Classifications

• • 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
  • F02F3/12—Pistons  having surface coverings on piston heads
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
  • C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
  • C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
  • C22C32/0036—Matrix based on Al, Mg, Be or alloys thereof
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
  • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
  • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
  • C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
  • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
  • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
  • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
  • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
  • C23C28/341—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one carbide layer
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
  • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
  • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
  • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
  • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
  • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
  • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
  • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
• • 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
  • F02F2200/00—Manufacturing
  • F02F2200/04—Forging of engine parts
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
  • F05C2201/00—Metals
  • F05C2201/02—Light metals
  • F05C2201/021—Aluminium
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
  • F05C2251/00—Material properties
  • F05C2251/04—Thermal properties
  • F05C2251/042—Expansivity

Definitions

• the present invention relates to the formation of articles, particularly but not exclusively pistons, of composite materials comprising two or more layers.
• an object of the invention is to provide a layered article which is less subject to the above mentioned difficulties but avoids the need of a mechanical connection.
• the invention provides in one aspect an article comprising two or more layers of different material compositions there being a controlled graded change of composition between layers or within at least one of the layers.
• the thickness of the graded change may be from about one millimetre to several centimetres, or even greater.
• Por composite materials with three or more layers, the material or materials of one or more of the layers can be a controlled mixture or a controlled graded mixture providing controlled graded discontinuous or continuous changes of thermal and mechanical properties within the composite layer.
• one or more of the layers can have a greater mechanical strength than the other layer or layers.
• One or more of the layers can have a low thermal conductivity.
• One or more of the layers can have a low, medium or high value of mechanical elongation at rupture.
• the region of the controlled graded layer contiguous to the second layer may have a thermal expansion coefficient and/or a value of elongation at rupture which are intermediate between the value of the thermal expansion coefficient and/or the value of elongation at rupture for the second layer and the value of the thermal expansion coefficient and/or the value of elongation at rupture in the noncontiguous regions of the controlled graded layer.
• at least one intermediate layer can have a thermal expansion coefficient and/or a mechanical elongation at rupture which are intermediate between the values of the corresponding coefficients and elongations for the contiguous layers.
• the properties of low thermal conductivity, high mechanical strength and non-negligible elongation may apply individually or jointly to a given layer, to contiguous layers or to non-contiguous layers, and a layer with one, two or all three of these properties can be an outer layer, an intermediate layer, or the innermost layer. In some cases, however the different layers may be provided by different zones of the article having a graded change of composition from one zone to the next.
• the invention provides in a further aspect a method of manufacturing an article, comprising the steps of starting with at least two layers of different material compositions, there being a controlled graded change of composition between layers or within at least one of the layers, and subsequently bonding the layers together.
• One or more of the layers may be of a material or materials produced by casting, forging, stamping, rolling produced as a single material or as a controlled mixture of materials bonded to the contiguous layer or layers.
• One or more of the layers may be bonded to another layer or layers by sintering, casting or by friction welding.
• One or more of the layers may be produced by existing methods used for coatings, which include roll-bonding, diffusion-bonding, spraying (including fusion spraying), sintering, deposition (including explosive deposition, electro-deposition, electro-static deposition, electroless deposition), brushing and dipping, without or with surface treatment of the layers, or the contiguous layer or layers.
• the layers can have the same thickness or different thicknesses, depending on design and operating requirements.
• the invention has particular application to pistons for use in internal combustion engines.
• the skirt has a first composition and the crown has a second composition, and between the skirt and the crown the piston has an intermediate zone in which the relative proportions of the materials lies intermediate those in the skirt and the crown.
• thermal conductivity, mechanical strength and other properties can be graded between the skirt and the crown.
• the piston may comprise three or more distinct layers, each having different proportions of said materials, the proportions being substantially uniform throughout each layer and the relative proportions of the materials being graded from one layer to the next. However there may be a continuous grading of the materials throughout part or the whole of the piston. The proportion of one of the materials in one or other of the outer layers may be zero.
• aluminium or an aluminium alloy for example silicon-aluminium
• the crown having a significant proportion of alumina
• the intermediate layer or layers having a smaller proportion of alumina
• the skirt having a still smaller proportion of alumina, which may be zero.
• the proportion of alumina to aluminium or aluminium alloy may vary from the skirt to the crown with the range 0 to 30% by weight.
• Figure 1 is a vertical section of a piston having three uninterrupted layers and showing two half-sections at right angles to each other;
• Figure 2 is a similar view to Figure 1 of a piston comprising uninterrupted layers.
• a piston primarily for an internal combustion engine is made as a composite-material design with three uninterrupted layers 1, 2, 3.
• the outermost layer 1 i.e. at the crown end of the piston is a layer with a high percentage of alumina mixed with aluminium or silicon-aluminium, this layer providing most of the mechanical strength and having a lower thermal conductivity than the other two layers.
• the layer 1 extends from the crown 4, to the peripheral edge 5 of the piston, and down along the side of the piston to the region 6 below the bottom compression ring.
• the intermediate layer 2 extends down below the region 6 of the layer 1 and consists of a medium percentage of alumina with aluminium or silicon-aluminium, the layer having intermediate mechanical and thermal properties between those of the outer layer 1 and the inner surface layer 3 which extends downwardly beyond the region of the intermediate layer 2 below the area of the bottom compression ring groove and further downwardly along the side of the piston to a gudgeon pin boss 7 and to an area 8 in the bottom region of the piston skirt.
• the layer 3 is made of aluminium or silicon-aluminium or a mixture of a low percentage of alumina with aluminium or silicon-aluminium, and has a lower high-temperature mechanical strength and a higher thermal conductivity than the layer 2.
• layer 3 may contain from 0 to 10% by weight alumina, layer 1 up to 30% alumina, (and greater than in layer 3), and layer 2 an intermediate amount of alumina.
• the layers 1, 2, and 3 may be made by compacting and sintering. Alternatively layers 2 and 3, or layer 3, may be cast or sprayed on layer 1 or on layers 1 and 2 respectively.
• a piston is made as a composite-material design with three uninterrupted layers.
• the layer 9 in the crown 4 provides low thermal conductivity and comprises a mixture of aluminium or silicon-aluminium with a significant proportion of alumina.
• a lower layer 10 comprises a mixture of aluminium or silicon-aluminium with a smaller proportion of alumina, and can be either a homogeneous mixture or a controlled continuously graded layer having a higher proportion of alumina near the layer 9 and a lower proportion of alumina away from the layer 9.
• An insert 11 containing the compression ring grooves provides low thermal conductivity and/or mechanical strength and may be of the same material as the uppermost layer 9, or of other suitable materials.
• Layer 10 may be sprayed, sintered or cast.
• the lower layer 12 of the piston comprising the piston bosses and the skirt, may be of aluminium or silicon-aluminium but may also include a small proportion of alumina.
• This layer 12 may be made, for example as a separate casting. It can then be bonded, e.g. by friction welding, to the upper section of the piston.
• the layer 12 may comprise a continuously graded layer with a higher proportion of alumina near the layer 10 and a lower proportion of alumina (which may be zero) at the skirt end of the piston.
• the layer 10 may extend to the skirt end of the piston and be in the form of a single graded layer with a higher proportion of alumina nearer the layer 9 and a lower proportion of alumina (which may be zero) at the skirt end of the piston.
• the piston may be continuously graded throughout, the proportion of alumina increasing from the skirt towards the piston.
• pistons made from aluminium or siliconaluminium have been described it will be appreciated that other materials could alternatively be used. Moreover although the invention is especially applicable to pistons, clearly other articles may be made within the scope of the invention, such as, inter alia, cylinders with or without ribs or flanges, casings, turbi blades and combustors.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Inorganic Chemistry (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Ceramic Engineering (AREA)
• Composite Materials (AREA)
• Manufacturing & Machinery (AREA)
• Combustion & Propulsion (AREA)
• General Engineering & Computer Science (AREA)
• Pistons, Piston Rings, And Cylinders (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Laminated Bodies (AREA)
• Turbine Rotor Nozzle Sealing (AREA)
• Pressure Welding/Diffusion-Bonding (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=10163909

Family Applications (1)

Country Status (11)

Families Citing this family (6)

Family Cites Families (5)

• 1979
  • 1979-05-21 JP JP50076979A patent/JPS55500363A/ja active Pending
  • 1979-05-21 NO NO791675A patent/NO791675L/no unknown
  • 1979-05-21 WO PCT/GB1979/000069 patent/WO1979001103A1/en unknown
  • 1979-05-23 AU AU47327/79A patent/AU4732779A/en not_active Abandoned
  • 1979-05-23 IT IT7968102A patent/IT7968102A0/it unknown
  • 1979-05-23 ES ES480829A patent/ES480829A1/es not_active Expired
  • 1979-05-23 BE BE0/195361A patent/BE876507A/xx unknown
  • 1979-05-23 NL NL7904066A patent/NL7904066A/xx not_active Application Discontinuation
  • 1979-12-17 EP EP79900490A patent/EP0018377A1/en not_active Withdrawn
• 1980
  • 1980-01-18 DK DK21980A patent/DK21980A/da unknown
  • 1980-01-22 SE SE8000505A patent/SE8000505L/xx unknown

Non-Patent Citations (1)

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