CN110607495B - 涂层内燃机气缸曲轴箱的气缸缸套工作面的等离子喷涂法 - Google Patents

涂层内燃机气缸曲轴箱的气缸缸套工作面的等离子喷涂法 Download PDF

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CN110607495B
CN110607495B CN201910456716.5A CN201910456716A CN110607495B CN 110607495 B CN110607495 B CN 110607495B CN 201910456716 A CN201910456716 A CN 201910456716A CN 110607495 B CN110607495 B CN 110607495B
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K.克利梅克
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Abstract

本发明涉及一种用于涂层冲程活塞内燃机的气缸曲轴箱的气缸缸套工作面的等离子喷涂法。在此，本发明所基于的任务在于，提供一种涂层方法供使用，借助于其限制层构造中的氧化物或氧化物行状结构的构造并且由此避免由于出现的氧化物剥落和尤其由此产生的微槽性造成的负面影响。依照根据本发明的用于涂层冲程活塞内燃机的气缸曲轴箱(14)的气缸缸套工作面的等离子喷涂法，至少部分地以如下参数组合将涂层(12)施加到气缸曲轴箱(14)的气缸缸套工作面(18)上：a)旋转速度：600‑800转/分钟，b)喷涂物输送率：80‑180克/分钟，以及c)进给速度：24‑75毫米/秒。

Description

涂层内燃机气缸曲轴箱的气缸缸套工作面的等离子喷涂法
技术领域
本发明涉及一种用于涂层冲程活塞内燃机的气缸曲轴箱的气缸缸套工作面(Zylinderlaufbahn)的等离子喷涂法。
背景技术
由WO 2017/202852 A1已知一种用于涂层弯曲的表面、热涂层以及带有热涂层的气缸的涂层方法。在此，尤其参照在使用热喷涂设备、尤其等离子喷涂设备或带有燃烧器(Brenner，有时称为喷嘴)的HVOF喷涂设备的情况下粉末状的涂层材料的使用，其在燃烧器柄处绕柄轴线以预设的旋转频率旋转，其中，用于将涂层施加到弯曲表面上的涂层射束至少部分地径向远离柄轴线地指向弯曲的表面。在此，参照超过200转/分钟(U/min)、尤其直至800U/min或甚至更高的提高的旋转频率的使用，其中，粉末状的涂层材料的输送率(Förderrate)应当相应地“适宜地提高”。
文件WO 2017/202852 A1不参照涂层期间的进给(Vorschub，有时称为推进)并且也不探讨待获得的涂层的所谓的氧化物行状结构。
在用于冲程活塞内燃机的气缸曲轴箱的制造中日益尝试的是，减少气缸曲轴箱的重量。为此使用由铝构成的气缸曲轴箱，其然而在气缸缸套工作面的区域中需要保护层，例如借助于等离子喷涂施加的保护层。涂层的正面副作用除了气缸缸套工作面的稳固性提高之外是活塞组的区域中的明显降低的摩擦(和由此还有减少的CO2-排出)以及相对于腐蚀媒介的正面效用。由现有技术已知的涂层方法是粉末等离子喷涂(APS法)、线材喷涂法(如例如等离子转移电弧(PTWA/RSW)涂层方法)、光弧线材喷涂(LDS)和高速火焰喷涂(HVOF-喷涂)。
在曲轴箱中的气缸钻孔的由铝构成且部分还由灰口铸铁(Grauguss)构成的热涂层之前执行或需要用于夹紧(Verklammerung，有时称为联锁)涂层、也就是说用于改善涂层的黏附的粗糙化过程，由此可完全施加涂层。该粗糙化过程通过借助于刚玉和水(中压/高压水射束)、激光射束粗糙化或利用几何形状限定的刀刃(Schneide，有时称为刀具)的粗糙化的射束(strahlend，有时称为发出射束的)过程来呈现。
在使用粉末等离子喷涂(APS法)的情况中，当过程控制根据由现有技术已知的涂层过程利用例如4次双循环来选择时，在由于之前提到的粗糙化过程引起的不均匀处产生强化的氧化物形成。这可引起在涂层中平行于表面产生的氧化物行状结构。氧化物行状结构又引起减小的层稳定性并且可尤其在出现氧化物/氧化物行的情况下在完成珩磨(Fertighonen，有时称为生产珩磨)之后在涂层的表面(气缸缸套工作面)处引起氧化物的剥落(Ausbrechen，有时称为碎裂)且接下来引起气缸工作面(Zylinderlauffläche)的微槽性(Mikroriefigkeit，有时称为微纹性)。如果在表面处的氧化物/氧化物行通过珩磨过程被加应力，则可导致该氧化物的强化的剥落且由此导致缸套工作面表面的提高的孔面份额(Porenflächenanteil)。这可促使提高的油耗并且由此对应地引起提高的颗粒排出。由现有技术已知的方法的另一缺点是，其需要相对多的时间以用于涂层过程。
发明内容
本发明所基于的任务是，提供一种涂层方法供使用，借助于其限制层构造中的氧化物或氧化物行状结构的构造，并且由此避免由于出现的氧化物剥落和(尤其通过这样的氧化物剥落产生的或由于高的氧化物行状结构存在的)微槽性造成的负面影响。
依照根据本发明的用于涂层冲程活塞内燃机的气缸曲轴箱的气缸缸套工作面的等离子喷涂法将涂层至少部分以如下参数组合施加到气缸曲轴箱的气缸缸套工作面上：
a) 旋转速度：600-800转/分钟，
b) 喷涂物输送率：80-180克/分钟(g/min)，以及
c) 进给速度：24-75毫米/秒(mm/s)。
借助于详尽的经验的实验顺序并且在考虑修改的设备技术的情况下已查明，利用前述参数范围(其全部必须根据a),b)和c)来满足)来由此获得根据本发明的优点，可减少氧化物的形成且急剧地减小产生的氧化物行状结构。由此可获得特别均匀的表面，其最大程度上不具有由于提高的氧化物形成和高的氧化物行状结构产生的非期望的微槽性。此外，可在方法期间使用高的旋转速度并且由此在比利用迄今由现有技术已知的方法的更短的时间内施加期望的涂层。在燃烧器技术的旋转速度方面，在600-700U/min之间的值已证实为优选的。进一步优选的是在630U/min与770U/min之间的值，特别优选的是在640U/min与660U/min之间的值。特别良好的结果以650U/min的旋转速度来获得。
在喷涂物输送率方面尤其参照在80与150g/min之间的狭窄的值范围。进一步优选的是在90与130g/min之间的值范围，且特别优选的是在100与120g/min之间的值范围。关于喷涂物输送率特别参照110g/min的值，利用其尤其结合650U/min的旋转速度已获得气缸缸套工作面的涂层的质量上特别高价值的结果。
对于根据特征c)的进给速度，参照在30与70mm/s之间的值范围，进一步优选地参照在40与65mm/s的值范围，且特别优选地参照在50与65mm/s之间的值范围。此外参照在52与60mm/s之间的还要更窄的值范围，且进一步优选地在54与58mm/s之间。
在根据本发明的等离子喷涂法的实际的实施形式中借助于5-8次喷涂循环分别以双冲程的形式施加涂层。特别优选地，就此而言能够提及利用6-7次喷涂循环的施加。已证明，相应的涂层的厚度和结构结合相应地需要的加工时间在该情况中特别是高价值的且有效的。
作为涂层优选地施加钢层或陶瓷层。关于钢层尤其参照低合金和高合金的钢层，也就是说参照带有这样的钢(在其中合金元素的总和不超过5质量百分比的含量(低合金钢))或者这样的钢(在其中至少一个合金元素的平均质量含量大于等于5%(高合金钢))的钢层。低合金钢的使用相对于高合金钢是优选的。然而利用高合金钢同样获得这样的结果(其相对于由迄今的现有技术已知的结果是有利的)。
关于陶瓷层的施加尤其参照由二氧化钛(TiO2)构成的层。
陶瓷层独立于上述优选地结合之前的粗糙过程和之前的促进黏附的层的施加来施加。作为促进黏附的层尤其考虑镍铝层、铜层或低合金的钢层。促进黏附的层的厚度在此优选地为小于100μm，优选地小于60μm，且特别优选地最大40μm。
当在根据本发明的等离子喷涂法的情况中应获得以低合金钢层形式的涂层时，优选地借助于低合金的钢粉来施加该涂层。在此，具有少量份额的附属物(Satellite)的带有主要球状形态(Morphologie)的钢粉是特别优选的。
在根据本发明的等离子喷涂法的另一实际的实施形式(在其中施加钢层来作为涂层)中，借助于钢粉来施加涂层，其具有少于2重量%的碳(C)、少于2重量%的锰(Mn)、少于2重量%的铬(Cr)、少于1重量%的镍(Ni)、少于1重量%的氧气(O2)和少于1重量%的氮气(N2)。关于碳的份额尤其参照1.0至1.3的重量%份额。关于锰的份额尤其参照1.2至1.6重量%的份额。关于铬的重量份额尤其参照1.2至1.6重量%的值范围。关于镍的重量份额尤其参照少于0.5重量%的值范围。关于氧气的重量份额尤其参照少于0.2重量%的值，并且关于氮气的重量份额尤其参照少于0.5重量%的值范围。上述值范围优选地累加地适用，也就是说以该组合彼此关联。
当借助于钢粉施加钢层时，得到质量上特别高价值的涂层，钢粉的颗粒尺寸仅仅小于60μm并且/或者其颗粒尺寸大部分小于42μm。带有少于42μm的颗粒尺寸的钢粉的重量百分比的份额优选地为最大百分之90。带有小于26μm的颗粒尺寸的份额优选地为最大百分之50。带有少于16μm的颗粒尺寸的份额优选地为最大百分之10。
在根据本发明的等离子喷涂法的另一实际的实施形式中，在大气的影响下实施涂层。在该情况中该方法还被称为大气等离子喷涂法或APS法。APS法的优点是，可省去保护气体的使用和与此相关的附加的成本。备选地可在根据本发明的等离子喷涂法的情况中但是也在使用保护气体的情形下或在真空中施加涂层。在该情况中，虽然提高了用于执行该方法的成本，但在个别情况中可如此获得涂层的质量上仍明显更好的结果，也就是说，尤其获得具有更少氧化物份额或更少氧化物行状结构的涂层。
于是，尤其当在施加涂层之前借助于刚玉和/或水、借助于激光射束粗糙化或借助于利用几何形状限定的刀刃的粗造化执行至少一个射束的粗造化过程时，根据本发明的等离子喷涂法是有利的。在该情况中改善了待施加的涂层的黏附能力并且同时提高了获得的涂层的可耐久性。
附图说明
接下来结合附图说明本发明的另外的实际的实施形式。其中：
图1显示了带有涂层的气缸缸套工作面的局部的横截面图，
图2显示了朝着根据现有技术的气缸缸套工作面的涂层的表面的视角，
图3显示了穿过利用根据本发明的方法制造的在气缸缸套工作面上的涂层的横截面，以及
图4显示了根据图3的局部的放大的图示。
附图标记清单
10 铝基体
12 涂层
14 气缸曲轴箱
16 表面
18 气缸缸套工作面
20 黑色区域(氧化物)
22a-d 氧化物行。
具体实施方式
图1显示了冲程活塞内燃机的气缸曲轴箱的局部连同气缸曲轴箱14的铝基体10的气缸缸套工作面的局部，其中，铝基体10设有涂层12且背对铝基体10的表面16是气缸曲轴箱14的气缸缸套工作面18的部分。部分表示的黑色区域20是氧化物，其在借助于等离子喷涂法施加涂层12期间已形成。
图2显示了气缸缸套工作面18的表面16。如在图中可识别，在表面16上已形成各个氧化物行22a,22b,22c,22d，它们通过黑色的点形成，它们几乎布置成排。在此，其为开头提到的氧化物行状结构。
图3显示了类似于图1的视图，其中，借助于根据本发明的等离子喷涂法来施加涂层12。
图4显示了来自图3的视图的放大的图示。如可识别的是，形成气缸曲轴箱14的气缸缸套工作面18的表面16通过如下方式具有明显提高的品质，即不再可识别氧化物行状结构。此外可识别的是，在涂层12中已形成相比在根据现有技术的涂层12的情况中(其在在图1中示出)明显更少的氧化物。
本发明的在当前的说明书中、附图中以及权利要求书中公开的特征不仅可单独地而且可以任意组合对于本发明以其不同的实施形式的实现而言是重要的。本发明可在权利要求书的框架内且在考虑负责的本领域技术人员的认知的情况下改变。

Claims (10)

1.一种用于将涂层施加到冲程活塞内燃机的气缸曲轴箱的气缸缸套工作面上的等离子喷涂法，其特征在于，所述涂层(12)至少部分地以如下参数组合施加到所述气缸曲轴箱(14)的气缸缸套工作面(18)上：
a) 旋转速度：600-700转/分钟，
b) 喷涂物输送率：100-120克/分钟，以及
c) 进给速度：24-75毫米/秒。
2.根据权利要求1所述的等离子喷涂法，其特征在于，所述涂层(12)借助于5-8次喷涂循环分别以双冲程的形式来施加。
3.根据权利要求1或2所述的等离子喷涂法，其特征在于，将钢层或陶瓷层作为涂层(12)来施加。
4.根据权利要求3所述的等离子喷涂法，其特征在于，所述涂层(12)借助于低合金的钢粉来施加。
5.根据权利要求3所述的等离子喷涂法，其特征在于，借助于具有少量的份额的附属物的带有主要球状形态的钢粉施加钢层来作为涂层(12)。
6.根据权利要求3所述的等离子喷涂法，其特征在于，借助于钢粉施加钢层来作为涂层(12)，其具有少于2重量%的碳(C)、少于2重量%的锰(Mn)、少于2重量%的铬(Cr)、少于1重量%的镍(Ni)、少于1重量%的氧气(O2)以及少于1重量%的氮气(N2)。
7.根据权利要求3所述的等离子喷涂法，其特征在于，借助于钢粉来施加钢层，其颗粒尺寸仅仅小于60μm并且/或者大部分小于42μm。
8.根据权利要求1或2所述的等离子喷涂法，其特征在于，在大气影响下施加所述涂层(12)。
9.根据权利要求1或2所述的等离子喷涂法，其特征在于，在保护气体的使用下或在真空中施加所述涂层(12)。
10.根据权利要求1或2所述的等离子喷涂法，其特征在于，在施加所述涂层(12)之前借助于刚玉和/或水、借助于激光射束粗糙化或借助于利用几何形状限定的刀刃的粗糙化来执行至少一个射束的粗造化过程。
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