CN116209783A - 带过渡层的活塞环 - Google Patents

带过渡层的活塞环 Download PDF

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CN116209783A
CN116209783A CN202180064195.4A CN202180064195A CN116209783A CN 116209783 A CN116209783 A CN 116209783A CN 202180064195 A CN202180064195 A CN 202180064195A CN 116209783 A CN116209783 A CN 116209783A
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layer
wear
piston ring
running
transition
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彼得·施米特
迈克尔·布奇曼
马库斯·奥米勒
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Huimenbuershaid Co
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Huimenbuershaid Co
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Abstract

本申请具体涉及一种活塞环，其具有位于基底(2)上的耐磨层(6、22)、位于耐磨层(6、22)上的过渡层(8、24)和位于过渡层(8、24)上的磨合层(10、26)，其提供机械稳定且耐热的层接合。

Description

带过渡层的活塞环
技术领域
本申请涉及活塞环及其制造方法。活塞环具有耐磨层和磨合层，过渡层位于耐磨层和磨合层之间，这提供了机械稳定及耐热的层结合。
背景技术
大型发动机领域的进展导致燃烧压力持续增加，并且导致活塞环在温度和表面压力方面产生更高的应力。当前层系统的摩擦性能导致了一些问题，特别是在从软磨合层过渡到硬耐磨层的情况下。可能分别发生热过载或形成烧伤痕迹(擦伤)和层剥落。
在过去几年中，由于发动机性能的提高，同时减少了废气排放，某些材料(例如活塞环工作表面的材料)所承受的应力不断增加。因此，活塞环必须满足各种各样的要求，例如显示较低的油消耗，并且适合于使用无硫润滑油和燃料进行操作，这与增加的材料应力和磨损有关。
根据对机械强度、耐磨性和弹性的要求，活塞环由铸铁或钢制成。为了改善磨损性能，将涂层附着到环上。由此使用了多种电化学方法，例如镀铬或热喷涂以及物理CrN和化学DLC涂层。位于气缸运行表面的边缘层通常通过渗氮在钢环上固化。
德国专利说明书DE 3421569 C1公开了一种用于活塞环工作表面的涂层，该涂层分别具有从内向外连续径向变化的结构或组成，例如涂层的孔隙率，该孔隙率从内向外径向增加。涂层可以例如通过等离子体注射方法来生产。
在德国专利申请DE 4112422A1中描述了一种用于活塞环的耐磨涂层。涂层包含氮化铬，其中涂层的氮浓度从载体材料和涂层之间的边界层沿涂层外表面的方向连续增加。涂层是通过用不同比例的氮化铬气相沉积来获得的。
德国专利DE 10 2004 032 403 B3涉及一种用于活塞环的涂层和相应的制造方法。在活塞环的基体的外周表面上一层一层地施加若干层，其中面向外周表面的粘合剂层是基于Cr的PVD粘合剂层，将PVD-CrN梯度层施加到粘附层上，该梯度层具有通过Cr-Cr2N混合物、Cr2N、包括CrN的Cr2N-CrN混合物的Cr的层组成的氮含量(该氮含量向外增加)，以及将基于CrN、Cr2N或其混合物具有恒定组成的至少一个覆盖层施加到CrN梯度层。
由欧洲专利EP 2118534 B1已知包括3层系统的活塞环。将粘附促进层应用于以非圆形方式加工的坯料。所述粘附促进层用于补偿基材和耐磨层之间的热膨胀系数的差异，并改善热冲击性能。在粘附促进层上沉积有通常由金属(例如Ni、NiCr、Fe、FeCr、NiCr和钼(高耐烧性))与嵌入钼的硬质材料(CrC或MoC)组成的耐磨层。将软磨合层(AlCuFe)应用于耐磨层，该软磨合层提供了环表面形式到气缸表面形式的快速适应和短磨合。这些层分别通过等离子涂层(粘附促进剂和耐磨层)或电弧丝喷涂(磨合层)沉积，其中在各个层之间产生与工艺相关的粗糙、凹凸过渡。层变化的特征在于两层材料(磨合层到耐磨层)的不规则过渡，并由耐磨层的表面粗糙度定义。在去除软磨合层区域之后，运行表面的摩擦功能突然被耐磨层所取代。在层变化期间的摩擦条件根据时间由耐磨层的表面粗糙度决定。
活塞环另外分别具有凸形运行表面轮廓或桶形套筒表面。在高凸度区域(环中心，高表面压力)，磨合层很快被去除，而磨合层材料可以在低凸度区域存在更长时间。
为了减少换层过程中的热过载/磨损，在新环设计的条件下，对耐磨层进行抛光，即降低表面粗糙度。这种设计备选方案需要预先分别对环进行严格的圆形张紧处理或对耐磨表面进行复杂的抛光处理。磨合层的粘合强度也因表面的抛光或平滑而降低。为避免在这种设计情况下磨合层的分层剥落，磨合层的层厚不得超过100μm。
然而，目前还没有已知的措施，通过这些措施可以形成具有足够机械性和耐热性的多层涂层，这些涂层在内燃机的整个使用寿命内以令人满意的方式实现其功能。除了在载体上具有良好的耐温粘附力以及在层内具有良好的耐温粘结力(内聚力)之外，载体材料上的涂层，例如在活塞环的运行表面上的涂层也必须是耐磨的。在长时间调谐后，这些层还必须不显示任何热疲劳行为或仅显示低热疲劳行为(在层中形成撕裂)。
发明内容
因此，本申请的目的在于进一步提高活塞环的机械强度和耐磨性，从而提高活塞环在工作条件下的磨合性能，并确保了延长的工作寿命。
该目的通过用于载体材料的活塞环和相应的方法来解决，其中耐磨层被施加到载体材料并且提供磨合层。此外，在耐磨层和磨合层之间还存在过渡层，该过渡层确保材料的基本连续过渡。因此，根据本申请的涂层的耐磨性通过耐磨层提供，而通过磨合层获得良好的磨合性能。耐磨层可在发动机的整个使用寿命内防止极端工作条件下的过度磨损。磨合层不必进行后处理，而是通过磨合阶段发生的磨损获得最终形式。此外，在耐磨层和磨合层之间还存在过渡层，该过渡层在磨合层到耐磨层的过渡过程中改善了摩擦性能。
根据本申请，活塞环包括耐磨层，其位于由Ni、Cr、Mo和/或Cr3C2制成的载体材料上；由AlFeCu制成的磨合层；其中过渡层设置在耐磨层上，即耐磨层和磨合层之间。
现在已经发现，以这种方式涂覆的载体材料，特别是活塞环，在从磨合层到耐磨层的过渡过程中具有改进的机械强度。在根据本申请的涂层的情况下，由于“软”材料转变，可以进一步观察到整体改善的摩擦性能。同样有利的是，不出现稳定时间，并且在制造过程中，例如在多层涂层的热喷涂过程中，可以减少所需的材料量。
在一示例性实施例中，活塞环包括耐磨层，其成分为52-62重量％的钼、12-22重量％的铬、0.5-2重量％的碳和12-20重量％的镍以及不可避免的杂质。组分Mo、Cr、C和Ni以及不可避免的杂质在耐磨层的组成中加起来达到100重量％。
在活塞环的另一示例性实施例的情况下，磨合层包括5-7重量％的铝、1-3重量％的铁，其中100％的剩余部分由铜和不可避免的杂质形成。
活塞环优选包括具有40-60％的AlFeCu和60-40％的Ni、Cr、Mo和/或Cr3C2的过渡层。由此观察到良好的过渡行为。
活塞环优选具有过渡层，该过渡层由均匀分布的熔融粉末颗粒(称为飞溅物)形成。
颗粒尺寸为5-70μm的粉末材料优选用于在过渡层中获得均匀的飞溅结构。颗粒尺寸为5-70μm的粉末材料用于在过渡层中获得10-150μm的均匀飞溅结构。因此，飞溅尺寸或飞溅结构分别是指在活塞环的工作表面的平面内或与工作表面相切的平面内的单个飞溅物的平均直径。
根据前述权利要求之一所述的活塞环，其中使用粒度为5-70μm的粉末材料在过渡层(8、24)中获得10-150μm的均匀飞溅结构。
过渡层在表面上的表面分布为约50-75％的CrCNiC+Mo和50％-25％的AlCuFe，优选约45-55％的CrCNiC+Mo和55-45％的AlCuFe。
过渡层优选通过等离子涂覆形成。过渡层优选地通过等离子喷涂来产生。
过渡层的厚度优选在50μm和250μm之间，特别优选在100-180μm之间。
所用AlCuFe材料的显微硬度优选在150-300HV0.05之间。
Mo的显微硬度优选在300-720HV0.05之间。
CrC-NiCr的显微硬度优选在300-1200HV0.05之间。
优选在载体材料或基材与耐磨层之间分别形成粘附促进层或粘附层。
根据本申请的用于制造活塞环的方法包括以下步骤：
(b)将由Ni、Cr、Mo和/或Cr3C2制成的耐磨层施加到载体材料上；
(c)将过渡层施加到耐磨层；和
(d)向过渡层施加由AlFeCu制成的磨合层，
其中，在施加耐磨层之前，所述方法可以优选地包括：
(a)将粘合剂层施加到载体材料上。
层(b)至(d)或(a)至(d)的施加优选通过选自等离子喷涂、HVOF涂布(高速氧燃料喷涂)、电弧喷涂或这些方法的组合的方法进行。
首先，优选将粘附促进层施加到载体材料上。
因此，过渡层优选地以一定比例的耐磨层材料和一定比例磨合层材料为特征。
附图说明
本申请将基于微切片的形式在图中示出。
图1示出了根据本申请的层结构的入射光显微图像。
图2A和2B分别示出了以100倍或200倍数放大的根据本申请的层结构的入射光显微图像。
图3示出了没有过渡层的层结构的横截面抛光。
图4示出了去除磨合层后的运行表面的俯视图。
图5示出了具有过渡层的层结构的横截面抛光。
图6示出了磨合过程后运行表面的俯视图。
具体实施方式
以下将使用说明书中以及附图中相同或相似的附图标记，以指代相同或相似的元件和部件。
图1示出了根据本申请的层结构的入射光显微图像。由此，最下层由Mo基材料制成的耐磨层6形成。过渡层8设置在耐磨层6上，过渡层8又被磨合层10覆盖。
图2A和2B分别示出了放大100倍(图2A)或200倍(图2B)的本申请层结构的入射光显微图像。在由灰铸铁2制成的基底材料上施加粘附层4，该粘附层4实现耐磨层6在由灰铸钢2制成的基材上的最佳粘附。过渡层8被施加到耐磨层6上，并且由AlCuFe制成的磨合层被施加到过渡层8上。过渡层8位于由Mo基材料制成的耐磨层和由AlCuFe制成的磨合层10之间。
以下实例用于描述本申请，而不限制本申请。
在本申请中体现了耐磨层和磨合层之间具有附加过渡层的过渡。该过渡层由磨合层材料(AlFeCu)和耐磨层材料(Ni、Cr、Mo、Cr3C2)的材料混合物(体积百分比约为40％-60％:60％-40％)组成。
过渡层被施加在耐磨层的施加和磨合层的施加之间。过渡层的厚度在50μm至250μm之间。过渡层通过等离子涂覆的方式施加。由于系统的工艺控制，过渡层被具体化为不同材料组分均匀地层状分布，见图1和图2。熔融粉末颗粒以飞溅状的方式分离并均匀分布。90％的飞溅物直径为10μm至150μm。过渡层的结构是通过两种粉末尺寸的均匀粒度分布形成的。为了在过渡层中获得均匀的飞溅结构，使用粒度为5-70μm的粉末材料。
可用结构的特征在于表面分布为50-70％的CrCNiC+Mo和25-50％的AlCuFe，优选50％的CrCNiC+Mo和50％的AlCu Fe。因此，表面分布将平行于微截面或与过渡层相切。因此，飞溅物形成平坦的斑点或斑块，与它们的横向扩展相比，这些斑点或斑块相对平坦。在微切片的情况下，飞溅形成例如双色调的伪装图案。因此，飞溅物的表面分布基本上对应于薄截面的耐磨层CrCNiC+Mo和磨合层AlCuFe的材料的表面比率。
过渡层的宏观层硬度(HVI)介于200-400HVI之间。层组分的显微硬度为：
AlCuFe：150-300HV0.05；
钼：300-720HV0.05，以及
CrC-NiCr：300-1200HV0.05。
此外，过渡层的特征还在于运行表面孔隙度为2-8％。由软(AlCuFe)和硬(Ni、Cr、Mo、Cr3C2)材料颗粒组成的过渡层的均匀、精细分布结构改善了层变化后的摩擦性能，即去除纯AlCuFe磨合层。通过过渡层，更“平缓地”实现了纯磨合层和纯耐磨层之间的过渡。当层厚为50μm至250μm时，在环周(不同磨损率)和环的轴向高度上进一步实现了均匀磨合。由此显著提高了防止烧伤痕迹和擦伤形成的强度或抵抗力。
图3示出了没有过渡层的层结构的横截面抛光。横截面抛光示出了施加到基底20上的Mo/CrC/Ni/Cr耐磨层22。通过形成过渡区域25将AlCuFe过渡层26施加到其上。过渡区域25由耐磨层22的粗糙度限定，其中图3中的过渡区域25的厚度为10-40μm。过渡区域25不是作为单独的层形成的，而是当磨合层26被喷涂到耐磨层22的粗糙喷涂表面上时产生的。磨合层26的颗粒/飞溅物填充了耐磨层的表面不均匀，这导致了过渡区域25。在耐磨层22和磨合层26之间的单独的、非光滑的、但简单的粘性接触表面形成过渡区域25。
图4示出了去除磨合层26后的运行表面40的俯视图。在去除磨合层26之后，磨合层26的AlCuFe区域和耐磨层22的Mo/CrC/Ni/Cr区域在过渡区域25中彼此相邻。在图4中，过渡区域25由耐磨层22的粗糙度限定，此处为10-40μm。在过渡区域25的俯视图中可以清晰地看到磨合层26和耐磨层22的区或区域的不规则分布。在过渡区域25中，耐磨层22的飞溅物仅位于耐磨层22进一步的飞溅物上。磨合层26的材料的第一层飞溅物覆盖耐磨层22，并且所有其他飞溅物形成纯且基本同质的磨合层。在过渡区域中，没有耐磨层22的飞溅物位于磨合层26的材料的飞溅物之上。在去除磨合层的过程中，耐磨层22的材料的较大粘结区域出现在过渡区域25的区域中，紧邻着磨合层26的材料的较大粘结区域。
根据运行表面轮廓的凸度，相对较软的磨合层26在轴向环高度以上以不同的速度和不同的程度被去除。硬质耐磨材料的突然增加，增加了热过载的趋势/可能性。热过载会导致层撕裂，这会导致耐磨层的失效以及脱落。
图5示出了另一层结构的横截面抛光。Mo/CrC/Ni/Cr耐磨层22被施加到基底20上。将混合比为50∶50重量％的Mo/CrC/Ni/Cr+AlFeCu过渡层24施加到耐磨层22上，过渡层厚度为140-160μm。在过渡层24上方设置AlFeCu过渡层26。
图6示出了磨合过程后的运行表面的俯视图，在磨合过程中，图5的过渡层24被暴露。在图6中，AlFeCu磨合层26被分别完全去除或磨损。过渡层24位于活塞环的整个轴向高度之上。分别存在均匀分布的软AlFeCu颗粒(40)或“飞溅物”，以及硬MoCrCNiCr颗粒(42)或“飞溅物”。飞溅物的尺寸分布范围为50至100μm。与在耐磨层上的磨合层的传统组合相比，获得了更好、更长期(由过渡层24的层厚度限定)和更均匀的磨合过程结果，并且在通过磨合层之后获得了摩擦改善。在过渡层24的区域中，耐磨层22的材料飞溅物位于磨合层26的材料飞溅物的旁边/下方和上方，因为该过渡层24是在注射过程中注射的，在注射过程期间使用两种材料。由于过渡层24，在磨合层和耐磨层22之间没有清晰的边界表面，并且抛光部分在小的点处看起来是非粘性的。
附图标记
2基体灰铸铁
4粘合剂层
6钼基材料制成的耐磨层
8过渡层
10磨合层
20基材或活塞环材料
22耐磨层
24过渡层
25过渡区域
26由AlFeCu制成的磨合层
40AlFeCu颗粒或飞溅物
42Mo/CrC/Ni/Cr颗粒或飞溅物

Claims (15)

1.一种活塞环，包括：
耐磨层(6、22)，位于由Ni、Cr、Mo和/或Cr3C2制成的基底上；
磨合层(10、26)，由AlFeCu制成；
其特征在于，
过渡层(8、24)设置在所述耐磨层(6、22)上，即在所述耐磨层(6、22)和所述磨合层(10、26)之间。
2.根据权利要求1所述的活塞环，其中所述耐磨层(6、22)具有如下成分：
Mo：52–62重量％
Cr：12–22重量％
C：0.5–2重量％
Ni：12–20重量％，
其中所述成分Mo、Cr、C和Ni以及不可避免的杂质在所述耐磨层中加起来为100重量％。
3.根据权利要求1或2所述的活塞环，其中所述磨合层具有以下成分：
Al：5-7重量％
Fe:1-3重量％
100重量％的剩余为Cu和不可避免的杂质。
4.根据权利要求1、2或3所述的活塞环，其中所述过渡层(8、24)具有40-60％的AlFeCu和60-40％的Ni、Cr、Mo和/或Cr3C2。
5.根据权利要求1、2、3或44所述的活塞环，其中所述过渡层由熔融粉末颗粒形成，所述熔融粉末颗粒以飞溅状方式分离并均匀分布。
6.根据前述权利要求之一所述的活塞环，其中使用粒径为5-70μm的粉末材料在所述过渡层(8、24)中获得10μm-150μm的均匀飞溅结构。
7.根据前述权利要求之一所述的活塞环，其中所述过渡层(8、24)在表面上的表面分布为约50-75％的CrCNiC+Mo和50％-25％的AlCuFe，优选约45-55％的CrCNiC+Mo和55-45％的AlCuFe。
8.根据前述权利要求之一所述的活塞环，其中所述过渡层由等离子涂层形成。
9.根据前述权利要求之一所述的活塞环，其中所述过渡层的厚度在50μm和250μm之间，优选在100μm和180μm之间。
10.根据前述权利要求之一所述的活塞环，其中所述AlCuFe材料的显微硬度在150-300HV0.05之间。
11.根据前述权利要求之一所述的活塞环，其中所述Mo材料的显微硬度在300-720HV0.05之间。
12.根据前述权利要求之一所述的活塞环，其中所述CrC-NiCr材料的显微硬度在300-1200HV0.05之间。
13.根据前述权利要求之一所述的活塞环，其中粘合剂层位于所述基底和所述耐磨层之间。
14.一种生产活塞环的方法，包括以下步骤：
(b)施加由Ni、Cr、Mo和/或Cr3C2制成的耐磨层；
(c)将过渡层施加到所述耐磨层；和
(d)向所述过渡层施加由AlFeCu制成的磨合层，
其中，在步骤(b)中施加所述耐磨层之前，所述方法优选包括将由NiCrAl制成的粘合剂层施加到基底的步骤(a)。
15.根据权利要求14所述的方法，其中层(b)至(d)或(a)至(d)的施加通过选自等离子喷涂、HVOF涂布和电弧喷涂的方法或这些方法的组合进行。
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