CN1336969A - 一种保护薄层的生成方法及具有至少一件有一保护薄层的构件的机器 - Google Patents

一种保护薄层的生成方法及具有至少一件有一保护薄层的构件的机器 Download PDF

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CN1336969A
CN1336969A CN00802765A CN00802765A CN1336969A CN 1336969 A CN1336969 A CN 1336969A CN 00802765 A CN00802765 A CN 00802765A CN 00802765 A CN00802765 A CN 00802765A CN 1336969 A CN1336969 A CN 1336969A
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L·莫祖尔斯基
E·B·安德森
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MAN Energy Solutions Filial af MAN Energy Solutions SE
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Abstract

本发明涉及在铸铁作为基材制成的构件表面上生成保护薄层的方法,该保护层具有一较软的覆盖层(9),及其下面很硬的和耐磨的支撑层(8),通过本发明的方法,得到一种简单的生产方法和比较大硬度的支撑层,这样就可在由铸铁制成的基材上熔化上一铝青铜制的由至少二层保护薄层形成的层结构(7)。

Description

一种保护薄层的生成方法及具有 至少一件有一保护薄层的构件的机器
根据第一个发明构思，本发明涉及在铸铁作为基材制成的构件表面上生成保护薄层的方法，该保护薄层具有一层较软的覆盖层，及其下面很硬的和耐磨的支撑层。
从JP6-105102B2中可获悉一种活塞冲程一内燃机器，该机器中的气缸移动面一侧具有波浪形轮廓，在此波浪形轮廓的凸出部位要形成一个硬化了的区域，为了改善其移动性能，该区域具有一层二硫化钼镀层。这二硫化钼外镀层形成了一个移动层，该移动层已经在移动过程中磨损掉了。然后硬化了的区域起支撑区域的作用。通过一个硬化过程所获得的硬化深度是比较浅的。此外，通过硬化过程所获得的硬化度也是比较小的。此外，硬化和后接的二硫化钼镀层过程证明是非常麻烦的和昂贵的。
所以本发明的任务是，建立本文开始时所提到的一种方法，该方法以简单的方式而使得生成一比较软的覆盖层和一比较硬的支撑层成为可能。
按照该种方法，这个任务以如下令人惊奇的简单方式解决，即至少一个由二层保护薄层形成的，由铝青铜制成的层结构被熔化到由铸铁制成的基材上。
优选通过将熔化了的铝青铜焊接到铸铁上的方法，令人惊奇地证实，靠近铸铁的区域比远离铸铁的区域硬得多。这样就自动得到靠近基材的较硬的支撑层和离基材远的较软的覆盖层，该覆盖层能多次用作为移动层，该移动层在移动过程中自我磨损掉，结果是下面的支撑层用于支撑。通过试验，在外层覆盖层区域产生了所预期的铝青铜的硬度和颜色。下面的靠近铸铁的支撑层能具有比外层硬得多的硬度。因为根据这样的发明，能同时生成软的覆盖层和硬的支撑层，所以也保证了该方法有高的和优越的经济性。
上述方法的优点将在后面的权利要求书中进一步给出。如果在二层保护薄层形成的层结构熔化之前，预热基材证明是特别实用的。这样能增加硬支撑层的厚度。
对将要应用的铝青铜，对于其成分要与个别情况的需求相适应。如果要得到一个特别软的覆盖层，下碳的铝青铜被证实是特别实用的，即含有8％-11％的铝，4％-6％的镍，3％-5％的铁，1％-2％的锰和余量为铜的铝青铜。如果想得到较硬的覆盖层，可以有目的的应用如下的铝青铜，即含有13～16％的铝，4％-5％的铁，0.2％-0.8％的硅，1％-2％的锰，碳的最高含量为0.2％和余量为铜的铝青铜。
根据进一步的发明构思，所提出的发明涉及一种机器，该机器具有至少一件由铸铁制成的构件，在构件表面有比较软的移动层，以及在移动层下面的较硬的支撑层。
与此相关的本发明任务是，以简单的和经济的方法，使这种构件的支撑层能达到较大的硬度。
这个任务按照发明将如下解决，即为了形成移动层和支撑层，构件具有至少一个由铸铁制成的基材上由铝青铜熔化制成的层结构。
比较大的硬度优先保证了长的使用寿命。因为支撑层和混动层能在一个工序中同时制成，所以就有一个极好的经济价值。
下面所附的图更清楚地解释了发明的实施例：
图1一个二冲程大柴油发动机的部分侧面剖面图；
图2一个根据图1中的二冲程大柴油发动机所具有的保护薄层的片段放大图。
所提出的发明可应用于如下所有的地方，即具有层状、蠕虫状或球状石墨的铸铁，特别是灰口铸铁制成的构件表面上需要保护薄层的地方，该保护薄层具有较软的外层覆盖层，覆盖层下面有一个很硬的支撑层。例如这些构件可以是发动机的各种部件，如活塞、活塞环、活塞环槽，活塞，活塞外套，汽缸移动面等等。因为这些部件需要一个软的外层移动层，该移动层在移动过程中磨损掉，和一个较硬的内层支撑层，其可以在接着的移动过程中作为支撑件，而且具有长的使用寿命。
根据图1所示的二冲程大柴油发动机的汽缸有一个在图中没有画出的具有开口槽的套筒1，在该套筒里插入一个没具体画出的可拆卸安置的气缸头。汽缸套筒1的内侧是以一个移动层构成的，一个具有在活塞环槽2内安置了活塞环3的活塞4与汽缸套筒共同协同工作。汽缸套筒1，活塞4和活塞环3由铸铁、通常是灰口铸铁制成，灰口铸铁含有层状，蠕虫状或球状石墨。在汽缸套筒1的移动面，活塞环3的周围表面和活塞环槽2的侧面区域，在所举的例子中每个部件具有一保护薄层5，当所用的基材为铸铁时，有较好的支撑性能，而且相应地延长了使用寿命。
当然，这样一种保护薄层也可以安置到另外的具有类似的负重行为的构件上，例如对于二冲程大柴油发动机来说，有十字头轴承和十字头导向器。
如最好从图2可获知的那样，保护薄层5是通过在基材6上有目的地焊接上熔化了的铝青铜层结构7而形成的。这样，以令人惊奇的方式产生了二层保护层8、9，在图2中用虚线表示。在此，离基材远的外层9由于应用了铝青铜而具有被期望的颜色和硬度。这个外层覆盖层相应地是比较软的，所以适合于作为移动层，该移动层在移动过程中自我磨损掉。离基材近的内层8具有相对于外层比较大的硬度，所以能起到作为耐磨支撑层的作用，当移动层磨损掉后，该层就用于支撑。
铝青铜通常具有200HV的硬度，对保护层的铝青铜的试验得出，外层有预期的200HV硬度，而在内层有四倍高的硬度，即800HV。层结构7所含的二层保护层8、9的厚度大约为2.5mm，其中，硬的内支撑层的厚度为大约1.5mm，软的外覆盖层的厚度为大约1mm。通过预热基材6到大约400℃，能够增大硬支撑层的宽度。
作为生成层结构7的材料能应用一种铝青铜，该铝青铜含有8％～25％的铝，及下列成分：锑、钴、铍、铬、锡、锰、硅、镉、锌、铁、镍、铅、碳和铁中的至少一个元素，其含量各为0.2％～10％，余量为铜。如果要得到较软的覆盖层，就要用含铝8％～11％，镍4％～6％，铁3％～5％，锰1％～2％，余量为铜的铝青铜。应用这样一种铝青铜，外覆盖层9区域的硬度大约为200HV。一种这样的铝青铜是以上述例子作为依据。在有些情况下，外覆盖层可能有较大的硬度。这儿有一种铝青铜证明是实用的，该铝青铜含有13％～16％铝，4％～5％铁，0.2％～0.8％硅，1％～2％锰，最高含量为0.2％的铈，铜为余量。用这种铝青铜，覆盖层9的硬度可达到350HV。内支撑层8的硬度无论如何都要比外覆盖层9的硬度大得多。这儿其硬度可达到900HV。
由铝青铜制成的层结构7，如上所述，能够通过焊接过程而熔化到基材上。在此，能应用电弧或火花或激光照射而进行焊接熔化过程。
进一步的试验表明，也可以产生多个层结构，尤其是上下重叠的二个层结构，而在此，层结构的硬度水平随着离开基材越远而越大，即外层的硬度水平大于下面内层的硬度。这个事实通过由相同的铝青铜的二个层结构的实验所确认，即用含有13％～16％的铝，4％～5％的铁，0.2～0.8％的硅，1％～2％的锰，小于0.2％的碳，余量为铜的铝青铜进行试验，结果表明，第一个层结构的上层区域的硬度可至大约400HV，第二层结构的外层区域的硬度可达到600HV。

Claims (10)

1.产生一种保护薄层的方法，该保护薄层有一层为较软的覆盖层，位于下面的是一层硬得多的耐磨的支撑层，该支撑层就在作为所要生产的构件的铸铁基材表面上，其特征在于，在铸铁构成的基材(6)上至少有一个由铝青铜熔化形成的具有二层保护薄层的层结构(7)。
2.根据权利要求1的方法，其特征在于，层结构(7)熔化之前，基材要预热。
3.根据权利要求2的方法，其特征在于，基材要预热到大约400℃温度。
4.根据上述权利要求之一的方法，其特征在于，可以生成多个、特别是两个互相重叠的层结构。
5.根据上述权利要求之一的方法，其特征在于，为了形成至少一个层结构(7)，应用这种铝青铜，该铝青铜含有8％～25％的铝和成分锑、钴、铍、铬、锡、锰、硅、镉、锌、铁、镍、铅、碳和铁中至少一种元素，其含量各为0.2％～10％，余量为铜。
6.根据权利要求5的方法，其特征在于，为了形成至少一个层结构(7)，以及在层结构中形成一较软的覆盖层(9)，应用这种铝青铜，该铝青铜含有8％～11％的铝，4％～6％的镍，3％～5％的铁，1％～2％的锰，余量为铜。
7.根据权利要求5的方法，其特征在于，为了形成至少一个层结构(7)，以及在层结构中形成一较硬的覆盖层(9)，应用这种铝青铜，该铝青铜含有13～16％的铝，4％～5％的铁，0.2％～0.8％的硅，1％～2％的锰，小于0.2％的碳，余量为铜。
8.根据上述权利要求之一的方法，其特征在于，二层保护薄层所形成的层结构(7)具有2-3毫米的厚度，最好是2.5毫米。
9.根据上述权利要求之一的方法，其特征在于，基材是由含石墨的铸铁制成，在该基材上至少有一个镀有铝青铜的二层保护薄层形成的层结构。
10.具有至少一件铸铁制成的构件的机器，特别是活塞往复式机器，铸铁最好是含有层状、蠕虫状、或球状石墨，在构件表面具有一较软的、在移动过程中逐渐磨损掉的移动层(9)，和其下面的硬得多的、耐磨的支撑层(8)，其特征在于，为了形成移动层(9)和支撑层(8)，构件具有至少一个在铸铁制成的基材上由铝青铜熔化制成的层结构(7)。
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