CN113915021A - Cylindrical prefabricated body, light high-temperature-resistant composite piston and preparation method thereof - Google Patents
Cylindrical prefabricated body, light high-temperature-resistant composite piston and preparation method thereof Download PDFInfo
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- CN113915021A CN113915021A CN202111151639.6A CN202111151639A CN113915021A CN 113915021 A CN113915021 A CN 113915021A CN 202111151639 A CN202111151639 A CN 202111151639A CN 113915021 A CN113915021 A CN 113915021A
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- 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
- F02F3/0015—Multi-part pistons
- F02F3/0069—Multi-part pistons the crown and skirt being interconnected by the gudgeon pin
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
- C04B35/83—Carbon fibres in a carbon matrix
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5053—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials non-oxide ceramics
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
- C04B41/87—Ceramics
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- 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
- F02F3/0084—Pistons the pistons being constructed from specific materials
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- 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
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- 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
- F02F3/26—Pistons having combustion chamber in piston head
Abstract
A cylindrical preform, light high temperature resistant composite piston and its preparation method, said preparation method comprises, adopt the three-dimensional cylindrical preform that the axial carbon fiber non-woven cloth compound carbon fiber net child pricks, the annular carbon fiber twines compound carbon fiber net child needle pricks continuously, impregnate the densification with carbon-containing resin and/or pitch after heat treating the cylindrical preform, and/or adopt the chemical vapor deposition to densify, and/or adopt and impregnate and combine mode of chemical vapor deposition to densify, form carbon fiber reinforcement carbon matrix composite, in order to open the hole in high temperature heat treatment under inert atmosphere; machining a piston blank from the cylindrical composite material by adopting a machining method; then adopting a melting siliconizing process to densify the piston blank, and processing the piston blank into a final size after the required density is reached; and finally, carrying out heat insulation and anti-oxidation treatment on the top of the piston and the combustion chamber. The piston of the invention has the characteristics of low thermal expansion coefficient, small thermal deformation, low density, high temperature resistance, self lubrication and the like.
Description
Technical Field
The invention belongs to the technical field of internal combustion engine components, and particularly relates to a cylindrical prefabricated body, a piston and a preparation method of the cylindrical prefabricated body and the piston.
Background
The development of internal combustion engines presents unprecedented challenges against the dual background of increasingly strict fuel consumption regulations and environmental standards and the development of internal combustion engines in the direction of high load, high power and high reinforcement. The piston is used as the heart of an internal combustion engine, is subjected to mechanical load, thermal load and frictional wear during movement, is the worst component of the working environment in the internal combustion engine, and the working reliability and the service performance of the internal combustion engine are greatly dependent on the piston. The explosion pressure of the internal combustion engine market for the heavy vehicle in China is over 18MPa when the national five standards are implemented, the pressure of over 20MPa or even higher is expected to be implemented when the national six standards are implemented, meanwhile, when the piston works, the piston is directly contacted with high-temperature fuel gas in the cylinder, the top temperature of the piston is over 400 ℃, the temperature distribution is uneven, and the piston is required to have better high-temperature mechanical performance and lighter weight.
The piston market at present mainly has two kinds of aluminium pistons and steel pistons, and the aluminium piston has the outstanding advantages of low density, but unsatisfactory high-temperature mechanical property, mechanical property attenuation of more than 50% at the temperature of 150 ℃, use temperature of no more than 400 ℃, and reaching or approaching the use limit of the aluminium piston along with the temperature and pressure in a combustion chamber of an internal combustion engine becoming higher. The steel piston has higher mechanical strength, and the heat resistance, the corrosion resistance and the wear resistance of the steel piston are superior to those of aluminum alloy, but the steel piston has high density, complex processing and high preparation cost, seriously wears a cylinder sleeve and cannot meet the development requirement of a new generation of internal combustion engines. The development of high-performance pistons which are matched with the development of internal combustion engines and meet the requirements of future markets is urgent.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a cylindrical prefabricated part, the structure of which is innovatively designed according to the stress characteristic in the reciprocating motion process of a piston, and the method is mainly characterized in that carbon fiber laid cloth is axially introduced into the prefabricated part, and needling is radially carried out, so that the axial bearing capacity is greatly improved, and the reliability of the piston in the service process is ensured.
The second purpose of the invention is to provide a preparation method of the light high-temperature-resistant composite piston.
A third object of the present invention is to provide a piston.
The invention relates to an improvement on the manufacture and structure of a light high-temperature-resistant composite piston for an internal combustion engine, in particular to a piston for a heavy-duty vehicle internal combustion engine. The invention realizes the aim by providing a novel light high-temperature-resistant composite material piston, which comprises a three-dimensional cylindrical prefabricated body structure formed by needling an axial carbon fiber weftless fabric composite carbon fiber net tire and needling a circumferential carbon fiber continuously wound composite carbon fiber net tire. After the cylindrical preform is subjected to heat treatment, carbon-containing resin and/or asphalt is used for impregnation densification, and/or chemical vapor deposition is used for densification, and/or a combination mode of impregnation and chemical vapor deposition is used for densification, so that the carbon fiber reinforced carbon matrix composite material is formed, and then the carbon fiber reinforced carbon matrix composite material is subjected to high-temperature heat treatment under an inert atmosphere to open pores. At the moment, a piston blank is machined from the cylindrical composite material by adopting a machining method. And then, densifying the piston blank by adopting a melting siliconizing process, and processing the piston blank into a final size after the required density is reached. And finally, carrying out heat insulation and anti-oxidation treatment on the top of the piston and the combustion chamber.
The technical scheme of the invention is as follows:
a cylindrical prefabricated body comprises two unit layers, wherein one unit layer is overlapped with the other unit layer, and needling carbon fibers are arranged between the unit layers; the two unit layers are axial carbon fiber non-woven fabric composite carbon fiber net tire unit layers, and the circumferential carbon fibers are continuously wound on the composite carbon fiber net tire unit layers. The unit layer of the carbon fiber non-woven fabric composite carbon fiber net tire in the axial direction is formed by compounding one layer of carbon fiber non-woven fabric with one layer of carbon fiber net tire, and the unit layer of the annular carbon fiber continuous winding composite carbon fiber net tire is formed by continuously winding one layer of carbon fiber on one layer of carbon fiber net tire.
The density of the unit layers is 10 to 50 layers/cm, and the density of the needle-punched carbon fibers 2 is 20 to 100 needles/m2And the needling direction is perpendicular to the circumferential carbon fiber and continuously winds the composite carbon fiber net tire unit layer 3, and the needle insertion depth is 5-75 mm.
The invention discloses a carbon fiber reinforced three-dimensional cylindrical preform comprising a complete piston structure, which is characterized in that a piston blank is processed from a cylindrical composite material after a carbon matrix is prepared and densified to form a carbon fiber reinforced carbon matrix composite material, then the piston blank is densified to reach the required density by adopting a melting siliconizing process, the piston blank is processed to the final size, and finally, an anti-oxidation treatment is carried out on a piston combustion chamber to prepare the light high-temperature-resistant composite material piston. The method for preparing the light high-temperature-resistant composite piston by using the carbon fiber preform comprises the following steps:
preparing a cylindrical preform (a preform for short);
performing heat treatment on the prefabricated body in a high-temperature vacuum environment, wherein the treatment temperature is 900-2500 ℃, the treatment time is 0.5-3 h, and the heating rate is 5-15 ℃/min;
the carbon matrix of the prefabricated body can be densified by adopting carbon-containing resin and/or asphalt impregnation, or by adopting a chemical vapor deposition method, or by adopting a mode of combining the carbon matrix and the asphalt. Wherein the carbon-containing resin and/or asphalt is impregnated and densified at the temperature of 25-120 ℃, vacuum impregnation is carried out for 1-1.5 h, then pressurization is carried out for impregnation at the pressure of more than 1.5MPa for 0.5-1 h, the impregnation is completed, curing is carried out for 2-5 h at the temperature of 100-300 ℃, and then the treatment is carried out for 0.5-1.5 h at the temperature of 900-1200 ℃ under the inert gas protective atmosphere to convert the organic matrix into carbon; the densification by the chemical vapor deposition method is usually performed under the conditions that natural gas, propane, propylene, acetylene or a mixed gas thereof, a diluent gas is nitrogen, hydrogen or a mixed gas thereof, the volume ratio of the source gas to the diluent gas is 1: 1-14, the infiltration time is 100-500 h, the residence time is 0.6-10 s, the infiltration temperature is 860-1250 ℃, and the pressure is 1000-5000 Pa. The inert gas can be nitrogen and/or argon;
the high-temperature heat treatment of the carbon fiber reinforced carbon matrix composite material is generally carried out at 1900-2500 ℃, the treatment time is 1-3 h, the atmosphere is protected by inert gas, and the inert gas is argon and/or helium. The high-temperature heat treatment of the carbon fiber reinforced carbon matrix composite can remove non-carbon impurities, open surface pores, provide channels for subsequent densification, improve the ordering of matrix carbon lattices, improve the bonding strength of fibers and matrix carbon interfaces, and facilitate the improvement of the mechanical properties of materials.
Carbon fiberThe density of the vitamin reinforced carbon matrix composite material reaches 1.2 to 1.5g/cm3And then machining the cylindrical material into a piston blank by adopting a machining mode, wherein the size of the piston blank is 0.15-0.75 mm of subsequent polishing allowance relative to the size of the finished piston product. The machining of the piston blank includes all the structure in the piston 5. The machining mode can be selected from grinding, turning, milling or combined modes, preferably grinding machining is carried out, because the turning and the milling are point machining, the surface damage of the composite material is easily caused, the grinding is surface contact, the damage to the composite material can be avoided, the tool bit of the machining tool can be a metal tool bit with a diamond coating, also can be an artificial or natural diamond tool bit, and preferably is a diamond tool bit, so that the machining precision is better guaranteed.
The melting siliconizing densification is generally carried out under the protection atmosphere of inert gas at the constant temperature of 1450-1850 ℃ for 30-150 min, and the density of the piston blank after melting siliconizing is 1.95-2.15g/cm3The purity of the silicon powder is generally more than 99%, the granularity is 100-300 meshes, and the inert gas can be argon or helium.
The piston blank reaches the target density of 1.95-2.15g/cm3And finally polishing the piston blank to a final size by using a grinding tool with a diamond coating. The purpose of the polishing is to minimize or eliminate wear that may occur when the piston surface initially contacts the cylinder surface.
The heat-insulating and oxidation-preventing treatment of the piston top and the combustion chamber is usually performed by coating a ceramic coating with heat-insulating and self-healing functions as required to form a dense surface, so as to provide oxidation-resistant protection, insulate heat and reduce heat loss. The ceramic coating may be a phosphate coating, a borate coating, and/or a hybrid coating thereof, and the like.
The light high-temperature-resistant composite material has the characteristics of low thermal expansion coefficient, small thermal deformation, low density, high temperature resistance, self-lubrication and the like, so that the composite material piston structure does not need to additionally consider complicated weight reduction, deformation prevention and cooling structures, and the strength and the service life of the piston are ensured on the premise of ensuring the structural integrity of the fiber preform. The designed composite piston structure is as follows: the piston comprises a piston top, a piston head, an inner cavity, a clamp spring groove, a pin hole, a pin seat, a skirt part and a face window; the combustion chamber is located at the top of the piston.
The piston head comprises ring grooves and a ring land, and the number of the ring grooves is 0-3; the number of the ring grooves is 2, the 2 ring grooves are respectively a ring groove and a double ring groove, and the ring lands comprise a first ring land and a second ring land; the piston top position can be processed into combustion chambers (not shown) with different shapes according to different use requirements, and the distance T1 from the top end of the inner cavity to the bottom end of the combustion chamber is 8-15 mm; the thickness T6 of the second ring bank is 6-12 mm; the distance T5 between the bottom end of the two ring grooves and the top end of the pin hole is 7-11 mm; the distance T4 between the bottom end of the pin hole and the bottom end of the pin base is 10-15 mm, and the thickness T3 of the skirt wall is 6-11 mm; the bottom end of the pin boss is a plane and is parallel to the plane of the piston top, and the width T2 of the bottom end of the pin boss is 20-30 mm.
The light high-temperature-resistant composite material is a composite material taking carbon fibers as a reinforcement and carbon and ceramic phases as matrixes, has the characteristics of good self-lubricating property, excellent heat-resistant performance, good dimensional stability, small thermal expansion coefficient, low volume density, corrosion resistance and the like, and the density of the manufactured piston is reduced by more than 20 percent compared with that of an aluminum alloy piston, can still keep higher strength under the working condition of more than 1000 ℃, has the characteristics of self-lubricating property and good dimensional stability, does not need a larger gap reserved between the piston and a cylinder, and does not need or only needs a small amount of piston rings to be arranged in a ring groove. The light high-temperature-resistant composite piston not only has longer service life and stability, but also can reduce oil consumption, improve fuel efficiency and engine output power, improve exhaust emission and reduce noise.
The invention aims to reduce the piston mass by using the light high-temperature-resistant composite material and reduce the inertia force and the inertia moment generated in the reciprocating motion process, thereby reducing the weight of an internal combustion engine and/or the engine and reducing the oil consumption; the mechanical strength, especially the high-temperature strength, is improved so as to meet the use requirements of a high-power internal combustion engine and/or an engine and improve the fuel efficiency; the thermal expansion coefficient is reduced, and the lubricating oil has self-lubricating property, so that the clearance between a piston and a cylinder is reduced, the noise is reduced, the tail gas emission is reduced, and the cylinder-pulling fault is avoided when the lubricating oil is poor; the fuel gas corrosion resistance of the piston is improved, and the service life of the piston is prolonged.
The preform in the invention is a novel annular needling preform. Adopt above-mentioned technical scheme's novel high temperature resistant combined material piston of light, its advantage and positive effect fully separate and present:
(1) the whole mass of the light high-temperature-resistant composite piston is reduced by more than 30% compared with that of an aluminum alloy piston, the mass of the piston determines the mass of an engine, and the reduction of the mass of the piston is beneficial to improving the rotating speed of the engine and improving the motion performance;
(2) the composite material piston has small thermal expansion coefficient and self-lubrication, can reduce the clearance between the piston and the cylinder, reduce the number of piston rings and reduce the dependence of the piston on lubricating oil, thereby improving the fuel efficiency of an engine, reducing noise, improving tail gas emission and avoiding the occurrence of 'knocking' faults of the engine in lean oil;
(3) the composite piston is high temperature resistant, and can maintain high strength at the temperature of over 1000 ℃, so that the temperature of a combustion chamber can be greatly increased, the cooling of the piston is reduced, the fuel efficiency and the power of an engine are improved, the heat in partial waste gas can be recovered, and the fuel economy is improved.
(4) The lightweight high-temperature-resistant composite material piston has small thermal deformation, so that a complex deformation-preventing structure does not need to be additionally considered when the structure is designed, on one hand, the integrity of the fiber preform structure is ensured, the strength of the piston is improved, the service life is prolonged, and on the other hand, the processing cost is reduced.
Drawings
The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic diagram of a novel lightweight refractory composite piston according to one embodiment of the invention;
FIG. 2 shows a view in the direction F of FIG. 1;
FIG. 3 shows a diagram of a cylindrical preform for a new lightweight refractory composite piston according to one embodiment of the invention;
fig. 4 is a diagram of a piston preform.
The composite carbon fiber net tire comprises 1-a cylindrical prefabricated body, 2-needled carbon fibers, 3-annular carbon fibers, a composite carbon fiber net tire unit layer, 4-an axial carbon fiber weftless fabric composite carbon fiber net tire unit layer, 5-a novel light high-temperature-resistant composite material piston, 501-a piston top, 502-a piston head, 503-an inner cavity, 504-a clamp spring groove, 505-a pin hole, 506-a pin seat, 507-a skirt part, 508-a face window, 5021-a ring groove, 5022-a second ring bank and 5023-a second ring groove.
Detailed Description
For a more clear understanding of the above objects, features and advantages of the present invention, reference is now made to the following detailed description of the invention, taken in conjunction with the accompanying drawings. It should be noted that the embodiments and features of the embodiments of the present application may be combined with each other without conflict.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, but the present invention may be practiced in other ways than those specifically described herein, and thus the scope of the present invention is not limited by the specific embodiments disclosed below.
Fig. 1 and 2 show a piston structure of light high temperature resistant composite material machined from a cylindrical preform 1. The invention relates to an improvement on the manufacture and structure of a light high-temperature-resistant multi-element carbon and ceramic matrix composite piston for a high-power engine. The invention discloses a carbon fiber reinforced three-dimensional cylindrical preform comprising a complete piston structure, which is characterized in that a piston blank is processed from a cylindrical composite material after a carbon matrix is prepared and densified to form a carbon fiber reinforced carbon matrix composite material, then the piston blank is densified to reach the required density by adopting a melting siliconizing process, the piston blank is processed to the final size, and finally, an anti-oxidation treatment is carried out on a piston combustion chamber to prepare the light high-temperature-resistant composite material piston. As shown in fig. 1, a lightweight refractory composite piston 5 is depicted, the piston 5 including a piston crown 501, a piston head 502, an inner cavity 503, a circlip groove 504, a pin bore 505, a pin boss 506, and a skirt 507, a face window 508. The piston head 502 includes a ring groove 5021, a second land 5022, and a ring groove 5023. The light high-temperature-resistant composite material has the characteristics of low thermal expansion coefficient, small thermal deformation, low density, high temperature resistance, self-lubrication and the like, so that the composite material piston structure does not need to additionally consider complicated weight reduction, deformation prevention and cooling structures, and the strength and the service life of the piston are ensured on the premise of ensuring the structural integrity of the fiber preform.
Cylindrical preform 1 includes axial carbon fiber weftless fabric composite carbon fiber net child unit layer 4, and the continuous winding of hoop carbon fiber composite carbon fiber net child unit layer 3 adopts acupuncture carbon fiber 2 to improve overall structure intensity between unit layer and the unit layer. The density of unit layers is about 10-50 layers/cm in the manufacturing process of the cylindrical prefabricated body 1, and the density of the needle-punched carbon fiber 2 is about 20-100 needles/m2The needling direction is vertical to the unit layers, and the needle insertion depth is about 5-75 mm; the size of the cylindrical prefabricated body is larger than that of the finished piston, specifically, the size is at least larger than 4mm in the diameter direction and at least larger than 3mm in the height direction.
The novel light-weight high-temperature-resistant composite piston according to the embodiment of the invention is specifically described below with reference to the accompanying drawings.
The first embodiment is as follows:
1. cylindrical preforms (see FIGS. 3 and 4) were prepared with an interlaminar cell density of 25 layers/cm and a needled fiber density of 40 needles/m2The needling direction is vertical to the unit layers, and the needle inserting depth is 30 mm;
2. carrying out heat treatment on the prefabricated body for 1h in a vacuum environment at 950 ℃, wherein the heating rate is 5 ℃/min;
3. adopting phenolic resin to densify the prefabricated body, wherein the technological parameters are as follows: vacuum soaking at 80 deg.C for 1.5 hr, pressurizing to 1.5MPa, soaking for 0.5 hr, curing at 200 deg.C for 2.5 hr, treating at 1000 deg.C for 0.5 hr under nitrogen atmosphere, and repeating above steps to density of 1.35g/cm3；
4. Treating the carbon fiber reinforced carbon matrix composite material at 2200 ℃ for 2h, and performing helium protection atmosphere;
5. the carbon fiber reinforced carbon matrix composite material is ground and processed into a piston blank by adopting a grinding tool with a diamond coating, the piston blank reserves a margin of 0.45mm in the diameter direction relative to the finished product size, and reserves a margin of 0.25mm in the height direction, and the piston blank has the following structural size: the distance between the top end of the inner cavity and the top of the piston is 13.1 mm; the thickness of the second ring bank is 9.9 mm; the distance between the bottom end of the two ring grooves and the top end of the pin hole is 9.46 mm; the distance from the bottom end of the pin hole to the bottom end of the pin seat is 11.5mm, and the thickness of the skirt wall is 8.3 mm; the pin boss is directly arranged along the inner wall of the skirt along the radial direction, the bottom end of the pin boss is a plane and is parallel to the plane of the piston top, and the maximum width T2 of the pin boss is 26.5 mm.
6. Performing melt siliconizing densification treatment on the piston blank at 1550 ℃, wherein the constant temperature time is 120min, the purity of the silicon powder is 99.9 percent, the granularity is 300 meshes, and the density of the piston after treatment is 2.10g/cm3；
7. Polishing the piston blank to a final size by using a grinding tool with a diamond coating;
8. and (3) carrying out heat insulation and anti-oxidation treatment on the top of the piston and the combustion chamber by adopting a phosphate coating.
Example two:
1. preparing a cylindrical preform having an interlaminar density of 32 layers/cm and a density of 45 needles/m for the needled fibers2The needling direction is vertical to the unit layers, and the needle inserting depth is 25 mm;
2. carrying out heat treatment on the prefabricated body for 1h in a vacuum environment at the temperature of 1000 ℃, wherein the heating rate is 10 ℃/min;
3. the epoxy resin is adopted to densify the prefabricated body, and the technological parameters are as follows: vacuum soaking at 120 deg.C for 1 hr, pressurizing to 1.5MPa, soaking for 0.5 hr, curing at 250 deg.C for 2 hr, treating at 1100 deg.C for 1.5 hr under nitrogen atmosphere, and repeating above steps until the density is 1.25g/cm3；
4. Treating the carbon fiber reinforced carbon matrix composite material at 2100 ℃ for 2h, and performing helium protection atmosphere;
5. the carbon fiber reinforced carbon matrix composite material is ground and processed into a piston blank by adopting a grinding tool with a diamond coating, the piston blank is reserved with a margin of 0.20mm in the diameter direction and a margin of 0.15mm in the height direction relative to the finished product size, and the piston blank has the following structural size: the distance between the top end of the inner cavity and the top of the piston is 13.1 mm; the thickness of the second ring bank is 9.9 mm; the distance between the bottom end of the two ring grooves and the top end of the pin hole is 9.46 mm; the distance from the bottom end of the pin hole to the bottom end of the pin seat is 11.5mm, and the thickness of the skirt wall is 8.3 mm; the pin boss is directly arranged along the inner wall of the skirt along the radial direction, the bottom end of the pin boss is a plane and is parallel to the plane of the piston top, and the maximum width T2 of the pin boss is 26.5 mm.
6. Performing melt siliconizing densification treatment on the piston blank at 1510 ℃ for 90min at constant temperature, wherein the purity of the silicon powder is 99.9 percent, the granularity is 300 meshes, and the density of the treated piston is 2.05g/cm3；
7. Polishing the piston blank to a final size by using a grinding tool with a diamond coating;
8. and (3) carrying out heat insulation and anti-oxidation treatment on the top of the piston and the combustion chamber by adopting a phosphate coating.
Example three:
1. preparing a cylindrical preform having an interlaminar density of 45 layers/cm and a density of 60 needles/m for the needled fibers2The needling direction is vertical to the unit layers, and the needle insertion depth is 15 mm;
2. carrying out heat treatment on the prefabricated body for 2h in a vacuum environment at 2100 ℃, wherein the heating rate is 15 ℃/min;
3. taking natural gas as a carbon source, taking nitrogen as diluent gas, wherein the volume ratio of the natural gas to the nitrogen is 1:8.5, the infiltration time is 200h, the residence time is 1.2s, the infiltration temperature is 1070 ℃, the pressure is 3000Pa, and the preparation density is 1.25g/cm3The carbon fiber-reinforced carbon matrix composite of (a);
4. treating the carbon fiber reinforced carbon matrix composite material at 2050 ℃ for 2h in an argon protective atmosphere;
5. the carbon fiber reinforced carbon matrix composite material is ground and processed into a piston blank by adopting a grinding tool with a diamond coating, the piston blank is reserved with a margin of 0.20mm in the diameter direction and a margin of 0.15mm in the height direction relative to the finished product size, and the piston blank has the following structural size: the distance between the top end of the inner cavity and the top of the piston is 13.1 mm; the thickness of the second ring bank is 9.9 mm; the distance between the bottom end of the two ring grooves and the top end of the pin hole is 9.46 mm; the distance from the bottom end of the pin hole to the bottom end of the pin seat is 11.5mm, and the thickness of the skirt wall is 8.3 mm; the pin boss is directly arranged along the inner wall of the skirt along the radial direction, the bottom end of the pin boss is a plane and is parallel to the plane of the piston top, and the maximum width T2 of the pin boss is 26.5 mm.
6. The piston blank is subjected to melt siliconizing densification treatment at 1600 ℃, the constant temperature time is 1h, the purity of the silicon powder is 99.9 percent,the granularity is 300 meshes, and the piston density after treatment is 2.03g/cm3；
7. Polishing the piston blank to a final size by using a grinding tool with a diamond coating;
8. and (3) carrying out heat insulation and anti-oxidation treatment on the top of the piston and the combustion chamber by adopting a phosphate coating.
Claims (10)
1. A cylindrical preform characterized by: comprises two unit layers, wherein one unit layer is overlapped with the other unit layer, and the unit layers are provided with acupuncture carbon fibers (2); the two unit layers are axial carbon fiber non-woven cloth composite carbon fiber net tire unit layers (4), and the circumferential carbon fibers are continuously wound on the composite carbon fiber net tire unit layers (3).
2. The cylindrical preform as set forth in claim 1, wherein: the density of the unit layers is 10 to 50 layers/cm, and the density of the needle-punched carbon fibers (2) is 20 to 100 needles/m2The needling direction is perpendicular to the circumferential carbon fiber and continuously winds the composite carbon fiber net tire unit layer (3), and the needle insertion depth is 5-75 mm.
3. A preparation method of a light high-temperature-resistant composite piston is characterized by comprising the following steps: the method comprises the following steps:
1) preparing a cylindrical prefabricated body, wherein two unit layers, namely an axial carbon fiber non-woven cloth composite carbon fiber net tire unit layer (4) and a circumferential carbon fiber continuous winding composite carbon fiber net tire unit layer (3), are formed into the cylindrical prefabricated body through needling; the diameter direction of the cylindrical prefabricated part is at least more than 4mm than that of the piston finished product, and the height direction of the cylindrical prefabricated part is at least more than 3mm than that of the piston finished product;
2) and (3) carrying out heat treatment on the cylindrical preform: the treatment is carried out in a high-temperature vacuum environment at 900-2500 ℃, the treatment time is 0.5-3 h, and the heating rate is 5-15 ℃/min;
3) densifying by adopting a liquid phase impregnation method and/or a chemical vapor deposition method to form the carbon fiber reinforced carbon matrix composite material; impregnating carbon-containing resin and/or asphalt in a densification process by a liquid-phase impregnation method, impregnating the carbon-containing resin and/or asphalt at the temperature of 25-120 ℃, performing vacuum impregnation for 1-1.5 h, pressurizing to above 1.5MPa, impregnating for 0.5-1 h, curing for 2-5 h at the temperature of 100-300 ℃ after impregnation is completed, and then treating at the temperature of 900-1200 ℃ for 0.5-1.5 h in an inert gas protective atmosphere to convert an organic matrix into carbon; the densification by the chemical vapor deposition method is carried out under the conditions that natural gas, propane, propylene, acetylene or a mixed gas thereof, a diluent gas is nitrogen, hydrogen or a mixed gas thereof, the volume ratio of the source gas to the diluent gas is 1: 1-14, the infiltration time is 100-500 h, the residence time is 0.6-10 s, the infiltration temperature is 860-1250 ℃, and the pressure is 1000-5000 Pa;
4) carrying out high-temperature heat treatment on the carbon fiber reinforced carbon matrix composite material in an inert atmosphere, wherein the temperature of the high-temperature heat treatment is 1900-2500 ℃, the treatment time is 1-3 h, and the gas in the inert atmosphere is argon and/or helium;
5) processing a piston blank on the carbon fiber reinforced carbon matrix composite treated in the step 4) by adopting a mechanical processing method: the carbon fiber reinforced carbon matrix composite material reaches 1.2-1.5 g/cm3Then processing the carbon fiber reinforced carbon matrix composite into a piston blank by adopting a mechanical processing mode; the mechanical processing mode is grinding, turning, milling or combination;
6) and adopting a melting siliconizing process to densify the piston blank: the piston blank densification treatment is carried out by the melting siliconizing process at the constant temperature of 1450-1850 ℃ for 30-150 min under the inert gas protective atmosphere, and the density of the piston blank after melting siliconizing is 1.95-2.15g/cm3The purity of the silicon powder is more than 99%, the granularity is 100-300 meshes, and the gas in the inert gas protective atmosphere is argon and/or helium;
7) and after the piston blank reaches the target density after the piston blank is subjected to densification treatment, performing heat insulation and oxidation resistance treatment on the top of the piston blank and a combustion chamber to obtain a piston finished product.
4. The method for preparing the light high-temperature-resistant composite piston according to claim 3, wherein the method comprises the following steps: the inert gas in the step 3) is nitrogen and/or argon.
5. The method for preparing the light high-temperature-resistant composite piston according to claim 3, wherein the method comprises the following steps: the carbon-containing resin in the step 3) is phenolic resin or epoxy resin.
6. The method for preparing the light high-temperature-resistant composite piston according to claim 3, wherein the method comprises the following steps: the tool bit of the machining tool machined in the step 5) is a metal tool bit with a diamond coating, an artificial diamond tool bit or a natural diamond tool bit.
7. The method for preparing the light high-temperature-resistant composite piston according to claim 3, wherein the method comprises the following steps: in the step 7), the piston blank is adopted to reach the target density of 1.95-2.15g/cm3And then, polishing the piston blank to a final size by using a grinding tool with a diamond coating, and then carrying out heat insulation and oxidation prevention treatment on the top of the piston blank and a combustion chamber.
8. The method for preparing the light high-temperature-resistant composite piston according to claim 3, wherein the method comprises the following steps: the heat insulation and anti-oxidation treatment of the piston top of the piston blank and the combustion chamber in the step 7) comprises the following steps: and coating a ceramic coating with heat insulation and self-healing functions on the top of the piston and the combustion chamber, wherein the ceramic coating is a phosphate coating, a borate coating and/or a mixed coating thereof.
9. A piston manufactured by the manufacturing method of the light high temperature resistant composite piston according to claims 3-8, characterized in that: the piston comprises a piston top (501), a piston head (502), an inner cavity (503), a clamp spring groove (504), a pin hole (505), a pin seat (506), a skirt part (507) and a face window (508); the combustion chamber is located at the piston crown (501).
10. The piston of claim 9, wherein: the piston head (502) comprises ring grooves and a ring land, and the number of the ring grooves is 0-3; the number of the ring grooves is 2, the 2 ring grooves are respectively a ring groove (5021) and a double ring groove (5023), and the ring bank comprises a first ring bank and a second ring bank (5022); the distance T1 between the top end of the inner cavity (503) and the bottom end of the combustion chamber is 8-15 mm; the thickness T6 of the second ring bank (5022) is 6-12 mm; the distance T5 between the bottom end of the secondary ring groove (5023) and the top end of the pin hole (505) is 7-11 mm; the distance T4 between the bottom end of the pin hole (505) and the bottom end of the pin seat (506) is 10-15 mm, and the thickness T3 of the skirt wall of the skirt part (507) is 6-11 mm; the bottom end of the pin seat (506) is a plane parallel to the plane of the piston top (501), and the maximum width T2 of the pin seat (506) is 20-30 mm.
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