EP0191008B1 - Hülsen- oder rohrförmiger Gegenstand und Verfahren zu seiner Herstellung - Google Patents

Hülsen- oder rohrförmiger Gegenstand und Verfahren zu seiner Herstellung Download PDF

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Publication number
EP0191008B1
EP0191008B1 EP19860850030 EP86850030A EP0191008B1 EP 0191008 B1 EP0191008 B1 EP 0191008B1 EP 19860850030 EP19860850030 EP 19860850030 EP 86850030 A EP86850030 A EP 86850030A EP 0191008 B1 EP0191008 B1 EP 0191008B1
Authority
EP
European Patent Office
Prior art keywords
layer
additional
core body
spraying
metal alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP19860850030
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English (en)
French (fr)
Other versions
EP0191008A1 (de
Inventor
Nils-Eric Björklund
Hâkan Lindgren
Sten Gustafson
Mats Dahlén
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Volvo AB
Original Assignee
Volvo AB
Kanthal AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Volvo AB, Kanthal AB filed Critical Volvo AB
Publication of EP0191008A1 publication Critical patent/EP0191008A1/de
Application granted granted Critical
Publication of EP0191008B1 publication Critical patent/EP0191008B1/de
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/003—Moulding by spraying metal on a surface

Definitions

  • the invention relates to a method to manufacture a shell or tubular object to be incorporated in a heat and corrosion resistant part of a combustion engine, as defined in the first part of claim 1.
  • the background of the invention is a desire to make it possible to operate internal combustion engines at a higherworking temperature, whereby an increased efficiency and a more complete combustion can be achieved.
  • it is a well-known problem to accomplish temperature and corrosion resistance of the materials, especially in combustion chambers and exhaust channels, in case the working temperature is to be raised above what is normal in today's engines.
  • ceramic materials are high-temperature and corrosion resistant, but it is complicated and expensive to combine ceramics with other, metallic construction materials, such as iron and nickel alloys. Tensions are caused by different temperature coefficients. Certain ceramics will also be subjected to phase transformations in temperature intervals within or very close to the working temperatures in question. Moreover, the subsequent treatment, e. g. the boring of holes, becomes more difficult, if ceramics are used.
  • the published Swedish Patent Application SE-A-8 300 603-1 discloses a method of manufacturing a machine part, including a heat insulated inlet gas channel, by thermally spraying a very thin first layer, having a thickness of 0.1-0.2 mm, of a soft metal material, such as zinc, tin, lead, copper or aluminium, onto a sand core.
  • a second layer, having a thickness of 0.5-2.5 mm, of a metal material, such as carbon steel, is thermally sprayed onto the first layer, and thereafter a third layer, serving as a heat barrier and consisting of a ceramic material is applied, e. g. by thermal spraying.
  • the sand core with the three layers applied thereon is placed in a mold for molding the machine part in a conventional manner. Upon molding, the sand core is removed, so that the three layers form an internal surface of a channel in the machine part.
  • the innermost layer, forming the internal surface layer of the machine part is not corrosion resistant and is not suitable e. g. for exhaust channels.
  • the melting point of the soft metal material is far too low to permit the use in an exhaust channel of a combustion engine.
  • a typical temperature of the exhaust gases is about 850 °C, whereas the melting point of Zn is about 420 °C.
  • the object of the invention is to eliminate the disadvantages and restrictions of the known methods and to enable a simple manufacture of shell or tubular objects, even with a complicated geometry, by thermal spraying of a heat and corrosion resistant metal alloy so as to form a dense, first surface layer and an additional layer serving as a heat barrier, without any risk of cracking during the spraying process.
  • a further object is to enable the molding of such an object into a molded body having one or several channels or cavities constituted by the molded shell or tubular object according to the invention.
  • the main object is achieved by a method as defined in the characterizing clause of claim 1.
  • the invention also relates to a shell or tubular object to be incorporated in a machine part of a combustion engine, as defined in claim 6.
  • Other suitable features are stated in the claims 2-5 and 7, respectively.
  • the core body, onto which a first layer is sprayed will be removed before additional material is applied by spraying. It is particularly suitable to make the core body of molding sand which can loose its form stability and be discharged from the tube or shell, e. g. upon heating. Without risk of cracking due to tensions, which would unavoidably arise if the core body were to remain, continuous spraying may thereafter be effected up to a desired thickness.
  • the thermal spraying of the additional layer should be controlled in such a way that the second or third layer contains more oxides and/or pores than the first layer, whereby the desired qualities, especially a lower thermal conductivity, are obtained in the second or third layer.
  • a relatively thin layer either as a second layer between a first and a third layer or as a third layer sprayed onto the second layer.
  • such a relatively thin layer may e. g. be used as a diffusion barrier for carbon or nickel. Also, it can be used to increase the mechanical qualities at higher temperatures.
  • a core body 1 is made of molding sand and a phenol resin as a binding agent.
  • the core body 1 has an external configuration of the tubular object and, in addition thereto, holding portions 1a, 1b at each end for holding the core body.
  • the desired object comprises an exhaust channel in a cylinder head of a combustion engine.
  • a relatively thin and essentially pore-free layer 2 of a metal alloy containing about 5 % Al, 22 % Cr and the rest mainly Fe (the contents are by weight) is sprayed onto the core body 1.
  • Porosity if any, must consist of closed pores.
  • the spraying operation is interrupted, whereupon the sand core 1 is removed in that the sand core and the layer sprayed thereon is heated in a furnace at about 600 °C for 2-3 hours, and thereafter the sand is discharged from the tubular metal alloy layer 2.
  • a second layer 3 is sprayed onto the first, self-supporting layer 2.
  • the first layer is permitted to expand and shrink freely due to variations of temperature, without any risk of tensions and accompanying cracking.
  • the thickness of the second layer may be at least 1 mm. The spraying process can be performed without interruption for cooling.
  • the first, relatively thin layer 2 is sprayed by means of a wire-fed flame sprayer so as to form a dense layer.
  • the layer may be applied by plasma spraying.
  • the second layer 3 may preferably be applied by means of a powder-fed flame sprayer in order to obtain a suitable quantity of pores and oxides. In this case, a quantity of 5-25 %, preferably about 15 %, pores and oxides is desired.
  • the second layer 3 does not have to be of the same material composition as the first layer 2, but may e. g. consist of another metal alloy of high heat resistance.
  • the layer consists of the same material and differs only in porosity and oxide contents.
  • a thin third layer may be applied either between or on top of the two above-mentioned layers.
  • the third layer may i. a. function as an adhesive layer or diffusion barrier.
  • the object and the manufacturing method according to the invention have several advantages.
  • the geometric shape as well as the materials and the thickness thereof can be chosen at will.
  • very thick layers (the second layer 3) may be applied after the removal of the core body.
  • the manufacturing method is relatively quick (metal can be sprayed onto a red hot substrate) and the handling rather simple.
  • the cassation is very low because of the eliminated risk of cracking. Even the subsequent operations, e. g. molding, are facilitated and can therefore be performed with great accuracy.
  • the recircling of scrap is made easier.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)

Claims (7)

1. Ein Verfahren zur Herstellung eines hülsen-oder rohrförmigen Gegenstandes, der in einen hitze- und korrosionsbeständigen Teil eines Verbrennungsmotors eingebaut werden soll, wobei der Gegenstand durch thermisches Aufsprühen einer ersten Schicht (2) aus einem hochtemperaturbeständigen Metall-Legierungsmaterial auf einen Kernkörper (1) hergestellt wird, dessen Außenabmessungen den Innenabmessungen des fertigen Gegenstandes entsprechen, dadurch gekennzeichnet, daß, nachdem die erste, dichte Schicht (2) durch thermisches Aufsprühen eines hochtemperatur- und korrosionsbeständigen Metall-Legierungsmaterials auf den Kernkörper (1) gebildet ist, der Kernkörper (1) entfernt wird, so daß eine selbsttragende Hülse oder ein selbsttragendes Rohr verbleibt, und daß durch thermisches Aufsprühen eines hitzebeständigen Metall-Legierungsmaterials auf die Außenfläche der selbsttragenden Hülse oder des selbsttragenden Rohres (2) wenigstens eine zusätzliche Schicht (3) gebildet wird, wobei eine solche zusätzliche Schicht (3) mit größerer Dicke als die erste Schicht (2) aufgebracht und das thermische Aufsprühen derart gesteuert wird, daß die zusätzliche Schicht (3) mehr Oxide und/oder Poren als die erste Schicht (2) enthält und als Hitzesperre im fertigen Gegenstand (2, 3) dient.
2. Ein Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Kernkörper (1) aus Formsand gemacht wird.
3. Ein Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß das Material, welches beim Aufsprühen der ersten Schicht (2) verwendet wird, aus 1 bis 12 % AI, 10 bis 30 % Cr, gegebenenfalls kleinen Mengen an einem oder mehreren Elementen der Gruppe Si, Mn, Co, Y, Hf, gegebenenfalls kleinen Mengen an Oxiden und Nitriden und der Rest aus Fe besteht.
4. Ein Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß beim Aufsprühen der ersten Schicht (2) und der wenigstens einen zusätzlichen Schicht (3) dasselbe Material verwendet wird.
5. Ein Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß die wenigstens eine zusätzliche Schicht eine zweite Schicht und eine dritte Schicht einschließt, wobei die zweite oder dritte Schicht im wesentlichen dünner als die beiden anderen Schichten sind und als eine Adhäsionsschicht oder eine Diffusionssperre dienen.
6. Ein hülsen- oder rohrförmiger Gegenstand, herstellbar durch das Verfahren nach einem der Ansprüche 1 bis 5 zum Einbau in einen Teil eines Verbrennungsmotors, wobei der Gegenstand wenigstens zwei Schichten (2, 3) aus einem hochtemperaturbeständigen Metall-Legierungsmaterial hat, dadurch gekennzeichnet, daß die erste, dichte, thermisch aufgesprühte Schicht (2) eine Dicke von 0,5 bis 1,5 mm hat und daß die Porosität der ersten Schicht (2) aus geschlossenen Poren besteht, während die Gesamtporosität und die Oxidgehalte einer zusätzlichen dritten Schicht (3) 10 % überschreiten, wobei die zusätzliche dritte Schicht (3) als Hitzesperre dient.
7. Ein Gegenstand nach Anspruch 6, dadurch gekennzeichnet, daß eine zweite oder dritte Schicht (3) eine Dicke größer als 1 mm, vorzugsweise eine Dicke von etwa 2,5 mm haben.
EP19860850030 1985-02-01 1986-01-31 Hülsen- oder rohrförmiger Gegenstand und Verfahren zu seiner Herstellung Expired EP0191008B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE8500473 1985-02-01
SE8500473A SE452859B (sv) 1985-02-01 1985-02-01 Skal- eller rorformigt foremal, i synnerhet med komplicerad form, vilket foremal er avsett att inga i en maskin, t ex en forbrenningsmotor, samt sett att framstella foremalet

Publications (2)

Publication Number Publication Date
EP0191008A1 EP0191008A1 (de) 1986-08-13
EP0191008B1 true EP0191008B1 (de) 1989-03-15

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP19860850030 Expired EP0191008B1 (de) 1985-02-01 1986-01-31 Hülsen- oder rohrförmiger Gegenstand und Verfahren zu seiner Herstellung

Country Status (3)

Country Link
EP (1) EP0191008B1 (de)
DE (1) DE3662340D1 (de)
SE (1) SE452859B (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20240091849A1 (en) * 2022-09-21 2024-03-21 The Boeing Company Additively manufactured channels for mold die castings

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB9210763D0 (en) * 1992-05-20 1992-07-08 Lucas Ind Plc Improvements in and relating to thixoformable layered materials and articles made from them
US6250362B1 (en) 1998-03-02 2001-06-26 Alcoa Inc. Method and apparatus for producing a porous metal via spray casting
AUPP939099A0 (en) * 1999-03-23 1999-04-15 Cast Centre Pty Ltd Die coatings for gravity and low pressure diecasting

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2431335A1 (fr) * 1978-07-21 1980-02-15 Peugeot Procede de revetement de cavites internes de pieces moulees, notamment de chapelles d'echappement de moteur a combustion interne

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20240091849A1 (en) * 2022-09-21 2024-03-21 The Boeing Company Additively manufactured channels for mold die castings

Also Published As

Publication number Publication date
SE8500473D0 (sv) 1985-02-01
SE452859B (sv) 1987-12-21
SE8500473L (sv) 1986-08-02
EP0191008A1 (de) 1986-08-13
DE3662340D1 (en) 1989-04-20

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