DE3590587T1 - Deployment method, deployment device, deployment item - Google Patents

Description

Description of deployment method, deployment device, deployment item

The present invention relates to the insertion in which an aluminum alloy, an FRM, steel, a Ti alloy, a Ni alloy, a Co alloy or the like is used in an aluminum alloy.

Aluminum alloy castings have the advantage that they are easily melted and for permanent mold casting, forging Metal as well as low pressure casting are usable and have high productivity. However, because they have lower strength have, their wear resistance and the like. Inferior to that of cast iron, and their application range is limited.

In view of this situation, a high strength material such as an iron-based material on a Used in the area of an aluminum alloy casting that requires high strength. When simply inserting, if z. B. an iron-based material incorporated into an aluminum alloy. is, remains on the border between Iron and aluminum alloy a non-welded area.

Since the boundary between iron and aluminum alloy remains unwelded, the strength of a product is sufficient of inserting.

As a method of avoiding such unwelded areas and diffusion welding the iron-aluminum boundary to achieve, the alphine treatment is known. However, alphine treatment does require one great labor input and increases the cost and weight of the resulting material.

According to the present invention, an insert made of a material such as aluminum alloy, FRM, steel, a Ti alloy, a Ni alloy, a Co alloy

tion or the like, subjected to a pretreatment, for example rinsing with water, degreasing, pickling, Drying and the like. Thereafter, the insert is immersed in a plating bath and coated while vibrates a vibrating plate located near the insert in the coating bath is. The insert is then transferred to an insert receiver, e.g. B. one made of an aluminum alloy Insert pick-up inserted.

The plating bath is vibrated to remove the surface oxide of the insert and a to form a uniform coating layer. The insert is placed in an insert transducer, ζ.Β. an aluminum alloy inserted with the coating layer between them. Next are the mission and mission acceptors completely welded together and a diffusion weld area formed between the two materials.

The material of the insert and the insert receiver are firmly connected to one another, and it can be an insert item of satisfactory strength. Because the coating bath only vibrates must be, the manufacturing process is simple and the cost is low.

Fig. 1 is a sectional view of a pull-up device used in Example 1 of the present invention;

Figure 2 shows a tapered shaft made by the method of Example 1;

3 is a photomicrograph (x 100) of a boundary between the insert and insert receptor of a insert manufactured by the method according to Example 1 of the present invention;

Figure 4 is a photomicrograph (x 100) of a boundary between the insert and the insert receiver

an object of a comparative example, obtained by inserting an insert into an insert receiver without overcoating the former (the item corresponds to the one that has not been preheated Area without treatment for the comparative example in the table);

5 is a photomicrograph (× 100) of a boundary area between a piston main body 13 and a wear ring 12 of a piston of Example 2;

Fig. 6 is a sectional view of a mold 19 in the example 5;

Fig. 7 is a photomicrograph (x 100) of a boundary area between steel wire 14 and aluminum alloy 20 of test piece No. 4 in Example 5;

Fig. 8 is a photomicrograph (x 100) of a boundary area between steel wire 14 and aluminum alloy 20 of test piece No. 6 in Example 5;

Fig. 9 is a sectional view of a motor connecting rod in Example 5;

Fig. 10 is a perspective view of the cam member 18 in Example 6;

Fig. 11 is a sectional view of a camshaft in Example 6;

Fig. 12 is a sectional view of a piston in Example 7;

Fig. 13 is a sectional view of a cylinder head in example 4;

Fig. 14 is a sectional view of an engine having a cylinder head of Example 8; and

15 is a front view of a rocker arm of an indoor motor according to the present invention.

The invention will now be described by means of its examples.

example 1

A JISA2024S aluminum alloy insert is prepared.

The insert is subjected to cleaning / drying, i. H. a pretreatment in the order of rinsing with water, degreasing, rinsing with water, pickling, rinsing with water and drying by means of a pretreatment device .

Then the coating takes place in a coating device 1 shown in FIG.

The coating device 1 consists of a soft solder melting furnace 2 and an ultrasonic wave vibrator 3. The furnace 2 consists of a solder container 5, which has a plating or coating bath 4 on its upper part contains, and arranged below the container 5 heating area (heating coil) 6 for heating the same. One of vibration plates 8, which branch out in a Y-shape, is on a vibration arm 7 of the vibration generator 3 while the other plate 8 is immersed in the coating bath 4 in the container 5. Between two vibrating plates 8 is inserted feed 9 and is due to the surface tension of the coating bath with a gap of 1.0 mm with respect to the two Plates 8 arranged.

The insert 9 is coated under the following conditions:

1. Composition of the coating bath: Molten aluminum solder (eutectic Zn-5A1 alloy (95% Zn - 5% Al); Melting point = 380 ° C).

2. Ultrasonic vibration conditions: 18 kHz vibration frequency, 20 μπι amplitude, 2 to 3 seconds application time.

3. Temperature of the coating bath: 400 to 420 ° C.

4. Thickness of the coating film: 50 | in.

5. Duration of the coating: 7 minutes.

The Zn-5A alloy coated insert 9 is placed in a mold of a casting device (not shown). Molten AC4B aluminum alloy is used as a single

rate receiver poured by gravity, whereby the The tapered shaft 10 shown in Fig. 2 is formed. The tapered shaft 10 consists of an AC4B main body 11 and the insert 9.

Comparative example

Insert materials were molded from JISA2024S material and one untreated Zn plating, Sn plating, Kanigen plating and plating with molten aluminum solder exposed. After that everyone became Material used in an AC4B aluminum alloy to produce a tapered shaft (similar to Example 1).

The sealing performance and the presence / absence of feed loss in Example 1 and in Comparative example checked. The results obtained are shown in Table 1.

Table 1

Type of Preheating Result X Present O Surface temperature his / her absence chenbe (*) of Δ sness X plot Use Sweat too X of a O was standing loss of records Δ X χ ο (no ver O desire) X here none room (partial come temperature χ (not ver liches 300 ° C ver welds) Ver Ashes) fah (partly ren se ver & O Zn over- room welds) draw temperature 300 ° C Sn over room draw temperature 300 ° C Kanigen- room Overlay temperature
300 * C ο O Overlay with ge melted Al-Lot (ul room trasound temperature do not wave invented created) manic according to Ultrasonic ses wave ang Ver lays fah Overlay room ren with ge temperature melted Al.

(*) The effect obtained was tested when the insert was heated to 300 ° C for the welding performance to improve. Loss of use occurs when heated to 300 ° C. With the conventional method, the welding performance is unsatisfactory even in this state.

As can be seen from this table, Example 1 gives better results than the comparative example, and it

no loss of bet will be suffered.

When comparing a microphotograph of χ 100 (Fig. 3) of a structure at the border between Insert 9 and main body 11 in Example 1 and one Photomicrograph of χ 100 (Fig. 4) of the boundary between the insert and the main body in the comparative example, which was obtained without treatment and without preheating does not become a non-welded area between the Insert and the main body observed in Example 1, while a non-welded area between the two Materials in the comparative example is present. Therefore, the products of the comparative example appear to have low strength.

The insert is subjected to ultrasonic vibration while welding is carried out with molten aluminum is to thereby remove the oxide layer formed on the surface of the insert and a to form a uniform eutectic layer of aluminum-aluminum solder. The eutectic layer has a low one Melting point, easily melts in a bath of molten aluminum alloy as an insert receiver and mixed with the same.

Example 2

A wear-resistant ring of a piston for a diesel engine was prepared as an insert. Following the same procedures as in Example 1, Zn-5A1 solder was obtained melted and used to coat the ring. The coated ring was placed in a mold and AC8A aluminum alloy as an insert receiver is injected into the mold to form a piston. The casting temperature was 700 ° C. DSr wear-resistant ring was made of ADC10 aluminum alloy in which a Si-N powder is dispersed was. A photomicrograph (x 100; Fig. 5) of a structure at a boundary between the wear ring 12 and the AC8A aluminum alloy cast main body 13 of the piston reveals that no unwelded Area between the wear ring 12 and

the main body 13 of the piston remains, and that the both materials are completely welded.

Example 3

A cylinder liner made of ADCIO aluminum alloy was used, in which Si ^ N powder was dispersed, prepared and using Zn-5A1 alloy such as in example 1 coated with aluminum alloy solder. The obtained cylinder liner was placed in a mold and molten aluminum alloy injected into the mold around a main body of a cylinder block to cast and thereby obtain a cylinder block in which the cylinder block is inserted into the main body of the cylinder block is used.

The boundary between the main body of the cylinder block and the cylinder liner was completely welded.

Example 4

Made of a FRM with great thermal fatigue strength (i.e., containing long carbon fibers and JISA6061 aluminum alloy as matrix) a ceiling member was prepared, which has a fireproof combustion chamber wall should form a cylinder head. Next, following the same procedural steps as In Example 1, the ceiling member coated with aluminum alloy solder and the coated ceiling member in a Given shape. As an insert receiver, an aluminum alloy was injected into the mold around a cylinder main body to pour. Thus, as shown in Fig. 13, a ceiling member 32 has been incorporated into a main body 31 of a cylinder head used to complete the cylinder head 3 3.

In this case, there was no unwelded area between the ceiling member and the main body of the cylinder head observed, and the two materials were completely welded together.

Example 5

There were wires made of SUS6 30 steel and MASIC steel with pretreated to a diameter of 3.0 mm. Then each wire was covered with aluminum solder, including Almit AM3501 was used as JISZ3281 aluminum solder. After preheating each wire 14 to 300 ° C., it was placed in the Mold 19 shown in Fig. 6 was given, and AC4B aluminum alloy 20 kept at 700 ° C was used in preparation a casting is injected into the mold as an insert receiver. Reference numeral 21 denotes a support frame for holding the steel wire 14 in the mold 19. Each casting became a JIS tensile test piece (No. 4) 15 cut out (indicated in Fig. 6 by a dashed line with alternating two long and one short dash). The wire 14 served as the center, and each test piece was subjected to a tensile strength test. Each tensile strength test piece 15 had a size of 7 (diameter) χ 32 mm in a parallel portion the same (marked distance: 2 5 mm). About the influence of the clamping on the insert transducer during the tensile strength test off, had a clamping area of the same thread of M12 and P1.5.

The coating conditions and tensile test results are shown in Table 2 below.

Table 2

Preparation conditions for operational test piece, and tensile test results

No. Casting preparation conditions mission
material Stall condition Treatment
temperature
χ time ultrasonic
wave application
conditional
gung _; Solder layer
thickness no coating (comparative example) 500 ° C
χ 5 min '. 18 kHz,
20 µm Ampli
tude,
5 s 100 um no coating (comparative example) Tensile test results fracture
Status * SUS304 material 500 ° C
χ 5 min. 18 kHz,
20 \ in the Ampli
tude,
5 s 100 um Almit
AM350 500 ° C
χ 10 min. Steel and al.
both ge
broke 1 Almit
AM350 * 500 ° C
χ 10 min. Tensile strength
speed
kg / mm ² 2 38.0 only Al.
Broken 3 MASIC-
steel 37.2 Steel and al.
both ge
broke 4th 20.5 5 53.2 only Al.
Broken 6th 52.5 20.3

* 1 "Almit-AM3501: product of Nihon Almit K.K., Al solder: 95% Zn, 5% Al

* 2 "MASIC steel 1: Product of DAIDO STEEL CO., LTD., High-strength steel (tensile strength

kg / mm ² or more) C: 0.03% or less, Si: 0.1% or less, Mn: 0.1% or
less, Ni: 18.5%, Mo: 4.8%, Co: 9.0%, Ti: 0.6%, Al: 0.1%, Fe: balance

The test results reveal that a uniform coating layer can be obtained when an insert receiver iron-based is coated with aluminum solder under ultrasonic vibrations and that with such uniform coating layer the insert and the insert receiver (AC4B) are completely welded together at their boundary are, as can be seen from the χ 100 microphotograph of the structure in FIG. Be it it should be noted that FIG. 7 corresponds to test piece No. 4 in Table 2.

In the test piece of the comparative example (test piece No. 6), which is not subjected to ultrasonic vibration many non-welded areas remained in the boundary between the insert and the insert receiver, as can be seen from the photomicrograph (× 100) in FIG.

Example 5

Under the same conditions as in the test piece No. 4 in Example 4, wire 16 was made of MASIC steel with a Diameter of 4.0 mm subjected to a coating with aluminum solder. After the wire has been preheated to 30 0 ° C it was put in a mold and cast ADC10 aluminum alloy by the non-porous injection molding process, whereby a connecting rod 17 for an automobile engine as shown in FIG. 9 was formed. The emerging Tie rod 17 showed about a 50% improvement in strength compared to that at a similar wire was not used in MASIC steel. The MASIC steel and ADC10 material were through the aluminum solder completely welded together.

Example 6

Cam members 18 for an internal motor shown in Fig. 10 were formed by means of a sintered iron-based alloy manufactured. The sides and inner peripheral surfaces of the cam members 18 became the same

■ ψ "'

Process steps pretreated as in Example 1 and covered. After the curve members 18 coated with aluminum solder were preheated to 300 ° C., they were placed in a mold to cast a camshaft of an internal engine ^ and ADC10 aluminum alloy was after The injection molding process is injected into the mold and cast, whereby the cam members 18 on the shaft 19 as shown in FIG.

The cam members 18 and the shaft 19 were completely welded together by the aluminum solder.

Example 7

It became a wear-resistant ring 21 for a diesel engine made of Ni-resist cast iron coated with aluminum solder in the same way as test piece No. 4 in Example 5. After the wear-resistant ring was preheated to 300 ° C, it was placed in a mold and made of ADC10 aluminum alloy is injected by gravity molding to form the diesel engine piston 22 shown in FIG.

The wear-resistant ring and the ADC1O aluminum alloy were completely welded together by the aluminum solder.

Example 8

A cylinder liner was made with ADC1O aluminum alloy, in which a Si_Ni. powder was dispersed, molded. The cylinder liner was pretreated in the same process steps as in Example 1 and with pure Zinc coated under ultrasonic vibration. The stall conditions were as follows:

1. Composition of the coating bath: pure zinc

2. Temperature of the coating bath: 440-450 ° C

3. Thickness of the coating film: 50 μm

4. Ultrasonic vibration conditions: 18 kHz vibration frequency, 20 \ xm amplitude, two seconds application time.

. If

I l / 'ι:' - "'" ~ r "> 3 5 9 O 5 8

The zinc-plated cylinder liner was inserted into a mold and molten aluminum alloy (ADC1O alloy) injected into the mold to create a cylinder block 35 into which the cylinder liner 34 was inserted, as shown in FIG.

The boundary between the cylinder liner and the cylinder block was completely welded.

Example 9

As in Example 6, cams for an internal motor were prepared from a sintered iron-based alloy. The curve members were pretreated following the same procedures as in Example 8 and then coated with pure zinc. After the cam members were preheated to 300 ° C, they were in a Given shape and injection molded ADC10 aluminum alloy injected to cast a camshaft into which the cam links were inserted.

When checking the boundary between the cam elements and the camshaft, the two materials were completely welded.

The temperature of the zinc plating bath was 500 ° C, the Coating time five minutes and the application of ultrasonic vibration five seconds.

In the examples described above, the frequency of the ultrasonic vibration is 18 kHz. According to the present However, the invention can set the frequency of the ultrasonic vibration within a range of 1 to 1000 kHz and preferably 1 to 100 kHz. If the frequency of the ultrasonic oscillation is below 1 kHz, then the number of repetitions within a unit of time is small. The one on the surface of the material to be coated formed oxide film cannot be removed. Complete coating cannot be carried out

the. The coating layer is easy to peel off and it a uniform coating layer cannot be formed. If the frequency of the ultrasonic vibration exceeds 1000 kHz, the coating bath of the vibration may fail Do not follow the vibration plate, and the plating bath will peel off the surface of the vibration plate, causing cavitation, thereby damaging the vibration plate.

In the above examples, the thickness of the coating film is set so that it is in or μπι 100 50 \. According to the present invention, the thickness of the coating film is preferably within a range of 5 to 300 µm, particularly 30 to 100 µm. If the thickness of the coating film is below 5 μm, the welding of the aluminum alloy is incomplete during the use process. As can be achieved a complete welding between the insert and insertee at thicknesses of the coating film is 300 [in or below, is a cladding, which exceeds a thickness of 300 in the \ unnecessary.

In the examples described above, the amplitude of the vibrating plate was 20 µm. The amplitude is preferably within a range of 5 to 35 µm. If the amplitude is less than 5 µm, sufficient energy cannot be applied to the plating bath. The oxide that forms on the surface of the feed material cannot be removed and a uniform coating layer cannot be formed. But if the amplitude exceeds 35 \ im , the coating bath cannot follow the movement of the vibrating plate, and cavitation can damage the vibrating plate.

In the examples described above, the distance between the vibration plate and the coating surface was of the insert holder 0.1 mm. However, the distance can be 0.5 mm or less in order to

to enable the coating bath between the vibration plate and the insert. When the distance is 0.5mm exceeds, the wave force of the coating bath that is applied by vibration of the vibration plate, is not transferred to the insert to a sufficient extent, and a uniform, strong coating layer cannot be formed will. :

In the examples described above, the composition was of the coating bath Zn-Al alloy or pure zinc. Any aluminum solder can be used according to JISZ3281, SAL-BQZ or SAL-CRZ. In addition, a cadmium silver alloy (Cd: 95%, Ag: 5% (by weight)), a tin-zinc alloy (Sn: 85%, Zn: 15% (wt.%)) Or the like. Can be used.

In the examples described above, the input, Set material an aluminum alloy, stainless steel, high-strength steel · ,, cast iron, FRM (a carbon fiber containing aluminum alloy) or a sintered iron-based alloy. But it can also be iron-steel (including stainless steel or heat-resistant Steel), a titration alloy, a nickel alloy, a Cobalt alloy, an FRM using an aluminum or zinc alloy as a matrix, or the like will.

In the examples described above, ingredients an internal engine, such as a cylinder head, a cylinder block, a camshaft, a piston or a Prepared connecting rod. But there can also be components such as a crankshaft, a rocker arm Automobile suspension part (e.g. a suspension arm), a differential gear carrier, a disc brake caliper and various gears are prepared.

In particular, a rocker arm is composed of a sintered iron-based alloy particle and a

Main body 36 of the rocker arm made of an aluminum alloy, and the particle 37 stands with a cam in FIG sliding contact, as Fig. 15 shows. A Zu-Al alloy or the like is on the outer surface of the particle 37 applied with ultrasonic vibration and inserted into the main body 36 of the rocker arm.

In the case of a suspension arm, steel is used lengthways, with a bushing as the attachment part of the arm on the vehicle body and a connector to a wheel is inserted, the outer surface of the wire is coated according to the method of the present invention, the interface between the outer cylinder of steel the bushing and the connecting member is coated according to the method according to the invention and the three Links inserted into an aluminum alloy to prepare a suspension arm.

In the case of a differential gear according to the invention Proceed in the same way as for a mounting bushing on the vehicle body and a suspension arm applied. A wire, an FRM or the like is used according to the method according to the invention.

In the case of a gear, after a ring-shaped FRM according to the method according to the invention is coated, the FRM is set in an aluminum alloy to create a gear member. Then that will FRM cut to form gear teeth.

As a casting method for inserting one according to the invention Process of coated insert into an insert receiver can be any of the following methods be applied: sand mold casting, mold gravity casting, low pressure casting, permanent mold casting, forging molten Metal and the like.

-ψ

In the examples described above, if the insert is an iron-based material, this will be preferred preheated before insertion. However, preheating is not always necessary, and it can be at 400 ° C or take place underneath. Whether or not preheating is performed may vary in accordance with the one used Material of the insert can be determined.

In the examples described above, the coating is carried out while ultrasonic vibration is applied to the coating bath is created. The gap between the insert and the insert receiver is set to 0.1 mm. However the gap can be 0.5 mm or less. The only requirement is that the coating bath between the two materials are available. But if the gap is 0.5 mm or less, it will be caused by the vibrating plate Vibration applied to the plating bath is reflected from the insert. The reflected wave is through the Vibration energy of the vibration plate amplifies, and the amplified energy reaches the surface of the insert, to remove the oxide on the surface of the insert and form a uniform coating. But if the gap exceeds 0.5 mm, the wave reflected by the insert is attenuated. Even if then the damped reflected wave is amplified by the vibration plate, the vibration wave cannot have sufficient vibration energy. Therefore, the oxide on the surface of the feed material cannot completely removed. A uniform coating layer cannot form, and between the insert and the insert receiver creates a non-welded area.

The present invention can be used for the manufacture of cylinder heads, pistons, connecting rods, camshafts, Piston and cylinder blocks of engines, crankshafts, rocker arms, suspension arms, differential gear carriers, Disc brake calipers and various gears can be applied.

Claims (18)

Expectations 1. Application process in which an insert is immersed in a coating bath after pretreatment, the insert is coated while a vibration plate is placed in the coating bath and in the vicinity of the insert is vibrated and the coated insert is inserted into an aluminum alloy. 2. Use method according to claim 1, wherein the Use is caused to vibrate by vibrating the coating bath. 3. Use method according to claim 1, wherein the pretreatment includes the steps of flushing the insert Water, degreasing it, rinsing it with water, pickling it, rinsing it with water and drying the same. 4. Use method according to claim 1, wherein the Coating bath consists of soft aluminum solder. 5. Use method according to claim 1, wherein the coating bath consists of pure zinc. 6. Use method according to claim 1, wherein the coating bath consists of a cadmium-silver alloy. 7. Use method according to claim 1, wherein the Plating bath consists of a tin-zinc alloy. 8. Use method according to claim 1, in which after after coating the insert, the insert is preheated to a temperature of 400 ° C or below and placed in a Aluminum alloy is inserted. 9. The method of use according to claim 1, wherein the coating layer formed on a surface of the insert has a thickness of 5 to 300 µm. 10. Use method according to claim 1, wherein the oscillation frequency is 1 to 1000 kHz. 11. Use method according to claim 1, wherein a Gap between the vibration plate and the insert is 0.5 mm or less. 12. Use method according to claim 1, wherein the insert consists of the material that consists of one Material based on iron, a titanium alloy, a nickel alloy, a cobalt alloy, an aluminum alloy, an FRM with an aluminum alloy as a matrix and an FRM with a zinc alloy as a matrix existing group is selected. 13. Use method according to claim 8, wherein the insert is made from an iron-based material is. 14. Application method in which an insert is coated while a coating bath is subjected to ultrasonic vibrations is subjected, the coated insert is inserted into an aluminum alloy, and the insert and the Aluminum alloy can be welded by diffusion. 15. Application process in which an insert, after it has been pretreated, is immersed in a coating bath the insert is coated while one is placed in the coating bath and near the insert Vibration plate is vibrated and the coated insert is inserted into an insert receiver , which consists essentially of an aluminum alloy. 16. Insert device with a pretreatment device for pretreating a feed material, a Coating device for coating the insert while a coating bath with a vibration plate is in Vibration is applied, and a casting device holding the coated insert in a mold and an aluminum alloy is injected into the mold to obtain a casting into which the insert is inserted. 17. Insertion device according to claim 12, wherein a gap between the vibration plate and the insert Is 0.5 mm or less. 18. Insert having an insert, a coating layer that is applied to a surface of the insert while vibration is generated in a plating bath, and an insert receiver made of an aluminum alloy consists, which is diffusion-welded to the insert through the coating layer.