CN114160899A - Manufacturing method of cast aluminum engine piston component - Google Patents
Manufacturing method of cast aluminum engine piston component Download PDFInfo
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- CN114160899A CN114160899A CN202111557548.2A CN202111557548A CN114160899A CN 114160899 A CN114160899 A CN 114160899A CN 202111557548 A CN202111557548 A CN 202111557548A CN 114160899 A CN114160899 A CN 114160899A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
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- Pistons, Piston Rings, And Cylinders (AREA)
Abstract
The invention discloses a method for manufacturing a cast aluminum engine piston component, which specifically comprises the following steps: the ceramic block is i3N4Or the PSZ is processed according to the irregular shape of the top of the cast aluminum piston (aluminum-silicon alloy or aluminum-copper alloy), and then the surface is subjected to pre-metallization treatment; manufacturing an intermediate transition layer according to the irregular shape of the top of the cast aluminum piston, matching the intermediate transition layer with the ceramic and the piston and reserving a brazing filler metal filling gap; filling different brazing materials between the ceramic and the intermediate transition layer, and between the intermediate layer and the top of the cast aluminum piston respectively, and connecting the brazing materials through brazing; and (4) carrying out heat treatment on the piston after welding to eliminate residual stress. The manufacturing method of the cast aluminum engine piston component has the advantages of firm welding seam combination, high thermal shock resistance, no ceramic crack and the like.
Description
Technical Field
The invention relates to a method for manufacturing a cast aluminum engine piston component, and belongs to the field of manufacturing of engine parts.
Background
The piston is a reciprocating member in the cylinder block of the engine. The basic structure of the piston can be divided into a crown, a crown and a skirt. The piston crown is the main part that makes up the combustion chamber and its shape is related to the combustion chamber form chosen. The gasoline engine mostly adopts a flat-top piston, and has the advantage of small heat absorption area. The top of the piston of a diesel engine often has various pits, the specific shape, position and size of which must be adapted to the requirements of the mixture formation and combustion of the diesel engine. The piston operates at high temperature, high pressure, high speed, and poor lubrication. The piston is directly contacted with high-temperature gas, the instantaneous temperature can reach more than 2500K, so the piston is heated seriously, the heat dissipation condition is poor, the temperature of the piston is very high when the piston works, the top of the piston is as high as 600-700K, and the temperature distribution is very uneven; the top of the piston bears great gas pressure, especially the maximum pressure of the power stroke, so that the piston generates impact and bears the action of lateral pressure; the piston reciprocates in the cylinder at a high speed (8-12 m/s) and the speed is constantly changed, so that a large inertia force is generated, and the piston is subjected to a large additional load. The pistons work under such severe conditions, generating deformations and accelerated wear, as well as additional loads and thermal stresses, and are subject to chemical corrosion by the gases.
The structural ceramic has the advantages of superior strength and hardness, high temperature resistance, oxidation resistance, wear resistance, corrosion resistance and the like, and can show higher stability and good mechanical property under severe working environment and application conditions, so that the composite structure manufactured by connecting the ceramic and the metal together has great application prospect.
Disclosure of Invention
The invention provides a method for manufacturing a cast aluminum engine piston.
The technical solution for realizing the purpose of the invention is as follows:
a method for manufacturing a piston component of a cast aluminum engine comprises the steps of brazing a ceramic and a pure copper intermediate layer by taking silver, copper and indium as brazing filler metal, and then connecting the copper intermediate layer and a cast aluminum piston by taking aluminum, silicon and copper as brazing filler metal. The method comprises the following specific steps:
step 1, processing a ceramic block according to the irregular shape of the top of an aluminum-cast piston, and then performing pre-metallization treatment on the surface of the ceramic block;
step 2, manufacturing an intermediate transition layer according to the irregular shape of the top of the piston, wherein the intermediate transition layer is matched with the ceramic and the piston without obvious dislocation and a gap is reserved;
step 3, filling brazing filler metal between the ceramic and the intermediate transition layer, enabling the ceramic and the intermediate transition layer to be tightly matched without obvious dislocation, then placing the ceramic and the intermediate transition layer into a furnace to be slowly heated, brazing the ceramic and the intermediate transition layer after the temperature of the brazing filler metal reaches a welding temperature, preserving the heat for a period of time, and then slowly cooling the temperature;
step 4, filling brazing filler metal between the middle layer and the top of the cast aluminum piston, matching tightly without obvious dislocation, and then placing the piston into a furnace for brazing;
and 5, carrying out heat treatment on the piston after welding to eliminate residual stress.
Wherein the ceramic material is Si3N4Or Partially Stabilized Zirconia (PSZ), and the cast aluminum is aluminum-silicon alloy or aluminum-copper alloy; the welding method is brazing in a vacuum chamber or under the protection of inert gases such as argon and the like;
wherein, in the step 1, the pre-metallization treatment is chemical nickel plating;
in the step 2, the intermediate transition layer is made of pure copper;
in the step 3, the brazing filler metal is silver, copper and indium, and is in a powder or foil shape;
wherein, in the step 3, the slow rising curve is that the temperature is raised to 480-plus 500 ℃ at 5-8 ℃/min, the temperature is preserved for 10-20min, and then the temperature is raised to 740-plus 760 ℃ at 3-5 ℃/min; the slow-falling curve is that the temperature is reduced to 450-550 ℃ at the speed of 1.5-2.5 ℃/min and then the air is cooled.
Wherein, the slow rising curve in the step 4 is that the temperature is raised to 380-400 ℃ at 8-10 ℃/min, the temperature is preserved for 10-20min, then the temperature is raised to 580-620 ℃ at 5-8 ℃/min, and the slow falling curve is that the temperature is first reduced to 350-450 ℃ at 2-5 ℃/min and then air-cooled.
In the step 4, the brazing filler metal is aluminum, silicon and magnesium and is in a powder or foil shape;
wherein, in the step 5, the heat treatment process is low-temperature annealing heat treatment, the temperature is raised at the speed of 1.5-2.5 ℃/min, the furnace is charged when the furnace temperature is lower than 300 ℃, the temperature is continuously raised to 500-550 ℃, the temperature is kept for 2-4 hours, and then the temperature is lowered to 300 ℃ at the speed of 1.5-2.5 ℃/min, and then the air cooling is carried out.
Compared with the prior art, the invention has the following remarkable advantages:
1. the ceramic used in the invention is not easy to crack;
2. the invention improves the wear resistance and corrosion resistance of the cast aluminum piston;
3. the invention improves the thermal shock resistance of the cast aluminum piston;
4. the lubricating property, the cold and hot impact resistance and the deformation resistance of the lubricating oil are improved;
5. the invention has high thermal fatigue strength and hardness;
6. the invention improves the service life and fuel efficiency of the engine.
Drawings
FIG. 1 is a process flow diagram of the present invention.
Fig. 2 is a schematic diagram of the present invention. Wherein 1 is a cast aluminum piston, 2 is ceramic, 3 is a ceramic nickel-plating layer, 4 is a silver-copper-indium brazing filler metal seam, 5 is a copper intermediate layer, and 6 is an aluminum-silicon-magnesium brazing filler metal seam.
Fig. 3 is an assembly view before welding.
Fig. 4 is an assembly view before welding and an external view after welding.
Detailed Description
The present invention is described in further detail below with reference to examples:
example 1
The matrix material is aluminum-silicon cast aluminum alloy, and the size is 110mm in diameter and 110mm in height. The size of the silicon nitride block is 100mm in diameter and 10mm in thickness.
Step 1, adding Si3N4Processing the ceramic according to the irregular shape of the top of the piston, and then carrying out chemical nickel plating on the surface;
step 2, manufacturing a pure copper intermediate transition layer according to the irregular shape of the top of the piston, wherein the pure copper intermediate transition layer is matched with the ceramic and the piston without obvious dislocation and a gap is reserved;
step 3, filling the silver-copper-indium solder between the ceramic and the copper intermediate layer, tightly matching without obvious dislocation, then placing the silver-copper-indium solder into a furnace, slowly heating to 500 ℃ at a speed of 3 ℃/min, preserving heat for 10min, then heating to 760 ℃ at a speed of 3 ℃/min for brazing, preserving heat for 25min, then cooling to 500 ℃ at a speed of 2 ℃/min, and then air-cooling;
step 4, filling the aluminum-silicon-magnesium brazing filler metal between the copper intermediate layer and the top of the cast aluminum piston, tightly matching without obvious dislocation, then placing the aluminum-silicon-magnesium brazing filler metal into a furnace, heating to 400 ℃ at a speed of 10 ℃/min, preserving heat for 10min, then heating to 600 ℃ at a speed of 5 ℃/min, brazing, preserving heat for 20min, then cooling to 400 ℃ at a speed of 3 ℃/min, and then air cooling;
and 5, carrying out low-temperature annealing heat treatment on the piston after welding, heating at the speed of 2 ℃/min, charging when the furnace temperature is lower than 300 ℃, continuously heating to 500 ℃, preserving heat for 2 hours, then cooling to 300 ℃ at the speed of 2 ℃/min, and then air-cooling.
And 6, after 200 times of thermal cycle tests of the silicon nitride ceramic and the cast aluminum joint, no crack is found.
Example 2
The base material is aluminum copper cast aluminum alloy, and the size is 110mm in diameter and 110mm in height. The PSZ block size is 100mm in diameter and 10mm in thickness.
Step 1, processing PSZ ceramic according to the irregular shape of the top of a piston, and then carrying out chemical nickel plating on the surface;
step 2, manufacturing a pure copper intermediate transition layer according to the irregular shape of the top of the piston, wherein the pure copper intermediate transition layer is matched with the ceramic and the piston without obvious dislocation and a gap is reserved;
step 3, filling the silver-copper-indium solder between the ceramic and the copper intermediate layer, tightly matching without obvious dislocation, then placing the silver-copper-indium solder into a furnace, slowly heating to 500 ℃ at a speed of 3 ℃/min, preserving heat for 10min, then heating to 760 ℃ at a speed of 3 ℃/min for brazing, preserving heat for 25min, then cooling to 500 ℃ at a speed of 2 ℃/min, and then air-cooling;
step 4, filling the aluminum-silicon-magnesium brazing filler metal between the copper intermediate layer and the top of the cast aluminum piston, tightly matching without obvious dislocation, then placing the aluminum-silicon-magnesium brazing filler metal into a furnace, heating to 400 ℃ at a speed of 10 ℃/min, preserving heat for 10min, then heating to 600 ℃ at a speed of 5 ℃/min, brazing, preserving heat for 20min, then cooling to 400 ℃ at a speed of 3 ℃/min, and then air cooling;
and 5, carrying out low-temperature annealing heat treatment on the piston after welding, heating at the speed of 2 ℃/min, charging when the furnace temperature is lower than 300 ℃, continuously heating to 500 ℃, preserving heat for 2 hours, then cooling to 300 ℃ at the speed of 2 ℃/min, and then air-cooling.
And 6, after 200 times of thermal cycle tests of the PSZ ceramic and the cast aluminum joint, no crack is found.
Claims (9)
1. A method for manufacturing a cast aluminum engine piston component, comprising the steps of:
step 1, processing a ceramic block according to the irregular shape of the top of a piston, and then performing pre-metallization treatment on the surface;
step 2, manufacturing an intermediate transition layer according to the irregular shape of the top of the piston, wherein the intermediate transition layer is matched with the ceramic and the piston without obvious dislocation and a gap is reserved;
step 3, filling brazing filler metal between the ceramic and the intermediate transition layer, enabling the ceramic and the intermediate transition layer to be tightly matched without obvious dislocation, then placing the ceramic and the intermediate transition layer into a furnace to be slowly heated, brazing the ceramic and the intermediate transition layer after the temperature of the brazing filler metal reaches a welding temperature, preserving the heat for a period of time, and then slowly cooling the temperature;
step 4, filling brazing filler metal between the middle layer and the top of the cast aluminum piston, enabling the brazing filler metal to be tightly matched without obvious dislocation, then placing the brazing filler metal into a furnace to be slowly heated, brazing the brazing filler metal after reaching the welding temperature, keeping the temperature for a period of time, and then slowly cooling the temperature;
and 5, carrying out heat treatment on the piston after welding to eliminate residual stress.
2. The method of manufacturing a cast aluminum engine piston component of claim 1, wherein the ceramic material used is Si3N4Or partially stabilized zirconia PSZ, the cast aluminum piston material is aluminum-silicon alloy or aluminum-copper alloy, and the welding method is brazing in a vacuum chamber or under the protection of inert gases such as argon and the like.
3. The method of manufacturing a cast aluminum engine piston component of claim 1, wherein in step 1, the pre-metallization treatment is electroless nickel plating.
4. The method of manufacturing a cast aluminum engine piston component of claim 1, wherein in step 2, the intermediate transition layer is pure copper.
5. The method for manufacturing a piston component of a cast-aluminum engine as claimed in claim 1, wherein in the step 3, the temperature is slowly raised to 480-500 ℃ at a rate of 5-8 ℃/min, the temperature is kept for 10-20min, and then the temperature is raised to 700-740 ℃ at a rate of 3-5 ℃/min; the slow cooling is to cool the mixture to 450-550 ℃ at a speed of 1.5-2.5 ℃/min and then to cool the mixture in air.
6. The method of manufacturing a cast aluminum engine piston component as claimed in claim 1, wherein in step 3, the brazing filler metal is silver-copper-indium brazing filler metal in a powder or foil shape.
7. The method for manufacturing a piston component of a cast-aluminum engine as claimed in claim 1, wherein in the step 4, the temperature is slowly increased to 380-400 ℃ at a rate of 8-10 ℃/min, the temperature is maintained for 10-20min, then the temperature is increased to 580-620 ℃ at a rate of 5-8 ℃/min, and the temperature is slowly decreased to 350-450 ℃ at a rate of 2-5 ℃/min, and then the piston component is air-cooled.
8. The method of manufacturing a cast aluminum engine piston component according to claim 1, wherein in step 4, the brazing filler metal is an aluminum silicon magnesium brazing filler metal in a powder or foil shape.
9. The method for manufacturing a cast-aluminum engine piston component as claimed in claim 1, wherein in the step 5, the heat treatment process is a low-temperature annealing heat treatment, the temperature is raised at a rate of 1.5-2.5 ℃/min, the furnace is charged when the furnace temperature is lower than 300 ℃, the temperature is continuously raised to 500-550 ℃, the temperature is kept for 2-4 hours, and then the temperature is lowered to 300 ℃ at a rate of 1.5-2.5 ℃/min, and then the piston component is air-cooled.
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| CN202111557548.2A CN114160899B (en) | 2021-12-19 | 2021-12-19 | Manufacturing method of cast aluminum engine piston component |
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Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05864A (en) * | 1991-07-12 | 1993-01-08 | Ngk Insulators Ltd | Engine parts |
| CN1396037A (en) * | 2002-08-09 | 2003-02-12 | 中国科学院上海硅酸盐研究所 | High-temp soldering method for aluminium nitride and copper |
| CN104093515A (en) * | 2012-01-19 | 2014-10-08 | 日本轻金属株式会社 | Method for surface brazing between aluminum alloy member and copper alloy member |
| CN105537712A (en) * | 2016-01-28 | 2016-05-04 | 北京航空航天大学 | Ceramic and metal brazing composite component and preparing method thereof |
| US20160284427A1 (en) * | 2011-09-23 | 2016-09-29 | Edison Welding Institute, Inc. | Method for fabricating silicon carbide assemblies |
| CN106475707A (en) * | 2016-12-30 | 2017-03-08 | 江苏科技大学 | Solder for soldering aluminium oxide ceramics and oxygen-free copper and preparation and method for welding |
| CN108672965A (en) * | 2018-05-07 | 2018-10-19 | 中国工程物理研究院电子工程研究所 | A method of alleviating ceramics and solder bonding metal connector residual stress |
-
2021
- 2021-12-19 CN CN202111557548.2A patent/CN114160899B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05864A (en) * | 1991-07-12 | 1993-01-08 | Ngk Insulators Ltd | Engine parts |
| CN1396037A (en) * | 2002-08-09 | 2003-02-12 | 中国科学院上海硅酸盐研究所 | High-temp soldering method for aluminium nitride and copper |
| US20160284427A1 (en) * | 2011-09-23 | 2016-09-29 | Edison Welding Institute, Inc. | Method for fabricating silicon carbide assemblies |
| CN104093515A (en) * | 2012-01-19 | 2014-10-08 | 日本轻金属株式会社 | Method for surface brazing between aluminum alloy member and copper alloy member |
| CN105537712A (en) * | 2016-01-28 | 2016-05-04 | 北京航空航天大学 | Ceramic and metal brazing composite component and preparing method thereof |
| CN106475707A (en) * | 2016-12-30 | 2017-03-08 | 江苏科技大学 | Solder for soldering aluminium oxide ceramics and oxygen-free copper and preparation and method for welding |
| CN108672965A (en) * | 2018-05-07 | 2018-10-19 | 中国工程物理研究院电子工程研究所 | A method of alleviating ceramics and solder bonding metal connector residual stress |
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