CN110997966A - 具有喷丸磨合层的活塞环及其制造方法 - Google Patents

具有喷丸磨合层的活塞环及其制造方法 Download PDF

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CN110997966A
CN110997966A CN201880048326.8A CN201880048326A CN110997966A CN 110997966 A CN110997966 A CN 110997966A CN 201880048326 A CN201880048326 A CN 201880048326A CN 110997966 A CN110997966 A CN 110997966A
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layer
running
piston ring
wear
wear resistant
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CN110997966B (zh
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迈克尔·布克曼
马库斯·奥米勒
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Federal Tycoon Friedberg
Federal Mogul Friedberg GmbH
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Abstract

本发明涉及一种活塞环，包括环形本体(2)、通过热喷涂施加至环形本体(2)的耐磨层(6)以及应变硬化的磨合层(8)，所述磨合层(8)由AlCuFe合金制成，其通过热喷涂施加至耐磨层(6)。

Description

具有喷丸磨合层的活塞环及其制造方法
技术领域
本发明涉及一种活塞环及其制造方法，尤其涉及一种用于内燃机的具有多层涂层的大口径活塞环，或者涉及一种用于二冲程应用的活塞环。
背景技术
对于往复式活塞内燃机中的活塞环，必须满足两个相互矛盾的要求。一方面，必须提供很高的耐磨性，否则，随着活塞环越来越薄，泄漏的气体和油耗会增加并损害内燃机的性能。另一方面，由于活塞环磨损，气缸壁和活塞环之间的间隙越来远大，从而使得燃烧气体更容易从活塞环逸出(所谓漏气)，这会降低发动机的效率。由于增大的间隙，残留在燃烧室中未刮掉的油膜变得越来越厚，从而使得单位时间内可能损失更多的油，即油耗增加。
为了实现发动机性能的最大优化，即为了获得最大密封效果和低磨损之间的最佳的折衷，活塞环与气缸壁之间的间隙尺寸必须因此尽可能保持精确。然而，这需要在内燃机制造和组装过程中采用复杂、高成本的工艺步骤，否则，会持续导致一定程度的不可避免的公差。所以，通常一种可能的最小或小间隙尺寸是可以被接受的，并且允许活塞环在运行过程中通过磨损达到最佳厚度。理想情况下，活塞环的运转面被磨损直到达到最佳的间隙直径。该过程也被称为“磨合”
所以，一方面，需要一种优选的耐磨材料，使得活塞环在正常运转过程中经历尽量少的磨损，并且间隙仅经历小幅度扩大。另一方面，为了获得良好的磨合性能，必须至少一部分运转表面能够承受相对较少的磨损，以便在磨合过程中，活塞环与气缸壁之间的过小间隙(例如，由于不可避免的部件公差)可以尽快增大到正确的尺寸。
因此，原则上，活塞环上设有涂层，旨在带来所需的性能。相对于使用具有所需性能的、很可能昂贵的材料制造整个活塞环，这自然更容易操作并且成本更低。对于这种涂层，还有进一步的要求。除了提供必需的性能，涂层设计还必须使其不会从活塞环剥离，即能够良好地附着在底层材料上。如果涂层包括几个不同的层，层之间良好的内聚力也是必要的。否则，存在形成裂缝或层剥离的风险，这对于发动机来说是不利的。
活塞环的运转表面上的涂层在与气缸壁接触的表面区域必须是耐磨的。此外，在磨合阶段它们的固有磨损应当足以令人满意地适应对偶面。而且，这些层应当具有很高的抗断裂性，并且即使在长时间运行之后，也几乎不会或不会表现出疲劳性能。
例如，耐磨层由硬铬制成。DE 19931829A1描述了一种用于活塞环的电镀硬铬镀层。用于耐磨层的其他材料是具有氧化铝陶瓷的铬(例如，来自辉门公司(Federal-Mogul)的
Figure BDA0002374591690000021
)或者具有微粒金刚石的铬(例如，来自辉门公司(Federal-Mogul)的
Figure BDA0002374591690000022
)。
施加至
Figure BDA0002374591690000023
耐磨层的磨合层是基于钼，例如，其通过金属丝火焰喷涂施加至耐磨层。预先通过喷砂工艺(blasting process)激活耐磨层。
而且，由AlCuFe合金制造的磨合层可以通过热喷涂施加至
Figure BDA0002374591690000024
耐磨层。然而，为此，有必要首先将一个电镀中间层施加至
Figure BDA0002374591690000025
耐磨层。
但是，已知的具有铬基耐磨层的活塞环的磨合与磨损性能以及此处应用的磨合层需要进一步改进。
发明内容
本发明的目的在于提供一种具有改进的磨合与磨损性能的活塞环及其制造方法。
根据本发明的第一个实施例，提供一种活塞环，包括：
环形本体；
耐磨层，其通过热喷涂施加至所述环形本体；以及
应变硬化的磨合层，其由AlCuFe合金制成，通过热喷涂施加至所述耐磨层。
通过使用两种不同功能的层，根据本发明的活塞环提供了一种耐磨性能(由于耐磨层)和良好的磨合层性能(由于磨合层)的新颖、有利组合。所述磨合层通过适当地后处理，例如喷丸，从而是应变硬化的和压紧实的。所述耐磨层防止发动机在极端工作条件下过度磨损。
可选地，所述活塞环的特征在于：
环形本体；
耐磨层，其通过热喷涂施加至所述环形本体；以及
磨合层，其由AlCuFe合金制成，通过热喷涂施加至所述耐磨层，其中所述磨合层的粗糙度Rz小于100微米，优选地为60至95微米，尤其优选地为70至95微米。
进一步可选地，所述活塞环的特征在于：
环形本体；
耐磨层，其通过热喷涂施加至所述环形本体；以及
磨合层，其由AlCuFe合金制成，所述磨合层的硬度HV为150至250，优选地为170至210，尤其优选地为180至200，所述磨合层通过热喷涂施加至所述耐磨层。
在所述活塞环的一个实施例中，通过电弧丝喷涂将所述磨合层施加至所述耐磨层。电弧丝喷涂是将涂层应用到基底层上的一种简单的、经济有效的方式。该方法尤其适于产生相对较软的涂层，其可用于磨合层。电弧丝喷涂也可用于简单地产生一种耐磨AlCuFe层。
在所述活塞环的另一个实施例中，通过喷丸、滚压或捶打对所述AlCuFe磨合层进行应变硬化。应变硬化将压应力引入所述层内，导致所述磨合层硬化。由于磨合层的任务是在磨合阶段被移除，所以，到现在为止，它们还没有被进行后处理。表面上，似乎不需要将更多的注意力放在短期操作时间内几乎被完全移除的层上，为此，过去没有进一步的加工步骤。由于应变硬化，磨合层能够变得更加稳定并持续更长的时间，从而延长往复式发动机的磨合过程。此外，为了调整磨合期至所需的值，使用不同的材料或改变磨合层的厚度是很常见的。为了在相同的材料消耗的情况下延长磨合期，或为了在相同的磨合期减少材料的厚度，通过应变硬化增加磨合层的稳定性。磨合层仅具有很薄的厚度，并且应变硬化基本上可以在磨合层的整个厚度上实现硬化。
在所述活塞环的另一个实施例中，经过喷丸后，所述磨合层的表面覆盖范围为50％至100％，优选地为70％至100％，更优选地为90％至100％。至少50％的所述磨合层表面由于喷丸工艺受到喷丸丸粒的压痕影响。喷丸丸粒在所述磨合层表面上形成的压痕至少覆盖所述磨合层表面的50％，优选地至少为70％，更优选地至少为90％。在显微镜下，磨合层的表面结构显示了来自喷丸丸粒形成的印记。通过喷丸丸粒形成印记的表面结构，可以很容易确定所述磨合层是否已经通过喷丸进行应变硬化。
优选地，在所述环形本体和所述耐磨层之间提供一种粘合增进剂层。所述粘合增进剂层确保各层在所述环形本体上的最佳粘合。
所述耐磨层、所述磨合层以及可选的所述粘合增进剂层优选地采用过喷涂(oversprayed)的形式。
优选地，所述环形本体具有气体放电槽，所述气体放电槽的边缘处具有斜边。
所述斜边所具有的角度优选地为30°至70°。此外，所述斜边具有的宽度优选地为0.5至2.0毫米。
根据本发明的另一个方面，提供一种制作根据本发明第一个实施例的活塞环的方法，包括：
提供环形本体；
将耐磨层热喷涂至所述环形本体；以及
将由AlCuFe合金制成的磨合层热喷涂至所述耐磨层上，通过喷丸将所述磨合层压实。
所述耐磨层、所述磨合层以及可选的所述粘合增进剂层优选地采用过喷涂的形式。
所述热喷涂优选地包括如下涂覆工艺：
电弧丝涂覆工艺；
火焰涂覆工艺；
大气等离子喷涂(APS)；以及
高速氧燃料(HVOF)火焰喷涂。
在所述方法中，可以通过电弧丝喷涂工艺将所述磨合层施加至所述耐磨层。
可以通过喷丸、滚压或捶打对所述磨合层进行应变硬化。
喷丸应以这种方式进行，即实现的覆盖范围为50％至100％，优选地为70％至100％，更优选地为90％至100％。
优选地，所述方法还包括：
在粘合增进剂层上喷涂之前，在所述环形本体侧面的边缘处设置斜边。
如果所述环形本体具有气体放电槽，所述方法优选地还包括：
在粘合增进剂层上喷涂之前，在所述气体放电槽的边缘处设置斜边。
所述斜边所具有的角度优选地为30°至70°。另外，该斜边所具有的宽度优选地为0.5至2.0毫米。
附图说明
下面，参照示例性实施例的示意图对本发明进行描述。
图1A至图1F示出在各种加工步骤中基于活塞环剖视图的方法的一个实施例。
图2示出根据本发明一个实施例的活塞环的运转表面处应变硬化磨合层的俯视图。
说明书和附图中使用的相同或类似的附图标记表示相同或类似的元件和部件。
具体实施方式
活塞环的运转表面上的涂层，除了与基底具有良好的耐高温附着力和良好的层内耐温结合力(内聚力)，还必须在与气缸壁接触的表面区域耐磨。此外，在磨合阶段它们的固有磨损应当足以令人满意地适应对偶面。而且，这些层应当具有很高的抗断裂性，并且即使在长时间运行之后，也几乎不会或不会显示疲劳性能。在本发明中，采用一种由AlCuFe合金制成的应变硬化磨合层，所述磨合层通过电弧丝喷涂施加至活塞环。这里的应变硬化是通过喷丸实现的，导致所述磨合层的平滑和硬化。所述喷丸，即应变硬化，导致所喷涂的磨合层压实。应变硬化在磨合层上产生压应力，从而获得一个改进的、更强的磨合层。应变硬化实际上可能影响磨合层的整个厚度。使用直径为0.5至1毫米的钢丸丸粒实施喷丸加工，从而使磨合层的表面足够光滑、硬化。喷丸压力可以在2.5巴至6巴之间，优选在3巴至5.5巴之间，更优选地在4巴和5巴之间。这里，在距离所述磨合层表面50至500毫米的地方执行喷丸。在喷丸过程中，每分钟可使用1千克至3千克的抛丸质量。也可以使用滚压、滚花或捶打来代替喷丸进行应变硬化。
所以，本发明的目的在于采用火焰喷涂工艺提供一种具有耐磨层的活塞环运转表面，其能够承受极大的压力，但表现出良好的磨合性能。制备所述层的方法优选地旨在简单且经济有效，特别是能够制备耐磨涂层以及性能与特定应用相协调的磨合层。
根据本发明，在第一个实施例中，所述目的是通过一种涂层来实现的，所述涂层由至少两个不同的喷涂层组成，一个置于另一个之上：一个耐磨层、一个可选的粘合增进剂层以及一个外部的磨合层。各层之间的粘合力与内聚力可以通过涂覆之前在环形本体侧面倾斜边缘以及使用气体放电槽而进一步改进。
图1A和图1B示出活塞环或环形本体2如何倾斜的剖面图。根据本发明，在涂层之前，活塞环2的边缘在运转表面侧(在图的左边)可以设置一个斜边10。根据本发明，斜边10的角度α可以是30°至70°。在图2所示的实施例中，角度为45°。此外，根据本发明的各种实施例，斜边10的宽度d为0.5至2毫米。在制造活塞环的过程中，对边的切割是一个可选的步骤，即对于根据本发明形成的活塞环来说，斜边是一个可选的特征。可以使用任何合适的已知方法来实施切割。为了获得筒状的运转表面，同样也可以对活塞环的运转表面进行修圆磨光。可以使用任何合适的已知方法来对运转表面实施切割或成形。
图1C示出了涂覆第一层涂层的步骤的剖视图。将粘合增进剂层4施加至环形本体2。根据本发明，这是通过使用热喷涂工艺来实现的，包括高速氧燃料(HVOF)火焰喷涂、大气等离子喷涂(APS)、电弧丝涂层或金属丝火焰喷涂工艺。作为一个例子，这由HVOF装置12来说明。这里，粘合增进剂层4被设计为一种镍合金。
在图1D中，然后将耐磨层6施加至粘合增进剂层4。这个过程可以与施加粘合增进剂层一样，使用上述热喷涂工艺中的一种来实现，对于不同的各个层，还可以使用不同的工艺。在所示的例子中，同样也是通过HVOF装置14实现的。该层设计为FF，即过喷涂(oversprayed)。
根据本发明的第一实施例，耐磨层可以是具有碳化铬CrC或碳化钨WC或碳化钼MoC的钼合金。
在图1E中，接下来将磨合层8施加至耐磨层6。这个过程通过使用一个电弧丝喷涂装置16来进行电弧丝喷涂。该层设计同样是FF，即过喷涂(oversprayed)。磨合层包括铝铜铁合金(AlCuFe合金)。活塞环优选地为一种用于二冲程内燃机的大口径活塞环。
在图1F中，最后施加的磨合层通过喷丸在其表面或运转表面进行后处理。所述磨合层在运转表面应变硬化，由此延长发动机的磨合阶段，或通过使用更薄的磨合层减少磨损。喷丸装置26用于应变硬化。
在图1F中，示出了根据本发明的第一个实施例的成品活塞环剖面图，包括环形本体2、粘合增进剂层4、耐磨层6和磨合层8。
根据本发明的第二个实施例，活塞环包括环形本体、施加至环形本体的运转表面的耐磨层以及施加至所述耐磨层的应变硬化的AlCuFe合金磨合层。AlCuFe合金可以包括这些元素以及不可避免的杂质，或者AlCuFe合金也可以包括其他的合金元素以及固体润滑剂，例如，少量的碳。
图2示出了根据本发明的活塞环的运转表面的细节放大图，所述表面显示了通过喷丸丸粒在运转表面或磨合层8上形成的压痕42。这里的压痕42显示出很大的覆盖范围，因此磨合层8的整个表面被应变硬化。
通过使用两个不同的功能层，根据本发明的活塞环提供了一种耐磨性能(由于耐磨层)和良好的磨合层性能(由于AlCuFe磨合层)的新颖的、有优势的组合。在经喷涂后，磨合层8是应变硬化的，并且在磨合阶段通过磨损而移除。耐磨层6防止发动机在极端工作条件下的过度磨损。
耐磨层6优选地包括硬铬、具有氧化铝陶瓷的铬(例如，来自辉门公司(Federal-Mogul)的
Figure BDA0002374591690000071
)，或以及具有微粒金刚石的铬(例如，来自辉门公司(Federal-Mogul)的
Figure BDA0002374591690000072
)。耐磨层6同样可设有类金刚石(DLC)层或可包括这样的层。
磨合层8所具有的层厚度优选地为20至400微米。
所述耐磨层的应用优选地使用热喷涂工艺实现。热喷涂工艺优选地为大气等离子喷涂(APS，例如MKP)或高速氧燃料(HVOF)火焰喷涂(例如，来自辉门公司(Federal-Mogul)的
Figure BDA0002374591690000073
)。所述耐磨层优选地包括硬铬、具有氧化铝陶瓷的铬(例如，来自辉门公司(Federal-Mogul)的
Figure BDA0002374591690000074
)，或具有微粒金刚石或具有类金刚石层的铬(例如，来自辉门公司(Federal-Mogul)的
Figure BDA0002374591690000075
)。
所述耐磨层优选地通过喷砂工艺(blasting process)激活或者热激活。
磨合层8的施加采用热涂覆工艺。所述热涂覆工艺优选地为电弧丝喷涂。
磨合层8所具有的层厚度优选地为20至400微米。
附图标记列表
2 活塞环/环形本体
4 粘合增进剂层
6 耐磨层
8 磨合层
10 斜边
12 粘合增进剂层火焰喷涂装置
14 耐磨层火焰喷涂装置
16 电弧丝喷涂装置
20 电极丝
22 电弧
24 气流
26 喷丸装置
30 丸粒供应
32 气流
34 钢丸
42 喷丸压痕
α 斜边角度
d 斜边宽度

Claims (15)

1.一种活塞环，包括：
环形本体(2)；
耐磨层(6)，其通过热喷涂施加至所述环形本体(2)；以及
应变硬化的磨合层(8)，其由AlCuFe合金制成，通过热喷涂施加至所述耐磨层(6)。
2.一种活塞环，包括：
环形本体(2)；
耐磨层(6)，其通过热喷涂施加至所述环形本体(2)；以及
磨合层(8)，其由AlCuFe合金制成，并且所述磨合层(8)的粗糙度Rz小于100微米，优选地为60至95微米，尤其优选地为70至95微米，所述磨合层(8)通过热喷涂施加至所述耐磨层(6)。
3.一种活塞环，包括：
环形本体(2)；
耐磨层(6)，其通过热喷涂施加至所述环形本体(2)；以及
磨合层(8)，其由AlCuFe合金制成，并且所述磨合层(8)的硬度HV为150至250，优选地为170至210，尤其优选地为180至200，所述磨合层(8)通过热喷涂施加至所述耐磨层(6)。
4.根据权利要求1至3任一项所述的活塞环，其中，所述磨合层(8)通过电弧丝喷涂施加至所述耐磨层(6)。
5.根据权利要求1至4任一项所述的活塞环，其中，所述磨合层(8)通过喷丸、滚压或捶打进行应变硬化。
6.根据权利要求5所述的活塞环，其中，在喷丸过程中所实现的覆盖范围为50％至100％，优选地为70％至100％，更优选地为90％至100％。
7.根据前述任一权利要求所述的活塞环，还包括粘合增进剂层(4)，其通过热喷涂施加至所述环形本体(2)的运转表面，其中，所述耐磨层(6)施加至所述粘合增进剂层(4)。
8.根据前述任一权利要求所述的活塞环，其中，所述耐磨层(6)和所述磨合层(8)采用过喷涂的形式施加，以及/或者，其中所述环形本体(2)的侧面在边缘处具有斜边，其中所述斜边优选地具有30°至70°的角以及/或者0.5至2.0毫米的宽度，以及/或者，其中所述环形本体(2)具有气体放电槽，所述气体放电槽在边缘处具有斜边，其中所述斜边优选地具有30°至70°的角以及/或者0.5至2.0毫米的宽度。
9.根据前述任一权利要求所述的活塞环，其中，所述活塞环是大口径活塞环。
10.一种制造活塞环的方法：
提供环形本体(2)；
将耐磨层(6)热喷涂至所述环形本体(2)；以及
将由AlCuFe合金制成的磨合层(8)热喷涂至所述耐磨层(6)，以及
对所述磨合层进行应变硬化。
11.根据权利要求10所述的方法，其中，通过电弧丝喷涂将所述磨合层施加至所述耐磨层(6)。
12.根据权利要求10或11所述的方法，其中，应变硬化包括喷丸、滚压和/或捶打。
13.根据权利要求9至12任一者所述的方法，其中，在喷丸过程中，所实现的覆盖范围为50％至100％，优选地为70％至100％，更优选地为90％至100％。
14.根据权利要求9至13任一者所述的方法，其中，所述耐磨层的热喷涂包括：
电弧丝涂覆工艺；
金属丝火焰涂覆工艺；
大气等离子喷涂(APS)；以及
高速氧燃料(HVOF)火焰喷涂。
15.根据权利要求9至14任一项所述的方法，还包括：
在所述环形本体的侧面的边缘处设置斜边，其中所述斜边优选地具有30°至70°的角以及/或者0.5至2.0毫米的宽度，以及/或者
在气体放电槽的边缘处设置斜边，其中所述斜边优选地具有30°至70°的角以及/或者0.5至2.0毫米的宽度。
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