用时保持“清洁”，从而使其保持基本上没有积聚。
图1和2中所示的示例性活塞10的另一个重要方面是当从活塞10的底部观察时，至少设置在相对的裙板48和相对的活塞销凸台38之间的活塞10的顶部底表面24的中心部分52是凹入的形式。这样，在从活塞10的一侧到活塞10的相对侧的往复运动期间可以引导油，从而进一步增强活塞10的冷却。或者，当在不使用冷却油的情况下用于内燃机时，活塞10可以保持在可接受的温度。
活塞10还包括施加到上部燃烧表面16和/或上部平台17的热障层12，直到但不包括最上面的环形槽34。上部燃烧表面16和施加有热障层12的上部平台17都暴露于发动机的燃烧室。热障层12可以覆盖整个上部燃烧表面16和上部平台17，如图1所示，或者仅覆盖上部燃烧表面16的某些区域和/或上部平台17的某些区域。热障层12可以减少上部燃烧表面16的氧化，以及油降解和沿着顶部底表面24或顶部底面凹穴50的区域的厚碳层。应注意，热障层12还影响顶部底面凹穴50的区域的温度。热障层12还可以提高活塞10的热效率并提供更好的发动机燃料消耗。
热障层12的至少一部分的导热率低于用于形成活塞10的主体部分的钢的导热率。可以使用各种不同的组合物来形成热障层12。
在一个示例性实施例中，热障层12包括陶瓷材料，特别是二氧化铈、二氧化铈稳定的氧化锆以及二氧化铈稳定的氧化锆和氧化钇稳定的氧化锆的混合物中的至少一种。陶瓷材料具有低导热率，例如小于1W/m·K。陶瓷材料中使用的二氧化铈使得层12在发动机的高温、高压和其它苛刻条件下更稳定。陶瓷材料的组成还使其比其它陶瓷涂层(例如由氧化钇稳定的氧化锆形成的涂层)更不易受化学侵蚀，这可通过柴油发动机中的热效应和化学侵蚀而遭受不稳定。在这样的热和化学条件下，二氧化铈和二氧化铈稳定的氧化锆更稳定。二氧化铈的热膨胀系数与用于形成活塞主体部分的钢材相似。室温(21℃)下二氧化铈的热膨胀系数的范围为10E-6至11E-6，室温(21℃)下钢的热膨胀系数的范围为11E-6至14E-6。相似的热膨胀系数有助于避免热失配，从而产生应力裂纹。
在一个实施例中，用于形成热障层12的陶瓷材料包括基于陶瓷材料的总重量的90至100重量％的二氧化铈。在另一个示例性实施例中，陶瓷材料包括基于陶瓷材料的总重量的90至100重量％的二氧化铈稳定的氧化锆。在又一个示例性实施例中，陶瓷材料包括基于陶瓷材料的总重量的90至100重量％的二氧化铈/氧化钇稳定的氧化锆。在该实施例中，基于陶瓷材料的总重量约50重量％的氧化锆被二氧化铈稳定，以及约50重量％的氧化锆被氧化钇稳定。
可以以梯度结构施加热障层12以避免不连续的金属/陶瓷界面。梯度结构有助于减轻通过热失配产生的应力积聚，并减少在粘结材料/陶瓷界面处形成连续的弱氧化物边界层的趋势。换句话说，梯度结构避免了尖锐的界面。因此，热障层12在使用期间不太可能脱粘。
通过首先将金属粘结材料施加到上部燃烧表面16和/或上部平台17来形成热障层12的梯度结构。金属粘结材料的组成可以与用于形成活塞主体部分的材料相同，例如钢粉。或者，金属粘结材料可包括高性能超合金，例如用于喷气涡轮机涂层的超合金。通过从100％金属粘结材料逐渐过渡到100％陶瓷材料来形成梯度结构。热障层12包括施加到上部燃烧表面16和/或上部平台17的金属粘结材料，随后增加陶瓷材料的量和减少金属粘结材料的量。热障层12的最上部分完全由陶瓷材料形成。金属粘结材料通常由基于金属粘结材料的总重量的100重量％的金属组成，以及陶瓷材料通常由基于陶瓷材料的总重量的100重量％的陶瓷组成。通常，当热障层12包括梯度结构时，层12仅由金属粘结材料和陶瓷材料组成。
已经发现热障层12很好地粘附到钢活塞主体部分上。然而，对于额外的机械锚固，可以沿着上部燃烧表面16和/或上部平台17的至少一部分机加工断裂边缘，例如凹穴、凹陷、圆形边缘和/或倒角。这些特征有助于避免热障层12中的应力集中并避免可能导致层12失效的尖角或边缘。机加工的凹穴或凹槽将热障层12机械锁定在适当的位置，再次降低了分层失败的可能性。
本发明的另一方面提供一种制造用于内燃机的涂覆的无通道活塞10的方法。活塞10的主体部分(通常由钢制成)可以根据各种不同的方法制造，例如锻造或铸造。无通道活塞10的主体部分也可包括各种不同的设计，图中示出了设计的示例。
该方法还包括将热障层12施加到活塞10的上部燃烧表面16的至少一部分和/或上部平台17的至少一部分。可以使用各种不同的方法来施加热障层12。例如，热障层12可以喷涂、电镀、铸造或以任何方式永久地连接在活塞10的钢主体部分上。
在一个实施例中，通过热喷涂施加热障层12。例如，该方法可包括通过热喷涂技术(例如等离子喷涂)施加金属粘结材料和陶瓷材料。高速氧燃料(HVOF)喷涂是提供更致密层12的替代方案，但它是更昂贵的工艺。也可以使用将热障层12施加到活塞10的其他方法。
示例性方法开始于喷涂基于层12的总重量的100重量％的量的金属粘结材料和以0重量％的量的陶瓷材料。在整个喷涂过程中，增加量的陶瓷材料加入到组合物中，同时减少金属粘结材料的量。因此，热障层12的组成在层12的最外表面处逐渐在活塞主体部分从基于热障层12的总重量100重量％的金属粘结材料变为100重量％的陶瓷材料。通常使用多个粉末进料器来施加热障层12，并调节它们的进料速率以实现梯度结构。施加的热障层12的厚度优选小于500微米。在热喷涂工艺期间实现热障层12的梯度结构。
在施加热障层12之前，有助于机械锁定和减小应力上升的断裂边缘或特征机加工到活塞10的钢主体部分中，例如通过车削、铣削或任何其它适当的方式。然后在溶剂中洗涤上部燃烧表面16和/或上部平台17以除去污染物。该方法还可以包括喷砂处理活塞主体部分的表面，以改善热障层12的粘附性。
鉴于上述教导，本发明的许多修改和变化是可能的，并且可以在权利要求的范围内以不同于具体描述的方式实施。可以预期，所有权利要求和所有实施例的所有特征可以彼此组合，只要这种组合不会彼此矛盾。

Claims (20)

1.一种无通道活塞，包括：
由钢制成的主体部分，
所述主体部分包含包括顶部底表面的上壁，
当从所述活塞的下侧观察时，所述顶部底表面暴露，
所述上壁包括与所述顶部底表面相对的上部燃烧表面，
从所述上壁悬垂并围绕所述活塞的中心纵向轴线周向延伸的环形带，
从所述上壁悬垂的一对活塞销凸台，以及
从所述环形带悬垂并连接到所述活塞销凸台的一对裙板，
施加到所述上部燃烧表面的至少一部分和/或所述环形带的至少一部分上的热障层，所述热障层的导热率低于所述主体部分的所述钢的导热率。
2.根据权利要求1所述的无通道活塞，其中所述热障层包括陶瓷材料。
3.根据权利要求2所述的无通道活塞，其中所述热障层的所述陶瓷材料包括二氧化铈、二氧化铈稳定的氧化锆、二氧化铈稳定的氧化锆和氧化钇稳定的氧化锆的混合物中的至少一种。
4.根据权利要求3所述的无通道活塞，其中所述热障层的所述陶瓷材料包括基于所述陶瓷材料总重量的90至100重量％的二氧化铈。
5.根据权利要求4所述的无通道活塞，其中所述陶瓷材料的所述二氧化铈在21℃下具有10E-6至11E-6的热膨胀系数，以及所述主体部分的所述钢在21℃下具有11E-6至14E-6的热膨胀系数。
6.根据权利要求3所述的无通道活塞，其中所述热障层的所述陶瓷材料包括基于所述陶瓷材料总重量的90至100重量％的二氧化铈稳定的氧化锆。
7.根据权利要求3所述的无通道活塞，其中所述热障层的所述陶瓷材料包括基于所述陶瓷材料总重量的90至100重量％的二氧化铈/氧化钇稳定的氧化锆。
8.根据权利要求3所述的无通道活塞，其中所述陶瓷材料的导热率小于1W/m·K。
9.根据权利要求1所述的无通道活塞，其中所述热障层具有梯度结构。
10.根据权利要求9所述的无通道活塞，其中所述热障层包括施加到所述上部燃烧表面和/或所述环形带的金属粘结材料，以及所述热障层从基于所述热障层的总重量100重量％的所述金属粘结材料逐渐过渡到100重量％的陶瓷材料，以及所述热障层的最上部分完全由所述陶瓷材料形成。
11.根据权利要求10所述的无通道活塞，其中所述陶瓷材料包括二氧化铈、二氧化铈稳定的氧化锆、以及二氧化铈稳定的氧化锆和氧化钇稳定的氧化锆的混合物中的至少一种，并且所述金属粘结材料包括钢或超合金。
12.根据权利要求10所述的无通道活塞，其中所述金属粘结材料由基于所述金属粘结材料总重量的100重量％的量的金属组成，所述陶瓷材料由基于所述陶瓷材料总重量的100重量％的量的所述陶瓷组成，所述热障层仅由所述金属粘结材料和所述陶瓷材料组成。
13.根据权利要求1所述的无通道活塞，其中所述热障层的厚度小于500微米。
14.根据权利要求1所述的无通道活塞，其中所述主体部分由单件所述钢制成，多个支柱将所述裙板连接到所述活塞销凸台上，所述主体部分具有沿着所述顶部底表面延伸并被所述裙板和所述支柱和所述活塞销凸台包围的内部顶部底面区域，一对顶部底面凹穴沿着所述顶部底表面延伸，每个顶部底面凹穴由所述活塞销凸台中的一个和所述裙板中的一个围绕，并且所述支柱将所述一个活塞销凸台连接到所述一个裙板上，并且所述主体部分不具有冷却通道底板或沿着所述顶部底表面限定或部分限定冷却通道的其他特征。
15.根据权利要求1所述的无通道活塞，其中所述主体部分由单件所述钢制成，
所述钢在21℃时的热膨胀系数范围为11E-6至14E-6，
多个支柱将所述裙板连接到所述活塞销凸台上，
所述主体部分具有沿着所述顶部底表面延伸并被所述裙板和所述支柱和所述活塞销凸台包围的内部顶部底面区域，
一对顶部底面凹穴沿着所述顶部底表面延伸，
每个顶部底面凹穴由所述活塞销凸台中的一个和所述裙板中的一个围绕，并且所述支柱将所述一个活塞销凸台连接到所述一个裙板上，
并且所述主体部分不具有冷却通道底板或沿着所述顶部底表面限定或部分限定冷却通道的其他特征，
所述上部燃烧表面包括环形第一部分和第二部分，所述环形第一部分形成为沿所述上壁的外周延伸的基本上平坦的表面，所述第二部分形成燃烧碗，
所述上部燃烧表面的所述第二部分具有从所述第一部分悬垂的非平坦的、凹入的或起伏的表面，
所述环形带包括上部平台和多个环形槽，用于容纳一个或多个相应的活塞环，
所述上部平台从所述上部燃烧表面延伸到所述环形槽的最上面的一个，
所述活塞销凸台各自都有一个销孔，
所述销孔各自具有凹入的最上表面，
所述顶部底面凹穴位于所述活塞销凸台的径向外侧，
每个顶部底面凹穴的至少一部分形成所述顶部底表面的一部分，
所述活塞销凸台和所述裙板以及所述支柱限定所述内部顶部底面区域，所述内部顶部底面区域从所述支柱和所述裙板的最下表面延伸到所述顶部底表面，
当从所述活塞的所述下侧观察时，设置在所述相对的裙板和所述相对的活塞销凸台之间的所述顶部底表面的至少中心部分是凹的，
将所述热障层施加到所有所述上部燃烧表面和所述环形带的所述上部平台，
所述热障层的厚度小于500微米，
所述热障层包括陶瓷材料，
所述热障层的所述陶瓷材料包括二氧化铈、二氧化铈稳定的氧化锆，二氧化铈稳定的氧化锆和氧化钇稳定的氧化锆的混合物中的至少一种，其量为基于所述陶瓷材料总重量的90-100重量％，
所述陶瓷材料的导热率小于1W/m·K，
所述陶瓷材料的所述二氧化铈在21℃时的热膨胀系数范围为10E-6至11E-6，
所述热障层具有梯度结构，
所述热障层包括施加到所述上部燃烧表面和所述上部平台的金属粘结材料，
所述金属粘结材料包括钢或超合金，
所述热障层从基于所述热障层的总重量100重量％的所述金属粘结材料逐渐过渡到100重量％的所述陶瓷材料，以及
所述热障层的最上部分完全由所述陶瓷材料形成。
16.一种制造无通道活塞的方法，包括：
将热障层施加到活塞的主体部分的上部燃烧表面的至少一部分和/或环形带的至少一部分上，活塞的主体部分由钢制成，热障层的导热率低于主体部分的钢的导热率，以及
其中，主体部分包含包括上部燃烧表面的上壁和从活塞下侧暴露的顶部底表面，环形带从上壁悬垂并围绕活塞的中心纵向轴线周向延伸，一对活塞销凸台从上壁悬垂，并且一对裙板从环形带悬垂并连接到活塞销凸台。
17.根据权利要求16所述的方法，其中施加热障层的步骤包括喷涂、电镀或铸造。
18.根据权利要求17所述的方法，其中施加热障层的步骤包括热喷涂。
19.根据权利要求18所述的方法，其中热喷涂步骤包括等离子喷涂或高速氧燃料(HVOF)喷涂。
20.根据权利要求16所述的方法，其中施加热障层的步骤包括将热障层施加到所有上部燃烧表面和环形带的上部平台，
施加热障层的步骤包括热喷涂，
热喷涂步骤包括等离子喷涂或高速氧燃料(HVOF)喷涂，
热喷涂步骤包括通过首先喷洒基于上部燃烧表面上热障层总重量的100重量％的量的金属粘结材料和0重量％的量的陶瓷材料形成梯度结构，然后相对于金属粘结材料以增加的量喷涂陶瓷材料，直到热障层的组成为基于热障层总重量的100重量％的陶瓷材料，热障层的最上部分完全由陶瓷材料形成，
热喷涂步骤包括将热障层施加到小于500微米的厚度，
所述方法还包括在施加热障层之前，机加工上部燃烧表面和/或上部平台的至少一部分，以形成凹穴、凹槽、圆形边缘和/或倒角，
所述方法还包括提供由单件钢制成的主体部分，其在21℃下热膨胀系数的范围为11E-6至14E-6，
主体部分包括将裙板连接到活塞销凸台的多个支柱，主体部分具有沿顶部底表面延伸并由裙板和支柱以及活塞销凸台围绕的内部顶部底面区域，一对顶部底面凹穴沿顶部底表面延伸，每个顶部底面凹穴由一个活塞销凸台和一个裙板围绕，支柱将一个活塞销凸台连接到一个裙板上，主体部分没有冷却通道地板或沿着顶部底表面限定或部分限定冷却通道的其他特征，上部燃烧表面包括环形第一部分和第二部分，环形第一部分形成为沿上壁的外周延伸的基本上平坦的表面，第二部分形成燃烧碗，上部燃烧表面的第二部分具有从第一部分悬垂的非平坦的、凹入的或起伏的表面，环形带包括多个环形槽，用于容纳一个或多个相应的活塞环，上部平台从上部燃烧表面延伸到第一个环形槽，每个活塞销凸台都有销孔，每个销孔都有凹面的最上表面，顶部底面凹穴位于活塞销凸台的径向外侧，每个顶部底面凹穴的至少一部分形成顶部底表面的一部分，活塞销凸台和裙板以及支柱限定了从支柱和裙板的最下表面延伸到顶部底表面的内部顶部底面区域，当从活塞的下侧观察时，设置在相对的裙板和相对的活塞销凸台之间的顶部底表面的至少中心部分是凹的，
提供主体部分的步骤包括通过锻造或铸造形成单件材料，
热障层的陶瓷材料包括二氧化铈、二氧化铈稳定的氧化锆、以及二氧化铈稳定的氧化锆和氧化钇稳定的氧化锆的混合物中的至少一种，其量基于陶瓷材料的总重量为90-100重量％，陶瓷材料的导热率小于1W/m·K，陶瓷材料的二氧化铈在21℃时的热膨胀系数的范围为10E-6至11E-6，以及
热障层的金属粘结材料包括钢或超合金。
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US10273902B2 (en) 2019-04-30
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